FRICK

COMPRESSOR

03/14/15

FRICK
COMPRESSOR
Fluidized
bed reactor is the place where actual
polymerization of ethylene is taking place to form
polyethylene. This reaction is highly exothermic in nature
and results in the formation of lots of heat of reaction. This
heat of reaction has to be carried out of the reactor for
better quality and high throughputs of the polymer. This is
achieved by the use of Pentane injection in the gas loop
for carrying away the heat of reaction as pentane has high
specific heat. Pentane which is carried along with the
powder in adsorbed form is recovered and recycled back
to the reactor in secondary degasser via liquid propylene
at -40 0C which is being supplied by the Frick compressor
Propylene Refrigeration is achieved in the Frick
Refrigeration Unit PK-4115.

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FRICK REFRIGERATION UNIT

PK-4115

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It is a vapor compression cycle.

It is used for condensing and recovering
heaviers; basically pentane; from the recycle
gas and purge loop stream.
The pentane content in the streams is
somewhere around 15-16%.
VRU K-4114 is used to recycle vent gas to the
refrigeration unit.

FRICK
Components
of Frick refrigeration unit
COMPRESSOR

Frick compressor
Condenser
Receiver
Economizer
Vent gas condenser(E-4123)
Purge gas condenser(E-4122)

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FRICK
COMPRESSOR
R-1270 FROM E-4122 AND
4123

R-1270 TO E-4122 AND

4123

20 KPa, 229.3K

1548.6 KPa, 313K

TRAP

1548.6 KPa, 313K

20 KPa, 229.3K
RECEIVER

CWS
32C

COMPRESSOR
CONDENSER
1548.6 KPa,
342.6K

OIL SEPERATOR
208 KPa, 253.4K

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CWR
35.9C

ECONOMISER

FRICK
A typical
oil flooded twin-screw compressor
COMPRESSOR
consists of male and female rotors mounted on

bearings to fix their position in a rotor housing

which holds the rotors in closely toleranced
intersecting cylindrical bores.
The rotors basic shape is a screw thread, with
varying numbers of lobes on the male and
female rotors. The driving device is generally
connected to the male rotor
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FRICK
COMPRESSOR

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FRICK
COMPRESSOR

Ist Suction temperature

IInd Suction temperature
Ist Suction Mass flow rate
IInd Suction Mass flow rate
Discharge temperature
I Suction pressure
II Suction pressure
Discharge pressure
Discharge Mass flow rate

:
-43.7 OC
: -19.6 OC
: 18.3 kg/min
: 9.7 kg/min
: 69.9 0C
: 20 KPa
: 208 KPa
: 1548 KPa
: 28 kg/min

FRICK
COMPRESSOR
ENTHALPY :
H =Cp dt

WORK

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= MASS FLOWRATE * H

MINIMUM WORK REQUIRED BY

COMPRESSOR
= ENTHALPY (OUT) ENTHALPY (IN)
= m* H

47 C,1548 Kpa

m* H

(inlet )

= 16.24-(-19.47)
=35.71 kW.
ACTUAL WORK DONE BY THE
COMPRESSOR
= m* H

69.9

C ,1548 Kpa

= 34.02-(-19.47)
=53.49 kW.
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m* H

( inlet)

FRICK
COMPRESSOR
EFFICIENCY OF COMPRESSOR
=

MIN WORK /ACTUAL

WORK

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35.75/53.49=0.668

66.8 %

FRICK
COMPRESSOR

INCREASING THE THROUGHPUT OF THE COMPRESSOR BY

10%
Mass flow rate of propylene =28 *1.1%=30.8 kg/min
Thermodynamic discharge temperature = 47 c=320 K
Suction temperature = -3.0 c = 270 K
Work = mass flow rate * H . kW
MINIMUM WORK REQUIRED BY COMPRESSOR

= ENTHALPY (OUT) ENTHALPY (IN)

=m* H 47 C,1548 Kpa m* H (inlet )
= 17.87-(-21.42) =39.29 kW.
ACTUAL WORK DONE BY THE COMPRESSOR AT SAME
EFFICIENCY
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= min work/efficiency
= 39.29/.668 = 59.26 kW.

FRICK
COMPRESSOR

Efficiency of compressor is with in acceptable range ,but

is on lower side.
This may be due to following reasons.
This compressor is running for more than ten years.
Wearing of rotor threads.
Oil cooling not working correctly.
Oil flow to the to the compressor may be restricted.
Oil is not cooled to required temperature.
All these reasons leads to high discharge temperature
Which lead to deterioration of compressor efficiency.

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FRICK
HOW TO INCREASE EFFICIENCY
COMPRESSOR

EFFICIENCY OF THIS COMPRESSOR CAN BE

INCREASED BY
Increasing the flow of oil to the compressor, so maximum
heat is taken up by the oil.
Keeping the re injection oil temperature up to optimum.
Increasing the throughput to the compressor from
economizer
port inlet may help in decreasing the
discharge temperature

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 LOW

SUCTION PRESS.
HIGH DISC. PRESS.
Kpa
HIGH DISC.TEMP.
HIGH OIL TEMP.
LOW OIL TEMP.
LOW OIL

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53 Kpa
1861

100 0C
75 0C
9 0C
30 Sec.

OIL LEVEL SWITCH

REMOTE RUN
REMOTE LOAD
REMOTE UNLOAD
COMPRESSOR AUX.
OIL PUMP SEL. SW.

