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Centrifugal Compressor Operations

Tony Barletta and Scott W. Golden


Process Consulting Services Inc., Houston, Texas

U
nderstanding the interaction sor and its control system play a vital role Reactor Pressure
between fundamental principles in maintaining steady reactor operating Reactor operating pressure is set by main
of centrifugal compression, oper- pressure. Even though optimum FCC column overhead receiver pressure and
ating changes that influence compressor operations require balancing regenerator system pressure drop. System pressure
performance and basic control is impor- and reactor pressures against wet gas and drop depends on equipment design and
tant. Since the wet gas compressor plays a air blower constraints, throughout this operation, while compressor and control
central role in FCC operations, it will be paper reactor pressure is presumed con- system performance set receiver pressure.
used to review compressor performance stant to simplify discussions. Wet gas compressors operate at fixed or
fundamentals, common operating condi- Reactor operating pressure is regulated variable speed. Fixed speed compressors
tions that influence operations and basic by main column overhead receiver pres- throttle compressor suction while variable
control philosophy. sure and system pressure drop from the speed machines use steam turbines or
reactor to the overhead receiver. The wet variable speed motors to control receiver
Wet Gas Compressor gas machine needs to have sufficient pressure. If necessary, compressor surge
The FCC wet gas compressors major func- capacity to compress receiver wet gas to control systems recycle gas to ensure inlet
tion is reactor pressure control. The the gas plant operating pressure. Reactor gas flow rate is maintained above the min-
machine must compress gas from main effluent composition, overhead receiver imum flow (surge point or line). Even when
column overhead receiver to gas plant pressure and temperature, and gasoline receiver pressure is controlled, rapid sys-
operating pressure while maintaining sta- endpoint all influence the amount of wet tem pressure drop changes from tray flood-
ble regenerator-reactor differential pres- gas and its molecular weight. Variability in ing and dumping will cause rapid changes
sure (Figure 1). Typically reactor-regenera- main column overhead receiver pressure in reactor pressure.
tor differential pressure must be controlled or unstable system pressure drop produce Most motor driven compressors operate
within a relatively narrow +2 to -2 psi reactor pressure swings. These can cause at fixed speed using suction throttle valves
(+0.14 to -0.14 bar) range to permit stable catalyst circulation problems and other to vary pressure drop from the main col-
catalyst circulation. The wet gas compres- operability concerns. umn overhead receiver to the compressor

Wet gas
Differential Main column
compressor
pressure
Spillback
PC Gas plant
PC
PI PI
FI
Atmosphere Motor Spillback
Compressor
C.W. C.W.
FI
PC
Regenerator Reactor Main
column Inter-stage
Overhead
receiver receiver

