Compressing air to reach net zero. A 'revolutionary' innovation.

Air is NOT free! At least compressed air isn't anyway. Compressed air accounts for no less than 10% of the overall energy consumption and emissions from that sector. So anything that can be done to improve efficiency and therefore lower those emissions has got to be a positive step forward. Now a revolutionary design ( literally and figuratively) aims to achieve just that.

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[_aullik]

What are the big problems with the system? They created this concept more than 12 years ago. A market disruptor (and a 30% efficiency increase counts as a disruptor) does not need that long to become a finished product that is produced in bigger numbers. So there must be major challenges with the system. What are they? Have they overcome them? If you introduce such technologies please talk about this.

[warrenchristie]

I have worked in the industry, and designed compressors that are in testing. I am curious about about thermal management. It seems that their test runs are low pressure and therefore low heat generation. It is difficult to manage very tight tolerances on larger units when you start to have hot spots. This compressor has a cool intake section and hot exhaust that will have a larger temperature difference as the pressure increases, causing a change in the geometry. This is why traditional compressors have larger gaps. Most screw compressors use an oil wedge to help seal, that is mainly why it has a different shape and a tight spot. This does look like a clever design, but I have a hard time believing that it can be 30% more efficient. I have tested many compressors and the best way to have an increase like this, is when you put in a new system and fix all of your leaks. I think that a 3% overall efficiency increase would be huge, and more realistic.

[ZipperOfficial]

Very interesting.

Millwright here, it's important to note that thermal expansion is another reason why there are clearance gaps. In designs like screw compressions that have to have larger gaps than for example a reciprocating compressor because the materials expands towards each other. Vs a reciprocating compressor where the piston and the wall expands in relatively the same direction. (Although maybe that was beyond the scope of this video)

The circle design of this compressor takes advantage of this and thus requires less of a gap.

One issue with this design I am seeing however is that it seems like it would be quite prone to damage if it gets dirty or small bits of debris get in. It's relying on very accurate timing of two rotating parts moving in differing directions... ANY mis-alignment would be devastating. Maintenance of this machine would be constant and absolutely critical. (Constant filter change, I would even include a cyclone filter).

Worth the extra efficiency.

That said, if you can afford it there are more efficient systems out there. Large multi-stage axial compressors with intercoolers betwen stages have INCREDIBLE efficiency. However are extremely expensive to build and maintain.

So it's going to have a niche role. It needs to be cheaper than the aforementioned system, but more efficient than screw compressors. If they can make it cheaper enough it could be revolutionary.

[kleetus]

Depending on the application, the roots or screw compressor sealing gap is often solved by an oil flood system that takes up the space and gets continually circulated in a loop. While this adds some complexity, it also serves to cool the pump and working medium for more stable or predictable outlet temperatures.

[TheLostBear]

I used to work as an inspector in the quality control department at a company that manufactured multiple sizes and grades of screw blowers, from stock engine types for offroad ATV's to the top drag racing ones that you see on those super long dragsters. They were such a pain to measure all the tolerances and such. The biggest ones had multiple profiles in their outer diameters so the clearances would change on different parts of the rotation. There were by far my least favorite parts to inspect. Super high tolerances, and very difficult to get good repeatable readings.

[acchaladka]

Hi Dave, compressor tech and things like motor scheduling or variable / efficiency improvements are among the great technological leaps of the 20th century, you're quite right. I'd love to see a second video answering some of the excellent comments brought up in response to this video, a deeper dive. Specifically, what are the company responses to the filtration problem / multiple seals, turbulent flow patterns and opportunities, niches they see as most useful and viable, independent test results, and market issues. Thanks for a video on one of my favourite topics.

[markzart]

Presumably, it would increase round-trip efficiency on compressed air energy storage installations as well, which would be interesting.

[davidbutcher]

I'm a Millwright, and one of the things we learned at tradeschool was the importance of reducing air leaks wherever possible. I currently work on locomotives, and air compressors are an integral part of the vehicles functioning safely. This new design sounds like an excellent solution to the issues of both the screw and piston compressors.

[rajeshchheda]

A difficult engineering concept explained so easily by Dave.
Thank You very much for keeping us updated every week.

[scottwilliams]

"Free of ads and sponsorship messages" is an integral part of this channel, and I like that.

It sounds really weird in this particular video; the while entire thing is an ad/sponsorship message for Lontra.

[onebylandtwoifbysearunifby]

"Leave no stone unturned" approach. (With an Exceptionally thorough and clear explanation of how this device works). Rethinking existing products with efficiency in mind is too often overlooked. People want "New and Wild" all the time, but this design is revolutionary too (and you can even choose your direction).

[DAHKnght]

just googled and found out that Ford, Lontra, and Ricardo got a funding from the UK TSB to make a demonstration supercharger, can’t wait to see what comes of that

[rogerbarton]

I ran a grit-blasting business for three years and lived & breathed air compressors, including a bank of 10 fridge motors to fill my receivers overnight and warm the office up ready for work!

This technology could make liquified air energy storage more viable.

[Treyk]

I like how the design is relatively compact. This would be beneficial for automotive applications. Turbochargers are more efficient compared to screw and roots type superchargers but come with inherent flaws. It would be interesting to see this applied to get a good comparison of power and efficiency. Maybe even a compound setup to still take advantage of energy waste from exhaust.

[robertschulke]

Turbine manufacturers solve the precision end gap issue for turbine blades by allowing the blade ends to be abraded by the housings with the result of perfect clearance at max heat and RPM. Similar abrasive machining can bring roots type blowers into perfect clearance very cheaply.

[tommanseau]

I am curious to know what the difference in noise level is as well. Anyone who's used a typical air compressor knows it is typically noisy and gets hot.

[monkerud]

used to work with ac's and cooling machines, it is really something i remember almost being invisible when i was a kid, everyone knows there are cars and trains and power lines, but its so easy to miss all the heat pumps that are all over the place :) and compressors are not all that efficient :-) at least for non industrial applications, a lot of potential there for innovation.

[ChurchAutoTest]

Late to the party here, but the sealing issues for positive displacement roots/screw type blowers have been dramatically mitigated over the last couple of decades by the use of advanced coatings on the rotor packs. These durable yet flexible coatings literally wear in to a near optimum seal upon first use. This is one of the reasons we can see compressor efficiencies on vehicle ICE superchargers in excess of 70% now (best I've seen is 74%, may be some higher). Turbos are more efficient still which is why we don't see too many OEM PD supercharged vehicles anymore, but the existing tech, at least in the automotive space, isn't nearly as bad as this video makes it sound.

[robertschulke]

Positive displacement compressors and motors are better for variable speeds. Turbines are better for fairly constant speeds, especially at higher flow rates, which is why aircraft, power plants, ships, etc. use them. The precision timing of this design would lead to a catastrophic failure if the timing mechanism wore even a little.

[roystevens]

As a mechanical engineer I can see many ways why this hasn't been adopted but the major one is the geartrain needed that not only changes the direction of power by 90 degrees (huge energy waste right there) but also has to be zero backlash for millions of revolutions. A roots blower only has four points of high precision contact where this design has a dozen or so.