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COMPRESSOR START RELAY

SLIDE VALVE LOAD
SLIDE VALVE UNLOAD
SLIDE STOP INCREASE
SLIDE STOP DECREASE
OIL HEATER RELAY
OIL PUMP SEL. SW.
LIQUID INJECTION
HI Vi LIQUID INJ.
ECONOMISER

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MOTOR AMPS ( M 4J01)

OIL PRESS. ( PE 4J01 )
FILTER OIL PRESS. ( PE 4J02 )
DISCH. OIL PRESS.( PE 4J03)
SUCTION OIL PRESS.(PE-4J04)
SUCTION TEMP.( TE 4J01 )
DISCH. TEMP.( TE 4J02 )
OIL TEMP.( TE 4J03 )
SEPERATOR TEMP.( TE 4J04 )

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Operating Display ( F1 )
Adjustable Set point Display
Fixed Set point Display
Annunciator Display
Shutdown Record Display
Freeze Display
Security Display ( F2 )
Setback Display ( F3 )
Auto Cycle Display ( F4 )

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GENERAL MAINTEINANCE
KEEP

REFRIGERENT OIL CLEAN &DRY.

AVOID MOISTURE CONTAMINATION.
AFTER SERVICING ANY PORTION OF THE
REFRIGERATION SYSTEM,EVACUATE TO
REMOVE MOISTURE BEFORE RETURNING
TO SERVICE.
KEEP SUCTION STRAINER CLEAN,CHECK
PERIODICALLY,PARTICULARLY ON NEW
SYSTEMS WHERE WELDING SLAG OR PIPE
SCALE COULD FINDS IT WAY TO THE
COMPRESSOR SUCTION
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GENERAL MAINTEINANCE
KEEP

OIL FILTER CLEAN. IF FILTER

SHOW INCREASING PR. DROP
,INDICATING DIRT OR WATER,STOP THE
COMP. AND CHANGE THE FILTER.TRIP IS
AT 1.72 KG/CM2 DIFFERENTIAL PR.
AVOID SLUGGING COMP. WITH LIQUID
REFRIGERENT , WHILE SCREW COMP.
ARE MOST TOLLERENT TO INGESTION
OF SOME REFRIGERENT LIQUID.
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GENERAL MAINTEINANCE
PROTECT

THE COMP. DURING LONG

PERIODS OF SHUT DOWN.IF THE
COMP. WILL BE SETTING FOR LONG
PERIOD S WITHOUT RUNNING IT IS
ADVISABLE TO EVACUATE TO LOW
PRESSURE AND CHARGE WITH DRY
NITROGEN OR OIL, PARTICULARLY ON
SYSTEMS KNOWN TO CONTAIN
WATER VAPOR.

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GENERAL MAINTEINANCE
PREVENTION

MAINTENANCE
INSPECTION IS RECOMMENDED ANY
TIME A COMPRESSOR EXHIBITS A
NOTICEABLE CHANGE IN VIBRATION
LEVEL, NOISE OR PERFORMANCE.

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COMPRESSOR SHUTDOWN
REDUCE

THE SYSTEM PRESSURE TO

DESIRE CONDITION.
PRESS STOP KEY TO CEASE
OPERATION OF COMPRESSOR.
OPEN DISCONNECT SWITCHES FOR
COMPRESSOR MOTOR AND OIL PUMP
STARTER.
TURN OFF OIL HEATER CIRCUIT
BREAKER
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 CLOSE

SUCTION AND DISCHARGE

SERVICE VALVES, ALSO LIQUID
INJECTION & ECONOMIZER SERVICE
VALVES.
SHUTTOFF C.W SUPPLY VALVE TO OIL
COOLER .

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COMPRESSOR START-UP
ANY

WATER NECESSARY FOR THE

OPERATION OF SYSTEM THAT MAY
HAVE BEEN DRAINED OR SHUTOFF
SHOULD BE RESTORED & TURN ON,IF
OIL COOLER HEADS WERE
REMOVED,REINSTALLED & REMOVE
TAGS.

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 OPEN

SUC. & DIS. SERVICE VALVES &

ALSO LIQUID INJECTION &
ECONOMIZER SERVICE VALVE.
CLOSED DISCONNECT SWITCHES FOR
COMP, MOTOR & OIL PUMP
STARTERS.
TURN ON HEATER CIRCUIT BREAKER
PERFORM CHECK POINTS ON
PRESTART CHECK LIST. THEN START
UNIT.
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SUMMERY:

It is an YARK International (Screw Compressor) Frick

Compressor
Vapor compression refrigeration (where propylene is
used as a refrigerant)
Capacity control is based on suction pressure control.
Also there is an option of capacity control based on
liquid propylene supply temperature to E4123/E4122
Volume ratio - Stroke volume
Slide valve position Capacity control
Slide valve is the closed loop control valve. 100%
means close loop valve is 0% open.

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Suction Pressure = 1.25 Kg/Cm2 a

Discharge pressure = 13.0 Kg/Cm2 a Low
suction trip at 0.53 Kg/Cm2 a High discharge
temp trip at 100 0C(Gas Temp) High oil temp trip
at 75 0C
Low oil temp trip at 9 0C
Oil heaters off at 45 0C
Low oil cut at dP 0.30 Kg/Cm2
Sensor fault alarm settings
Low- High discharge temp 32-212 0F
Low-high oil temp 0-180 0F
Low- Suction for 29Hgs
Low or high set temp 0-180 0F
Compressor rotation is clockwise when facing the
compressor driving shaft. The compressor should
never be operated in reverse direction as bearing
damage could result.

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The compressor lubrication system performs

several functions such as
Provide lubrication to bearing and seal
Provide a cushion b/w the rotors to minimize
noise and vibrations.
Helps to keep the compressor cool and prevent
compressor overheating
Provides an oil supply to hydraulically actuate
the slide valve and slide stop
Provide oil pressure to the balance piston to
help increasing bearing life
Provides an oil seal b/w the rotors to prevent
rotor contact or gas bypassing

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THANK
YOU
03/14/15