Oil feed
Air

Figure 1. Regenerator-reactor differential pressure Figure 2. Fixed speed compressor and inter-condenser system
nlet (Figure 2). The pressure controller receiver pressure is reduced, thus machine curve represent overall performance. The
manipulates the throttle valve position and speed must be increased to compress the machines have lower efficiency and the
pressure drop to maintain constant receiv- higher gas flow rate and to meet higher gas temperature leaving is generally near
er pressure. Normal system pressure drop head requirements. Once the turbine gov- 300F rather than 200F with an inter-
variation is slow and predictable, there- ernor is wide-open or variable speed motor cooled design. These machines must com-
ore, receiver pressure can be adjusted to is operating at maximum speed or amps, press all wet gas from inlet conditions to
maintain constant reactor pressure. As feed rate or reactor temperature must be the gas plant operating pressure hence
ong as the throttle valve is not fully open, reduced to lower wet gas rate to the com- power consumption is higher.
hen the compressor has excess capacity. pressor capacity.
Once the throttle valve is fully open and Fixed or variable speed motors and tur- Wet Gas Compressor:
spillback valve closed, the machine can no bines must have sufficient power to com- Stable Operating Range
onger compress wet gas flow to the gas press the mass flow rate of gas while meet- Each compressor section must be operated
plant operating pressure. Generally, reac- ing the differential head between the over- within its stable flow range. At fixed speed
or temperature or feed rate is reduced to head receiver and the gas plant. the compressor curve begins at the surge
permit the compressor throttle valve to Otherwise, reactor temperature or feed rate point and ends at stonewall, or choke flow.
egain pressure control so that flaring can must be reduced to decrease the amount of Surge point is an unstable operating point
be avoided. receiver wet gas flow to the driver limit. where flow is at minimum. At surge, the
Variable speed compressors use steam compressor suffers from flow reversals that
urbines or variable speed motors to con- Compressor Design cause vibration and damage. At the other
rol receiver pressure. Speed is adjusted to Wet gas machines use 6-8 impellers end of the curve is the choke (or stonewall)
change the operating point on the com- (stages) to compress gas from the main col- point. At the choke point, the inlet flow is
pressor map to meet the system flow-head umn overhead receiver to the gas plant very high and the head developed very
equirements for stable reactor pressure operating pressure. Most have inter-stage low. Flow through the machine approach-
control. As system pressure drop increases condensing systems after the first 3 or 4 es sonic condition or a Mach number of 1.
stages (low-stage) that cool the Polytropic efficiency also drops rapidly
compressed gas, condense a near stonewall.
Low-stage High-stage small portion and separate the For variable speed compressors, there is
gas and liquid phases (Figure a region between the surge and stonewall
3). Inter-stage receiver gas is lines where there is stable machine perfor-
then compressed in the last 3 or mance (Figure 4). The compressor flow-
3-stages 3-stages
4 stages (high-stage). Inter- polytropic head can be varied anywhere
stage condensers reduce gas within this region. Because there is no
Suction Intercondenser Discharge
temperature and raise compres- throttling, all power goes into compression
system sor efficiency by 5-7%, but they which minimizes power consumption.
also generate pressure drop. Stable compressor performance is
Figure 3. Compressor schematic with inter-condenser Separate flow-polytropic head defined between these two flow-head limi-
and flow-polytropic efficiency tations. Some machine designs can vary
curves are needed to evaluate flow by 25% or more between surge and
overall compressor system per- stonewall points, while others have only 6-
formance. 8% flow variation between these limits.
11 These curves have inlet gas Compressors with small stable flow regions
0%
rat flow rate on the X-axis and need to have robust surge control systems.
Sp ed
ee polytropic head developed and The head-flow curve basic slope is rela-
d
Surge line polytropic efficiency on the Y- tively flat near the surge point and
100
% axis. Consequently overall becomes steeper as inlet flow is increased.
Polytropic head

compressor performance and The impeller blade angle determines the


90% power consumption depend on shape of the curve and the compressor effi-
each compressor sections per- ciency.
80% formance curves and the effects
of the inter-condenser system. Basic Compressor Control
70% Evaluating overall performance Reactor yield and condenser operating
of these compressors is more temperature and pressure change through-
Stonewall complex than for a machine out the day, hence the gas rate from the
without inter-cooling, but fun- main column receiver is variable.
damentally the same. Consequently the compressor control sys-
Inlet flow
Some compressors do not tem must be capable of maintaining con-
have inter-condenser systems. stant receiver pressure. Thus fixed speed
A single flow-polytropic head compressors have suction throttle valves
Figure 4. Variable speed flow-head map and flow-polytropic efficiency and variable speed machines change
speed to compensate for gas rate changes. Wet Gas Compressor the spillback valve opens recycling gas to
Because the compressor inlet gas flow rate Operation: ensure sufficient inlet flow into the
is not constant and may be below the surge No Inter-condenser machine. When the spillback is open,
point or line, the compressor is typically The simplest compressor to evaluate is a spillback flow rate determines the operat-
designed with a surge control system. fixed speed machine with no inter-con- ing point on the curve. Flow rate must
Surge control ensures that inlet flow rate densers. It has a single flow-head curve always be maintained above the surge
is maintained above minimum (surge point (and single flow-efficiency curve) with a point with suction pressure determined by
or surge line) at all times. A flow meter in the surge point rather than a line. the polytropic head generated at the mini-
compressor suction or discharge and inlet Although molecular weight does affect mum flow control point.
temperature and pressure are used to calcu- developed head, typical molecular weight Since the amount of gas leaving the
late the actual flow rate (ICFM) into the low- variations in a gas oil cracker do not mate- overhead receiver depends on reactor
and high-stages of compression. As suction rially change the compressor flow-head effluent composition and overhead receiv-
flow (ICFM) decreases toward the surge line performance curve. Whereas, resid crack- er conditions, the compressor suction pres-
(or point), the spillback control valve opens ers processing varying amounts and quali- sure will vary. As long as the suction throt-
to recycle gas from discharge to suction to ty of residues may have as much as 8 num- tle valve is not fully open, the compressor
raise inlet flow rate. Spillback flow is kept at ber variations in molecular weight, thus has unused capacity.
minimum to reduce power consumption. the flow-head performance curve is affect- When establishing operating conditions
Compressors with inter-condensers need ed. The manufacturer should provide to stay within an existing machine capaci-
two independent spillback systems from curves at maximum and minimum molec- ty or if considering a revamp, determining
discharge to the suction of each section. ular weight. the compressor suction pressure needed to
Spillback streams should be routed in front Figure 5 is the performance curve for a meet the proposed operation is critical.
of upstream exchangers so the heat of com- 6-stage FCC wet gas compressor that will Compressor suction pressure is calculated
pression is removed (Figure 2). be discussed in the case study presented from the compressor performance curve.
later in this paper. The com- Because the flow and head terms are
pressor develops a fixed poly- affected by suction pressure, estimating
60
tropic head for a given inlet this pressure is an iterative process.
Surge point flow rate and the curve can Centrifugal compressors generate a fixed
Polytropic head, 1,000 ft

