Compression Process Compressor Characteristics Key Design Parameters Calculation Methods Specification Data Sheet Selection Guidelines Control Systems Typical operating Problems Compressors & Gas Compression Positive Displacement Reciprocating (Piston, Diaphragm) Rotary Type (Screw, Lobe, Slidiong Vane
Dynamic Centrifugal (Radial and Axial) Blowers Categories and Types Compressors & Gas Compression Categories and Types Compressors & Gas Compression Centrifugal Compressor Compressors & Gas Compression Axial Compressor Compressors & Gas Compression Ranges of Application Compressors & Gas Compression Compression Process Gas compression is a thermodynamic process where change takes place in the physical state of the gas
Compression adds energy to the gas resulting in pressure- volume changes defined by ideal gas laws
Compression take place under conditions defined: Adiabatic: no heat added or removed from systems Isothermal: constant temperature in system Polytropic: heat added or removed from system
Compression of real gases in actual compressors deviate from conformance with ideality, usually significantly, affecting compressor design. Compressors & Gas Compression Compressor Characteristics Capacity/Head
Performance
Terminology Compressors & Gas Compression Reciprocating Compressor Performance Diagram
Terminology Piston Displacement Clearance Volume Volumetric Efficiency Pressure Ratio Rod Loading Compressors & Gas Compression Reciprocating Compressor Compressors & Gas Compression Reciprocating Compressor Compressors & Gas Compression Centrifugal Compressor Performance Curves
Terminology Operating Point Surge Point Stonewall Stability Turndown Compressors & Gas Compression Centrifugal Compressor Compressors & Gas Compression Centrifugal Compressor Compressors & Gas Compression Centrifugal Compressor Performance Compressors & Gas Compression Centrifugal Compressor Key Design Parameters Capacity Gas Properties Pressure Head Power Efficiency Multi-Stages Compressors & Gas Compression Centrifugal Compressor Key Design Parameters
Flow Rates Normal Maximum Minimum
Design Capacity Capacity Compressors & Gas Compression Centrifugal Compressor Key Design Parameters Composition Contaminants Molecular Weight MW Specific Heat Ratio Cp/Cv Compressibility Gas Properties Compressors & Gas Compression Centrifugal Compressor 10C 38C 66C 93C 121C Compressors & Gas Compression Centrifugal Compressor Compressors & Gas Compression Centrifugal Compressor Compressors & Gas Compression Centrifugal Compressor 100F = 560R: 560/549 = 1.02 100F = 311K, 549R = 305K: 311/305 = 1.02 PV = ZmRT/MW P=100psia = 6.89 bar a T=100F = 37.8C = 310.9K = m/V = P(MW)/(ZRT) = 6.89E5x34.27/(0.946x8314x310.9) = 9.7kg/m 3 = 0.61lb/ft 3 Compressors & Gas Compression Centrifugal Compressor 0.973 0.077 1.02 Compressors & Gas Compression Centrifugal Compressor 0.88 Compressors & Gas Compression Centrifugal Compressor Key Design Parameters Available vs. Required Head Available Head is Compressor Related H(Available) = CV 2 /g C = Pressure Coefficient (0.55) Required head is System-Related Head H(Required) Compressors & Gas Compression Centrifugal Compressor For centrifugal compressors the following method is normally used:
First, the required head is calculated. Either the polytropic or adiabatic efficiency is used with the companion head. Horsepower Calculation Compressors & Gas Compression Centrifugal Compressor Horsepower Calculation Where: Z = Average compressibility factor: using 1 will yield conservative results R = 1544/(mol weight) T1 = Suction Temperature, R P1, P2 = Suction, discharge pressures, psia K = Adiabatic exponent, (N-1)/N = (K-1)/(KE p ) E p = Polytropic Efficiency E A = Adiabatic Efficiency Compressors & Gas Compression Centrifugal Compressor Horsepower Calculation The polytropic and adiabatic efficiencies are related as follows: From Polytropic Head:
HP = WH poly /(E p 33000) From Adiabatic Head:
HP = WH AD /(E A 33000) Where:
HP = Gas Horse Power BHP = Brake Horsepower W = Flow, Lb/min BHP = HP/E m Compressors & Gas Compression Efficiency Hydraulic Efficiency Adiabatic Polytropic
Volumetric Efficiency Reciprocating
Mechanical Efficiency Drivers Compressors & Gas Compression Centrifugal Compressor Approximate polytropic efficiencies for centrifugal and axial compressors Compressors & Gas Compression Temperature Rise Temperature ratio across a compression stage is:
T 2 /T 1 = (P 2 /P 1 ) (K-1)/K Adiabatic
T 2 /T 1 = (P 2 /P 1 ) (N-1)/N Polytropic
Where:
K = Adiabatic exponent, C p /C v
N= Polytropic exponent, (N-1)/N = (K-1)/KE p
P 1 , P 2 = Suction, discharge pressures, psia T 1 , T 2 = Suction, discharge temperatures, R E p = Polytropic efficiency, fraction
Compressors & Gas Compression Temperature Rise The usual centrifugal compressor is uncooled internally and follows a polytropic path.
Temperature must often be limited to: Protect against polymerization as in olefin or butadiene plants At T > 230-260C, the approximate mechanical limit, problems of sealing and casing growth start to occur.
High temperature requires a special and more costly machine. Most multistage applications are designed to stay below 250- 300C Compressors & Gas Compression Temperature Rise Intercooling can be used to hold desired temperatures for high overall compression ratio applications. This can be done between stages in a single compressor frame or between series frames.
Sometimes economics rather than a temperature limit dictate intercooling.
