Professional Documents
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References:
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Gas Handling Equipment
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Gas Handling Equipment (Contd 1)
Fans, Blowers and Compressors are the commonly
used gas handling equipment. Classification is mainly based
on discharge pressure
Fans accept gases at near atmospheric pressure and
raise the pressure by around 130 to 1500 mm wc
Blowers raise the pressure of gases to an intermediate level,
usually to less than 4 kg / cm2 g
Compressors are used where higher pressures are
required. In modern terminology, the term
compressors includes blowers.
Vacuum pumps and steam jet ejectors are used to
generate vacuum
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Fans
Large Fans are the commonly used centrifugal
machines
Operate on the same principle as centrifugal pumps
Fan impellers are mounted in light sheet metal casings
Their impeller blades typically curve forward
In ventilating fans, nearly all of the added energy goes
to increase velocity and almost none to pressure
head
Since the change in density in a fan is small,
incompressible flow equations used for centrifugal
pumps can be applied to fans
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Fans (Contd)
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Centrifugal Compressors (Contd 2)
Section of a Compressor
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Centrifugal Compressors (Contd 3)
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Centrifugal Compressors (Contd 4)
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Centrifugal Compressors (Contd 5)
Section of a
three stage
Compressor
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Centrifugal Compressors (Contd 7)
Advantages
- Higher efficiencies compared to reciprocating
compressor
- Gives lubricant free air
- Does not require special foundations much less
vibration
Disadvantages
- High initial cost
- High rotational speed requires special bearings and
sophisticated vibration and clearance monitoring
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Compressor operating ranges
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Axial flow Compressors
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Axial flow Compressors (Contd 1)
Compresses the gas by first accelerating the fluid and
then diffusing it to increase its pressure
Gas flow is accelerated by a row of rotating airfoils
(blades) called the rotor, and then diffused in a row of
stationary blades (stator); stator converts the velocity
energy gained in the rotor to pressure energy.
There is no change in flow direction
One rotor and one stator make up a stage in a
compressor. Inter stage cooling is generally not
required
Driver of axial flow compressor can be steam turbine
or electric motor
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Axial flow Compressors (Contd 2)
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Compressor operating ranges
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Positive Displacement Compressors
Rotary compressor
- Commonly used for discharge pressures
up to about 6 Kg/cm2 g
- Derives its pressurizing ability from the spinning
component which is eccentric to the casing
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Positive Displacement Compressors (Contd 1)
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Positive Displacement Compressors (Contd 2)
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Positive Displacement Compressors (Contd 3)
A screw compressor
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Positive Displacement Compressors (Contd 4)
Reciprocating compressor
- Relatively low flow rate, high pressure machines
- Uses the positive movement of piston within a
cylinder to move gas from one pressure level to a
higher pressure level
- Single acting when the compressing is
accomplished only on one side of the piston,
double acting when it uses both sides of the piston
- These machines operate the same way as
reciprocating pump; important differences are
prevention of leakage is more difficult and
temperature rise is important.
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Positive Displacement Compressors (Contd 5)
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Positive Displacement Compressors (Contd 6)
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Design Considerations for Compressors
Fluid properties
- Gas composition Component name,
molecular weight, boiling point
- Corrosiveness e.g. H2S
- Fouling tendency : flushing
- Liquid in the gas stream
- Inlet pressure and temperature
- Discharge pressure and temperature
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Design Considerations for Compressors (Contd 1)
Mechanical design of compressor
- Casing & cylinder Maximum Allowable Working
Pressure (MAWP)
- Casing & cylinder Maximum Allowable Working
Temperature
- Piping flange and rating
- Shaft and piston rod seal
- Process Compression Stages Requirement of side
streams
Utilities available and their specs
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Vacuum Producing Equipment
Vacuum Pump
- A compressor that takes suction at a pressure
below atmospheric and discharges against
atmospheric pressure is called a vacuum pump
- Hence, any type of blower or compressor
reciprocating, rotatory or centrifugal can be
adapted to vacuum practice by modifying the
design
- Recips are effective for absolute pressure down to
about 10 mmHg; Rotary vacuum pumps can lower
the absolute pressure to 0.01 mmHg
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Vacuum Producing Equipment (Contd 1)
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Vacuum Producing Equipment (Contd 2)
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Vacuum Producing Equipment (Contd 3)
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Vacuum Producing Equipment (Contd 4)
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Vacuum Producing Equipment (Contd 7)
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Vacuum Producing Equipment (Contd 9)
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Vacuum Producing Equipment (Contd 10)
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Drivers for Moving Equipment
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Drivers for Moving Equipment (Contd 1)
Motors
- Three main classes
- Induction
- Synchronous
- Direct current.
Higher voltages are more efficient, but only in the
larger sizes. Commonly used voltages in Indian
industries are 415 V, 3.3 kV, 6.6 kV, 11kV
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Drivers for Moving Equipment (Contd 2)
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Drivers for Moving Equipment (Contd 3)
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Drivers for Moving Equipment (Contd 4)
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Drivers for Moving Equipment (Contd 6)
Steam Turbines
- Single stage normally used as drivers, normally of
condensing type. For multistage units, steam can
be bled at multiple reduced pressures to provide
steam at various pressures to the plant.