55
8,200 rpm be used to predict compres- polytropic head at a given inlet flow rate
sor performance at different and not a fixed discharge pressure, with
50
process conditions. suction pressure, gas molecular weight and
45
The suction throttle valve gas temperature all influencing both inlet
plays an important role for a flow rate and polytropic head. The poly-
40 Stonewall fixed speed motor driven tropic head equation is shown in Equation
compressor. Throttle valve 1.
35 pressure drop controls over-
10,200 10,400 10,600 10,800 11,000 11,200 11,400 Equation 1
head receiver pressure
Inlet volume flow, icfm
(Figure 6) so that reactor

 
n
pressure is stable. Throttle n - 1 

1,545 ZavgT1 P2
Figure 5. Flow-head curve for a 6-stage compressor Head = -1
valve position and pressure
 
MW n-1 P1
drop compensate for changes n
in receiver gas flow rate or Where: MW = Molecular weight
Main column Gas plant receiver pressure set point Zavg = Average compressibility
Spillback T1 = Suction temperature, R
changes. Because compres- n = Compression coefficient
Motor sor discharge pressure is held P1 = Suction pressure, psia
Compressor constant by the gas plant P2 = Discharge pressure, psia

pressure controller, suction


pressure will vary and follow
the flow-head curve. When Understanding each variables impact on
gas rate leaving the overhead inlet flow rate and polytropic head is
FC receiver is higher than flow at important. Molecular weight and suction
C.W.
the surge point, the spillback pressure have a significant influence on
PC is closed. Hence, compressor performance, while compressor discharge
suction pressure will ride up pressure (P2) is fixed and temperature
Overhead
receiver and down the flow-head effects are small. Gas molecular weight
curve as long as the throttle (MW) is primarily controlled by reactor
valve is generating pressure effluent composition. As molecular weight
drop and not fully open. As decreases the inlet flow rate increases.
Figure 6. Receiver pressure control- compressor compressor inlet flow rate Because the compressor discharge pres-
suction throttling approaches the surge point, sure is fixed, compressor suction pressure
must be high enough to generate the head of the rated speed for the curve shown in
corresponding to the inlet flow rate into the Figure 4. 40