Sometimes for high compression ratios, the job cannot be done in one frame. Usually a frame will not contain more than 8 stages (wheels). For many applications the compression ratio across a frame is about 2.5 4.0
The maximum head that one stage can handle depends on gas properties and inlet temperature. Usually this is about 2000 to 3400m for a single stage. Compressors & Gas Compression Surge Controls A centrifugal compressor surges at certain conditions of low flow.
Surge control help the machine to avoid surge by increasing flow. For an air compressor, a simple spill to atmosphere is sufficient. For a hydrocarbon compressor, recirculation from discharge to suction is used.
Compressors & Gas Compression Surge Controls There are many types of surge controls.
Avoid the low-budget systems with a narrow effective range, especially for large compressors.
Good systems include the flow/P type.
The correct flow to use is the compressor suction. However, a flow element in the suction can rob excessive horsepower. Therefore, sometimes the discharge flow is measured and the suction flow calculated within the controller by using pressure measurements. The compressor intake nozzle is also sometimes calibrated and used as a flow element. Compressors & Gas Compression Compressor Calculation Method Define gas properties: MW, Cp/Cv, Z 1
Define inlet conditions: Temp & Press. Calculate gas flow rate: Normal and Design 1
Establish total discharge pressure. Calculate compression ratio and number of stages Define selection & polytropic efficiency
1. At inlet conditions
Compressors & Gas Compression Compressor Calculation Method contd Calculate heat capacity factor M Calculate required polytropic head Calculate hydraulic gas horsepower Calculate discharge temperature Calculate total brake horsepower Estimate inter-stage cooling requirement
Compressors & Gas Compression Compressor Calculation Example 1: Calculate compressor required to handle a process gas at the following operating conditions: Inlet press and temp at 20 psia and 40F. Discharge pressure of 100 psia. Gas rate 2378 lb.mol/hr of the following composition and calculated properties: Mol% Mol/h Mol. Wt C p
Assume E p = 77%: M = (1.137 1)/(1.137 x 0.77) = 0.156 Calculation: Compressors & Gas Compression Compressor Calculation Example 1: contd Polytropic Head, H p
Calculation: = 0.97 x (1545/44.24) x (40 + 460)/0.156 x [(100/20) 0.156 -1] = 30 988 ft Compressors & Gas Compression Compressor Calculation Example 1: contd Discharge Temperature, T2
T2 = T1(P2/P1)M = 500(5)0.156 = 643R = 183F
Gas Horsepower (GHP) & Brake Horespower (BHP)
GHP = W . H poly /(33000E p ) = 1753 x 30988/(33000 x 0.77) = 2140
Calculation: Compressors & Gas Compression Example Calculate the Brake Horsepower for the following Compressor:
07TI001 07TI002 07TI004 07TI005 07TI006 07T1008 07TI010 07TI012 22 99 50 124 55 139 57 65 C C C C C C C C 07PIC004 07PI005 07PI006 07PI007 07PI017 07PI009 07PI013 07PI011 2418 4300 4250 7700 7643 14 14 14.6 kPa g kPa g kPa g kPa g kPa g MPa g MPa g MPa g 07FI003 07FI004 107 353 km n 3 /h km n 3 /h 11497 11464 0.0% 0.0% 20.0 0.1% 08AI004 87.0 2.5% km n 3 /h KNM3/H 15.0% % Argon Argon H2 65.6 Purge 0.0% to Flare N2 21.4 Actual Speed = Reference Speed = RECYCLE STAGE 1 STAGE 2 STAGE 3 STAGE 4 C3030 C3031 HC02 HC06 HC02 HC08 C3032 C3034 HC41 TO NH3 REACTOR Red Blocks = Local Readings (necessary for MW calculation) Compressors & Gas Compression Example Calculate the Brake Horsepower for the following Compressor:
Calculate Gas Mixture Properties
Composition: H2 = 65.6/(65.6+21.4) = 75.4 vol% N2 = 100 75.4 = 24.6 vol% Composition Mole% Mole Wt MW mass% Cp MW Hydrogen 75.4 2 1.51 18.0 14.3 2.57 Nitrogen 24.6 28 6.89 82 1.04 0.85 Total Gas Mix 100.0 8.40 11.04 3.42 Use Z = 1 for conservative results Compressors & Gas Compression Example Calculate the Brake Horsepower for Compressor: Contd
H poly = 1 x (8.314/8.4) x 295 x ((4400/2518) 0.416 -1) 0.416 = 183.4 kJ/kg
T 1 = 22C = 295K T 2 = 99C = 372K P 1 = 2418 kPag = 2518 kPa a P 2 = 4300 kPag = 4400 kPa a Compressors & Gas Compression Example Calculate the Brake Horsepower for Compressor: Contd
First stage: (N-1)/N = (K-1)/(KE p ) E p = (1.4 -1)/(1.4 x 0.416) = 0.69
W = (107 000/22.414) x 8.4 = 40100kg/h = 11.14 kg/s Cp/Cv = Cp/(Cp-R) = 3.42/(3.42-8.314/8.4) = 1.4 Compressors & Gas Compression Example Calculate the Brake Horsepower for Compressor: Contd
First stage: Gas Horsepower = W . H poly /E p
= (11.14 x 183.4)/0.69 = 2960 kJ/s = 3.0 MW
Similar for stage 2, 3 and Recycle: GHP(stage 2) = 2.9MW GHP(stage 3) = 3.3 MW GHP(recycle stage) = 1.0 MW
Total GHP = 3.0 + 2.9 + 3.3 + 1.0 = 10.2 MW
A good assumption for Mechanical Efficiency = 95%
BHP = 10.2/0.95 = 10.6 MW Compressors & Gas Compression Compressors & Gas Compression