I-Corps: Translation potential of near-isothermal gas compression technology to improve the efficiency of high-pressure air compression systems

Award ID: 2627680

This I-Corps project is based on the development of a compression system that can provide ultra-efficient compression of gas at very high pressures. Currently, conventional compressors lose substantial energy due to thermodynamic heating, resulting in high electricity consumption and operating costs. This technology is designed to maintain gas temperatures closer to isothermal conditions during compression, which reduces compression work and increases efficiency. In addition, this technology may be applied to both air and natural gas compressors. Both of these system classes would benefit from a low-cost, high-efficiency near-isothermal compression technology, since their overall costs are dominated by energy consumption. In addition, the lower temperatures of near-isothermal compression can allow a reduced number of compressor stages, which would reduce capital costs as well as on operational/maintenance costs. The technology is expected to result in reductions in energy expenses and favorable lifecycle economics, providing value to both equipment manufacturers and end users across multiple high-pressure gas applications. This I-Corps project utilizes experiential learning coupled with first-hand investigation of the industry ecosystem to assess the translation potential of a near-isothermal reciprocating compression system designed to improve the efficiency of high-pressure gas compression. The technology overcomes limitations of previous near-isothermal approaches, such as nozzle-intensive architectures and hydraulic losses, through a simpler and more practical implementation. This technology combines liquid-assisted thermal management with internal heat-exchange structures and a reciprocating mechanical piston. This system has been shown to achieve isothermal efficiencies as high as 90% in laboratory-scale experiments. Considering that energy consumption is the largest cost for reciprocating compression systems, this efficiency increase can represent a significant techno-economic advantage for the primary market of high pressure (e.g., 30-80 atmospheres) and large-scale (e.g., 500 kW to 10 MW of power) systems. This technology may accelerate the development of advanced compression technologies, supporting energy efficiency, manufacturing competitiveness, and broader adoption in industrial applications. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

NSF Program Director: Ruth Shuman