Polytropic head, 1,000 ft


compressor. For a fixed speed compressor,
30
as long as the compressor throttle valve is Compressor Capacity:
High-stage
not fully open, it has unused capacity. Driver Power
20
Thus, changes in molecular weight simply Compressor power consumption is a func-
cause throttle valve position and pressure tion of the mass flow, polytropic head,
10
drop to adjust to maintain receiver pres- polytropic efficiency, and gear losses.
sure. But once the throttle valve is fully Compressor shaft horsepower (SHP) is 0
open, the machine is operating at maxi- shown in Equation 2: 5 6 7 8 9 10
Inlet volume flow, 1,000 icfm
mum capacity.
Equation 2
Inlet gas temperature has little influence
Figure 8. High-stage curve
on compressor capacity because it is based
on absolute temperature. Hence, a 20F
ise in temperature changes the head term
Compressor SHP =
 m Hp  /  np 33,000 
 1.02
is used. The condenser outlet stream is
sent to a separator drum where the gas and
by only 3% and the flow term a similar Where: Hp = Polytropic head
liquids (oil and water) are separated. Inter-
amount. np = Polytropic efficiency stage drum gas is fed to the high-stage sec-
Compressor suction pressure has a large SHP = Shaft horsepower tion of the compressor. Each section has its
m = Mass flow rate of gas
nfluence on inlet gas flow rate. For a fixed 1.02 = 2% gear losses own flow-polytropic head and flow-poly-
mass flow rate, raising suction pressure tropic efficiency curves.
decreases inlet volume. At constant receiv- Fixed speed compressors have suction Because the inter-condenser system con-
er pressure, compressor inlet pressure is throttle valves to control overhead receiver denses a portion of the low-stage gas, mass
determined from the flow-head curve for a pressure. Satisfying the flow-head curve rate and gas molecular weight are lower
ixed speed compressor. Using the com- requires pressure drop across the control into the high-stage(typically 4-5 numbers
pressor curve shown in Figure 5, the suc- valve and throttling always wastes energy. lower than main column overhead receiver
ion pressure will be that needed to satisfy Because variable speed compressors gas). This reduces compressor power con-
he inlet flow and head term simultaneous- change speed to match the process flow- sumption and allows for more efficient
y. Throttle valve pressure drop will vary to head requirements, they consume less compressor design. Because the low-stage
maintain inlet flow rate between 10,400 energy. However, the capital cost of steam and high-stage sections have separate
and 11,100 ICFM while meeting the gas turbines or variable speed motors is higher operating curves, each requires an inde-
plant discharge pressure. As long the than a fixed speed motor. pendent surge control system. One part of
eceiver gas flow rate is above the surge the compressor may be operating with
point, then the spillback valve will be Wet Gas Compressor spillback to avoid surge, while the other
closed. However, as gas flow approaches Operation: may have the spillback closed.
surge, the spillback valve opens to main- With Inter-condenser Fixed speed compressors with an inter-
ain flow in a stable region of the curve. Figure 3 is a schematic of a 6-stage com- cooler have a suction throttle valve into
Suction pressure is a dependent variable pressor with 3-stages (Figure 7, low-stage) the low-stage to control main column over-
as long as the throttle valve has pressure in front and 3-stages (Figure 8, high-stage) head receiver pressure while high-stage
drop. Once the control valve is wide open behind the inter-condenser. Gas must still discharge pressure is controlled by the gas
he gas rate must be reduced or the suction be compressed from the overhead receiver plant sponge absorber or amine contactor
pressure increased to reduce the inlet vol- pressure to the gas plant operating pres- pressure controller. Typically there is no
ume into the compressor. sure, however, the low-stage discharges throttle valve in the suction of the high-
Variable speed compressors have an intermediate pressure gas (65-90 psig) to stage, consequently, discharge pressure
operating region between the surge and an inter-condenser where it is cooled from from the low-stage and suction pressure to
stonewall lines (Figure 4). Because there is approximately 200F to 100-130F the high-stage are dependent variables.
no throttle valve, main column overhead depending on whether air or cooling water Inlet flow rate into the low- and high-
eceiver pressure controller varies speed to stages must always be above the surge
maintain receiver pressure. As long as the 40 point. Separate spillback systems from the
eceiver gas flow rate is above the surge low-stage discharge to inlet of the main
Polytropic head, 1,000 ft

