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Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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CONTENTS
SECTION
INTRODUCTION/PURPOSE
SCOPE
FIELD OF APPLICATION
DEFINITIONS
5.1
5.2
5.3
4
4
5
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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7.1
Fans
7.2
Centrifugal Compressors
7.3
Axial Compressors
7.4
Reciprocating Compressors
7.5
Screw Compressors
7.6
7.7
7.8
11
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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APPENDICES
A
13
15
FIGURES
13
15
16
TABLES
1 COMPRESSOR/FAN OPERATING LIMITS
10
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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INTRODUCTION/PURPOSE
This GBHE Engineering Guide has been prepared to assist in the selection of
Fan or Compressor types and to prepare information for an enquiry to be issued
to a supplier.
SCOPE
This GBHE Engineering Guide defines the way in which the type of fan or
Compressor, and the number of units required for a particular duty, may be
determined from knowledge of the process parameters.
This Guide shall be read in conjunction with the relevant engineering and
purchase specification for the specified fan or compressor type.
FIELD OF APPLICATION
DEFINITIONS
For the purposes of this Engineering Guide, the following definitions apply:
There are no terms which are specific to the subject which require definition.
With the exceptions of terms used as proper nouns or titles, those terms with
initial capital letters which appear in this document and are not defined above are
defined in the Glossary of Engineering Terms.
Having obtained the process data, the first step in the selection process is the
preliminary choice of fan or compressor type. The choice is constrained by the
operating limits which are a characteristic of each machine type. Further
selection constraints arise from considerations of the plant operation such as
desired turndown and freedom from contamination of the product by the machine
lubricating oil or corrosion debris from the materials of construction, as well as
the required availability of the machine.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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Once the preliminary choice of fan or compressor type has been made, refer to
either Clause 6, 7 or 8 for more details of fan and compressor applications.
The sequence for preliminary selection is shown in Figure 1.
The purpose of the process data sheet is to describe the normal duty, including
all operating cases, all possible combinations of gases, pressures, flow and
temperatures. It should not, at this stage, contain any margins on the flowrate or
pressure.
A typical 'Process Data Sheet' is shown in Appendix B.
FIGURE 1: SELECTION SEQUENCE FOR FAN OR COMPRESSOR TYPE
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5.1
kg/hour
Gas composition
Molar percentage
Gas pressures
bars absolute
Temperatures
5.2
m3/hour.
Gas Properties
The following gas properties are to be given for the inlet to each stage:
(A)
(B)
(C)
(D)
(F)
5.3
Discharge Requirements
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6.1
The following essential data will be required to make the preliminary selection
from Table 2 and Figure 2.
(a)
(b)
Pressure
Inlet pressure
bars absolute =
Discharge pressure
bars absolute =
Pressure differential
bars =
Volume flowrate
The actual volume flowrate Q1 at the inlet can be calculated from the
expression:
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(c)
Power
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This clause provides guidance on the application of the various types of fans and
compressors available. The information should be read in conjunction with Table
1.
7.1
Fans
Centrifugal and axial fans are suitable for low pressure applications over a wide
range of flowrates. Special designs are available for high temperature duties.
Although fans are normally specified with a modest aerodynamic duty, care
needs to be taken with material selection and fan fabrication standards. Fans
which handle arduous duties (e.g. high tip speeds or contaminated fluids) will
need careful design specification.
Care should be taken with the selection of fans where a wide range of gas
densities is to handled. For example, extreme atmospheric variations will have a
significant effect on the fan absorbed power and driver power rating. To minimize
fan costs the selection may be made for normal ambient conditions, accepting
that in the occasional extreme condition the fan may fail to meet plant
requirements.
7.2
Centrifugal Compressors
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7.3
Axial Compressors
Axial compressors are generally used for high flows and low discharge pressure
applications, achieving high compression efficiencies. They should only be used
where the process gas is clean and dry.
