High-throughput diaphragm compressor

A diaphragm compressor system with main stage valve controlling a hydraulic drive thereof, the diaphragm compressor comprising:

• a main stage valve comprising:
• a valve body comprising a first end and a second end,
• a pilot port proximate the first end,
• a supply port,
• a first vent port,
• a cylinder port, and
• a pin subassembly comprising a spool, a pilot pin proximate the second end, and a return pin proximate the first end,
• wherein the pin subassembly is configured to move to a supply position with the supply port in fluid communication with the cylinder port and an end orifice configured to dampen motion of the pin subassembly into the supply position, and
• wherein the pin subassembly is configured to move to a vent position with the cylinder port in fluid communication with the first vent port and a vent damping orifice configured to dampen motion of the pin subassembly into the vent position;
• and
• a diaphragm compressor system comprising:
• a first compressor head comprising:
• a head cavity, and
• a diaphragm mounted in the head cavity and dividing the head cavity into a work oil region and a process gas region, the diaphragm configured to actuate during a discharge cycle to pressurize process gas in the process gas region,
• a hydraulic drive configured to pressurize work oil and provide the pressurized work oil to the compressor head, the hydraulic drive comprising:
• a drive housing comprising:
• a plurality of ports, the plurality of ports comprising a first port and a second port, wherein the hydraulic drive is configured to provide a variable-pressure supply of work oil to the drive cavity through one or more of the plurality of ports, and
• a drive cavity divided into a first actuation volume in communication with the first port and a second actuation volume in communication with the second port;
• a hydraulic power unit, and
• a plurality of pressure circuits comprising:
• a low-pressure circuit of work oil at a low pressure, and a high-pressure circuit of work oil at a high pressure, wherein, during the discharge cycle of the first compressor head:
• the hydraulic drive is configured to provide the variable-pressure supply of work oil through the second port to the second actuation volume 146, intensifying the work oil in the first variable volume region to an intensified pressure, and actuating the diaphragm of the first compressor head to the second position,
• wherein the main stage valve is mounted to the drive housing with the cylinder port in fluid communication with the drive cavity and the supply port operatively coupled to the hydraulic power unit, and
• wherein the main stage valve is configured to selectively move to the supply position to connect the high-pressure circuit to the drive cavity during the discharge cycle of the first compressor head.