ine flow rate, there will be no spillback. 30 column condensers and from the high-
However, if receiver gas flow is below the Low-stage stage discharge to the inlet of the inter-con-
surge line, then the spillback will open to 20 denser maintain flow above surge for both
meet the minimum flow. In Figure 4, max- compressor sections. Thus, suction and
mum compressor capacity occurs when 10 discharge pressure from the first 3-stages
he compressor is operated at maximum and suction and discharge pressure of the
speed. As long as the compressor driver 0 last 3-stages are dependent on each other,
22 28 32 36 40 44
has sufficient energy then minimum over- Inlet volume flow, 1,000 icfm inter-condenser system pressure drop, and
head receiver operating pressure will be the amount of material condensed.
based on the flow-head developed at 110% Figure 7. Low-stage curve While principles of compression are the
same, overall performance is more difficult by about 10%. Although temperature has
Table 1
to evaluate. Fortunately, process flow mod- little effect on gas volume, main column
els, such as Simsci ProII or Provision, Reactor system pressure drop overhead receiver temperature has a large
allow the low- and high-stage flow-poly- impact on condensation. Cost-effective
Components P, psi
tropic head curves and flow-polytropic effi- changes that reduce receiver temperature
ciency curves and the inter-condenser sys- Reactor cyclones 2 should always be considered to maximize
tem to be rigorously modeled. Thus inter- Reactor vapor line 1 existing compressor capacity or to mini-
stage operating pressures can be deter- mize the need for modifications.
Reactor line coke 4
mined through an iterative process without In this instance, raising receiver pressure
Main column 3
excessive calculations. from 5 to 12 psig and lowering temperature
Condenser 3 to 100F decreased the amount of wet gas
Case Study: Piping 2 produced so that the gas inlet flow rate was
Minimizing Wet Gas Flow control/metering 1 within the existing compressor capacity
Compressor Modifications (Figure 9). While raising compressor inlet
An FCC unit was revamped to increase Total 16 pressure (and lowering temperature)
unit capacity by 40%. In addition, gas decreased inlet flow rate, it also raised
plant limitations required undercutting system pressure drop was 16 psi, resulting compressor discharge pressure. Since cen-
gasoline to produce heavy naphtha from in a 4 psig compressor suction pressure. trifugal compressors develop fixed poly-
the main fractionator to reduce liquid load- High pressure drop components includ- tropic head, discharge pressure (P2 in
ing through the gas plant. The existing ed reactor line coke formation, main col- equation 1) from the existing 7-stages of
compressor was a 7-stage machine with no umn overhead system and column inter- compression would have been 350 psig,
inter-condenser and a 4400 horsepower nals pressure drop. Table 1
motor. A suction throttle valve controlled shows each major component
main fractionator overhead receiver pres- and its measured pressure Main column Gas plant
sure. Prior to the revamp reactor pressure drop. Substantial reduction in Spillback
was 20 psig with a compressor inlet pres- system pressure drop was Motor
sure of approximately 4-5 psig. The 40% required to lower compressor Compressor
higher feed rate and higher gas from under- inlet flow rate to within
cutting together would have increased inlet 10,400 to 11,200 inlet cubic Remove
stage
flow rate by more than 50% if the 4 psig feet per minute stable operat-
suction pressure was maintained. Thus, a ing range.
new parallel compressor or one new larger Increasing compressor suc- FC
compressor would have been required. tion pressure raises condensa- C.W.
Because this solution was high cost, alter- tion in the overhead receiver, PC 12 +40% feed rate
nates were considered. decreases inlet flow rate and 5 Base feed rate
When evaluating compressor perfor- increases compressor capaci- Overhead
mance, the complete system from the reac- ty. In this instance, main col- receiver

tor thorough the compressor outlet needs umn overhead receiver pres- Pressure, psig
to be evaluated as a single system. sure and temperature needed
Undercutting gasoline increases wet gas to be 12 Psig and 100F to
flow rate if no other changes are made maintain inlet flow rate within
Figure 9. Receiver operating pressure- before and
after revamp
because it decreases the amount of liquid stable operating range.
product from the main column overhead Coking in the reactor line,
receiver. Gasoline sponges C3+ hydro- main column pressure drop,
carbons leaving the condenser, thus under- piping, flow metering, and 70

cutting reduces sponging at fixed receiver condenser pressure drop all 65


Polytropic head, 1,000 ft

temperature and pressure. For instance, had to be reduced. Otherwise,


undercutting 10% of the gasoline raises a new parallel compressor 60 7-stages
wet gas flow rate by approximately 5-7%. would have been needed.
55
As the percent undercutting increases so Overhead condenser
does the amount of wet gas from the over- exchanger surface area, cool- 6-stages
50
head receiver. ing water (CW) flow rate, and
Increasing mass flow rate through the CW temperature all influence 45