As with fans and centrifugal compressors they should be avoided where a wide
range of gas density is to be handled.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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TABLE 1:
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Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
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7.4
Reciprocating Compressors
Reciprocating compressors are well suited to applications involving low flow rates
or high pressure ratios. They can accommodate a relatively wide range of gas
compositions, pressure ratios and flow rates, whilst maintaining a good
efficiency. Turndown in rate can be achieved by either individual valve lifters, or
by bypassing the stage or compressor. The latter is less efficient.
A disadvantage of the reciprocating compressor is the requirement for routine
maintenance which, in many cases, necessitates an installed spare. This
requirement should be considered when comparing costs with other compressor
types.
Oil lubricated reciprocating machines may subject the process to oil
contamination. The sensitivity of the process to oil contamination needs to be
checked. An important safety issue is the build up of carbonaceous deposits in
the compressor discharge system. This can lead to self ignition and fire or
explosion. Preventative measures include selecting the correct type of
oil, regular cleaning and temperature trip protection.
Reciprocating compressors are not ideally suited to dirty or polymerizing gases,
and cannot tolerate liquid droplets in the suction flow without causing erosion
damage.
7.5
Screw Compressors
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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7.6
7.7
Vane compressors are limited to low power, low pressure applications. They
generally operate at low speed and therefore noise levels are usually low.
Where vanes are oil lubricated, oil carryover into the process needs to be
considered.
For continuous duties reliability may be affected by vane wear.
7.8
Liquid ring compressors are generally limited to low power, low pressure
applications. The cooling effect of the sealing liquid means that discharge
temperatures are low, and in some applications discharge aftercoolers can be
eliminated. Since oil is not used to lubricate the compressor internally, the
discharge process gas is oil free.
Liquid ring compressors are suitable for dirty gas duties, however it is important
to ensure that the process gas is compatible with the circulating liquid.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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Whether to install a spare machine is a key decision in the selection process, not
only because of the effect on the total cost, but also because the choice of
multiple machines may allow several smaller machines to be used. Three factors
will influence this decision.
(a)
Reliability
Rotating machinery is intrinsically more reliable than reciprocating
machinery. For example, centrifugal compressors can be specified for
continuous operation for periods of up to 3 years. Therefore, a single
unspared centrifugal machine can be used, whereas the same duty may
require at least two reciprocating machines.
(b)
Availability requirements
In considering the likely availability of the plant to produce its final product
rather than the reliability of the compressor installation, repair time is a
significant factor. The definition of availability is:
Part-load performance
The required part-load performance of the plant shall be considered, and
for an installation with more than one machine, a machine failure may
allow the plant to continue in operation with reduced output.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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TABLE 2:
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Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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The total installed cost of the machine will be affected by many of the factors
listed below. This list is not intended to be a detailed list of all cost factors, but
only those which are likely to influence the preliminary choice of compressor
type.
(a)
(b)
Equipment costs
(1)
Driven machine.
(2)
(3)
(4)
(5)
(6)
Inlet filtration.
(7)
(8)
Driver.
(9)
Baseplate.
Installation costs
(1)
Foundations.
(2)
Area classification.
standard packaged machines are not suitable for installation in
some areas of process plant.
(3)
Noise control.
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(c)
Operating costs
(1)
(2)
Efficiency at turndown.
(3)
Maintenance requirements.
(4)
Major spares
Provided that an acceptable estimate of costs has been obtained, the preliminary
choice of fan or compressor can be confirmed. Then refer to the appropriate
GBHE Engineering Design Guide to specify the principle characteristics of the
chosen type.
An unacceptable estimate of costs will require a recycle to Clause 6 to establish
other feasible options, or to Clause 5 to revise the proposed process duty.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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APPENDIX B: CONTINUED
FIGURE 4: PROCESS DATA SHEET FOR COMPRESSOR - SHEET 2 OF 2
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GBH Enterprises
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com