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Drivers for Moving Equipment (Contd 7)
When gases (other than steam) are used as the
motive fluid, the equipment is called as gas expander.
They are used to recover energy from high pressure
process streams in a plant when the lower pressure
gas is adequate
Gas turbines are the equipment that recover power
from hot combustion gases
IC engines are an excellent choice when low cost fuel
is available. Their installation and operation cost is
low. Example of use is in offshore drilling
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Compression and Expansion of Gases
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Compression and Expansion of Gases (Contd 1)
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Mollier Diagram (Contd 1)
where
H1 = Specific enthalpy at the pressure and
temperature corresponding to the initial
gas condition,
and
H2 = Specific enthalpy at the pressure and
temperature corresponding to the final gas
condition
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Example 1
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Example 1 (Contd 1)
H2 = H1 + 2000
= 4500 + 2000
= 6500 cal /mol
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Example 1 (Contd 4)
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Compression and Expansion of Gases (Contd 3)
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Compression and Expansion of Gases (Contd 4)
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Compression and Expansion of Gases (Contd 5)
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Compression and Expansion of Gases (Contd 6)
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Example 2
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Example 2 (Contd 1)
Take inlet temperature of 30oC
At that temperature, specific volume
v1 = (22.4/29) x (303/273)
= 0.8573 m3/Kg
Work W = P1v1 ((/(-1)) [(P2/P1)((-1)/) - 1] (Eqn.2
with n= )
W = 1.0133 x 105 x 0.8573 x [1.4/(1.4-1)] x
[ (3.0133/1.0133) ((1.4 1)/1.4) 1]
= 1.0133 x 105 x 0.8573 x 3.5 x (2.9740.286 1)
= 1.0133 x 105 x 0.8573 x 3.5 x (1.366 -1)
= 111.28 KJ / Kg
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Example 2 (Contd 2)
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Multistage Compressor (Contd 1)
For a two stage compressor,
compression ratio (CR)in each stage is (P2 / P1) 1/2
and interstage pressure Pi ,is
Pi = CR x P1
For a three stage compressor, CR = (P2 / P1)1/3 and
interstage pressures Pi 1 and Pi 2 are
Pi1 = CR x P1
and Pi2 = CR x Pi1
= CR xCR x P1
and so on
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Example 3
Estimate the power required to compress 1000 m3/hr of air from
ambient conditions to 700 KN /m2 g using a two stage
reciprocating compressor with an intercooler
P1 = 1 atm = 101.33 KN/m2 abs
P2 = 700 + 101.33 = 801.33 KN/m2 abs
For air, = cp / cv = 1.4
Compression ratio (CR) in each stage
= (8.0133 x 105 / 1.0133 x 105 )0.5 = 2.812
Therefore, interstage pressure Pi =101.33 x 2.812
= 284.9KN/m2
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Example 3 (Contd 1)
Take inlet temperature of 30oC
v1 = (22.4 / 29) x (303 /273)
= 0.8573 m3 / kg
Work for each stage
Work W = P1v1 ((/(-1)) [(Pi /P1)((-1)/) - 1]
= 1.0133 x105 x 0.8573 x (1.4/(1.4-1))
x [ (2.849 /1.0133) ((1.4 1)/1.4) 1]
= 1.0133 x105 x 0.8573 x 3.5 [2.8120.286 1]
= 1.0133 x 105 x 0.8573 x 3.5 [1.344 -1]
= 1.0459 x 105 J/Kg = 104.59 KJ / Kg
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Example 3 (Contd 2)
For 2 stages,
W = 2 x 104.59 = 209.18 KJ / Kg
Compression ratio in each stage = 2.812
For Compression ratio = 2.812, = 83% (from fig 3.7)
So work required = 209.18 / 0.83 = 252.02 KJ / Kg
Mass flow rate = 1000 / ( 3600 x 0.8573)
= 0.324 Kg / sec
Power reqd. = 252.02 x 0.324
= 81.65
say 82 KW
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Electric Drives
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Approximate Efficiencies of Electric Motors
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Class Exercise
A three stage reciprocating compressor with
intercoolers is used to compress 1000m3 / hr of air
at 50oC from 100 kN / m2 g to 1800 kN / m2 g.
Calculate
a) Compression Ratio for each stage
b) Inter-stage pressures
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Answer
a) P 1 = 100 + 101.33 = 201.33 kN/m2 ab
P2 = 1800 + 101.33 =1901.33 kN/m2 ab
CR for each stage
= (1901.33 / 201.33)1/3 = 2.114
b) Inter-stage pressures
Pi1 = (CR x P1) = 2.114 x 201.33
= 425.61 kN / m2 ab
Pi2 = (CR x Pi1) = 2.114 x 425.61
= 899.74 kN / m2 ab
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