compressor without large changes in the wet gas flow rate. Each 1F 40
inlet flow rate requires higher suction pres- reduction in receiver tempera- 10,200 10,400 10,600 10,800 11,000 11,200 11,400
Inlet volume flow, icfm
sure. System pressure drop from the reac- ture lowers wet gas rate by
tor to the compressor inlet must be approximately 1%; thus,
reduced. In this case, the reactor pressure decreasing temperature by Figure 10. Flow-head curve for 7- and 6- stage
operated at approximately 20 psig and the 10F lowers the wet gas rate compressor
In this instance, the 7- ables are different. Understanding cen-
stage compressor devel- trifugal compressor flow-head and flow-
5,200
oped about 9,500 feet of efficiency curves is essential when evaluat-
7-stages head rise per stage of com- ing process changes or when revamping.
5,000
pression. Thus eliminating
a stage would reduce devel- THE AUTHORS
4,800
Total power, hp

oped head by about 9,500


Tony Barletta is a chemical
4,600 feet. Because compressor engineer with Process Consulting
discharge pressure needed Services in Houston, TX. His pri-
Motor horsepower mary responsibilities are conceptual
4,400 to be approximately 210 process design (CPD) and process
design for refinery revamps.
6-stages psig to meet gas plant oper- Previous positions include produc-
4,200 ating pressure and to stay tion planner at BPs Alliance
Refinery and technical service engi-
below the 250 psig pressure neer at Hess Oil St. Croix Refinery.
4,000 relief valve (PSV) settings, Barletta has authored numerous
10,200 10,400 10,600 10,800 11,000 11,200 11,400 technical papers on revamping
Inlet volume flow, icfm the required polytropic refinery units. He holds a BS degree in Chemical
Engineering from Lehigh University.
head at 12 psig suction and
210 psig discharge pressure
Figure 11. Flow-power requirements for was approximately 46,000 Scott W. Golden is a chemical
chemical engineer with Process
7- and 6- stage compressor feet of head. Therefore, Consulting Services in Houston,
destaging was a practical TX. The company specializes in
refinery unit revamps. His previous
which exceeded the maximum allowable solution. Figure 10 shows the comparison experience includes refinery process
engineering and distillation trou-
working pressure (MAWP) of the major between the flow-head curves for the orig- bleshooting and design. Golden has
equipment in the gas plant. Hence, com- inal 7-stage machine and a destaged 6- authored more than 80 technical
papers on revamping, troubleshoot-
pressor head had to be reduced. stage compressor generated by the OEM. ing, and distillation. He holds a BS
Compressor power requirements also Compressor drivers must also be able to degree in Chemical Engineering
from the University of Maine and is a registered profes-
have to be considered. Both the flow-head supply the power requirement throughout sional engineer in Texas.
and flow-polytropic efficiency curve is the stable operating range of the compres-
needed to evaluate power consumption. sor. Power consumption depends on mass
Power requirement would have been more flow rate through the machine, polytropic
han 5,100 horsepower due to the higher head developed and compressor polytrop-
mass flow rate; hence, the existing 4,400 ic efficiency. Flow-polytropic efficiency
horsepower motor would have to be curves are supplied by the manufacturer
eplaced. But replacing a motor or steam and allow power consumption throughout
urbine can be very costly because it often the stable flow range to be easily calculat-
equires major utilities system modifica- ed. Figure 11 shows a comparison between Process Consulting Services, Inc.
ions as well. the power requirements of a 7- and 6-stage 3400 Bissonnet
Although it is compressor OEM or com- compressor. By eliminating one stage of Suite 130
pressor expert who should do comprehen- compression, machine horsepower Houston, Texas 77005
sive compressor analyses, the revamp requirements were reduced below the U.S.A.
engineer can perform a preliminary review existing 4,400 horsepower motor. Phone: [1]-(713)-665-7046
by making simplifying assumptions such Though centrifugal machines are used in
Fax: [1]-(713)-665-7246
as equal head rise per stage of compres- many refinery units to compress gases, the
E-mail: info@revamps.com
sion to determine whether removing a principles of compression are the same
stage of compression or trimming the irrespective of the process units. Only the
Website: www.revamps.com
mpellers is needed. gases compressed and the process vari-

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