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Nitrogen+Syngas 2015
CRU
Hilton Bomonti 26.02.2015Istanbul, Turkey
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Aleksandr Liubimov – leading specialist on compressors
Increase of Capacity by 35% andEfficiency Raise of the Technological Air
Centrifugal Compressor 101Jin Ammonia Production
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3
1. About us
2. Experimental and calculation methods
3. Examples of performed works (ammonia production)
3.1 Air compr. item 402 3.3 Syn-gas compr. item 103J3.2 Natural gas compr. item 102J 3.4 Ammonia compr. item 105J
4. Air compressor item 101J
4.1 Original compressor 4.3 1800 t/day Modernization4.2 1700 t/day Modernization 4.4 1950 t/day Modernization
5. Conclusion
Contents
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1 About us
Contents
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1 About us23 years on turbo-compressor market
Improving the efficiency and reliability of the turbo-compressor units - a priority of the company
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1 About usProduction
Manufacture takes place in 4 main production facilities withmodern machine tool equipment
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1 About us
Components and parts for turbo-compressor modernizations aremade on our own production facilities
New machine tools
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2 Experimental and calculationmethods
Contents
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2 Experimental and calculation methods
Good results of turbo-compressor flow part modernizations areachieved by an unique experimental data base.
Experimental method
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2 Experimental and calculation methodsExperimental gasdynamic characteristics of the model stage
0
0.2
0.4
0.6
0.8
1
0.1 0.15 0.2 0.25 0.3 0.35
η н - 2 , η
п о л ,
ψ ,
Ω ,
ζ 2 - 4
φr2
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2 Experimental and calculation methodsCFD calculations
3. Choke2. Optimal1. Surge
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3 Examples of performed works(ammonia production)
Contents
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3 Examples of performed works (NH3)Entechmach RPC LLC has successfully completed a number of
compressor modernizations for large-scale ammonia productions.
Natural Gas
item 102J
Ammonia
item 105J
Synthesis Gas
item 103J
К 29
121 1
Air
item 101J
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3.1 Air compressor item 402
Contents
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3.1 Air compressor item 402
3 modernizations are already performed with increased capacity+21% and increased efficiency.
In 2014 – 2015 4 more modernization will be put into operation.
Air compressor item 402 (К1290-121-1)
Turbine
LPC
HPC
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3.1 Air compressor item 402Modernized rotors
LPC
HPC
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3.2 Natural gas compressor item 102J
Contents
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3.2 Natural gas compressor item 102J
3 modernizations are already performed with increased capacity+15% and increased efficiency.
In 2016 1 more modernization is planned to be put into operation.
Natural Gas compressor item 102J
Turbine
HPC
PC
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3.2 Natural gas compressor item 102JAfter the modernization
Turbine HPC
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3.3 Synthesis gas compressor item 103J
Contents
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3.3 Synthesis gas compressor item 103J
3 modernizations are already performed with increased capacity+30% and increased efficiency.
In 2015 1 more modernization will be put into operation.
Synthesis gas compressor item 103J
Turbine LPCPCPC
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3.3 Synthesis gas compressor item 103JModernized MPC and HPC rotors (1750 t/day)
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3.4 Ammonia compressor item 105J
Contents
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3.4 Ammonia compressor item 105J
1 modernization is already performed with increased capacity +30%and increased efficiency.
Ammonia compressor item. 105J
Turbine
PC
LPC
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3.4 Ammonia compressor item 105JThe LPC modernization was done on «Hitachi» (2MCL808+MCL806)
compressor in the existing cases with existing turbine.
TurbinePC
HPC
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4 Air compressor item 101J
Contents
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4.1 Original Compressor
Contents
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4.1 Original Compressor
11 modernizations are already performed with increased capacity+25% and increased efficiency and 1 with increased capacity +35%.
In 2016 2 more modernizations will be put into operation.
Air compressor item 101J
Turbine
LPC
HPC
l
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4.1 Original Compressor
Turbine LPC
HPC
l
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4.1 Original CompressorCompressor scheme
2 1
3 4
LPC
HPC
Turbine
atm.
atm.
O i i l C
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4.1 Original CompressorLPC cross-section
4 1 O i i l C
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4.1 Original CompressorHPC cross-section
C
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4.2 1700 t/day Modernization
Contents
4 2 1700 /d M d i i
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4.2 1700 t/day Modernization
In 2005 Entechmach RPC LLC worked on the 1st air compressormodernization to raise its capacity to obtain 1700 t/d of ammonia.
8 modernizations are already performed with increased capacity+16% and increased efficiency.
1700 t/day Modernization
NamingHitachi
1360 t/day
Entechmach
1700 t/day
Performance at the discharge at normalconditions Qg, Nm3/h
52000 60500
Discharge pressure pк, kgf/sm2, a. 37,6 35,0
Rotor speed n, rpm: LPC/HPC5250
1070051509967
Overall shaft power Nshaft, kW 10260 11290
4 2 1700 /d M d i i
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4.2 1700 t/day ModernizationDesign features (1700 t/day)
LPC
HPC
4 2 1700 t/d M d i ti
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4.2 1700 t/day ModernizationModernized LPC rotor (1700 t/day)
LPC
4 2 1700 t/d M d i ti
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4.2 1700 t/day ModernizationModernized HPC rotor (1700 t/day)
HPC
HPC
4 2 1700 t/d M d i ti
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4.2 1700 t/day ModernizationThe intermediate cooler sections were changed to new ones with heat
exchange surface increased by 25%.
4 2 1700 t/d M d i ti
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4.2 1700 t/day ModernizationResults, 1800 t/day
Q
g
Capacity
N
Shaftpower + 1 6 %
+ 1 0 %
C t t
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4.3 1800 t/day Modernization
Contents
4 3 1800 t/d M d i ti
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4.3 1800 t/day Modernization
In 2012 Entechmach RPC LLC worked on the 1st air compressormodernization to raise its capacity to obtain 1800 t/d of ammonia.
3 modernizations are already performed with increased capacity+21% and increased efficiency.
1800 t/day Modernization
NamingHitachi
1360 t/day
Entechmach
1700 t/day
Entechmach
1800 t/day
Performance at the discharge atnormal conditions Qg, Nm3/h
52000 60500 63000
Discharge pressure pк, kgf/sm2, a. 37,6 35,0 35,0
Rotor speed n, rpm: LPC/HPC5250
1070051509967
520010035
Overall shaft power Nshaft, kW 10260 11290 11290
4 3 1800 t/d M d i ti
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4.3 1800 t/day ModernizationDesign features
LPC
1800 t/day
HPC
1700 t/day
New gearbox couple
New HPC
4 3 1800 t/da Moderni ation
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4.3 1800 t/day ModernizationExperimental data (1800 t/day)
0.65
0.7
0.75
0.8
0.85
120 140 160 180 200 220 240
П о л и т р о п н ы й К П Д η п о л
1.6
1.8
2
2.2
2.4
2.6
120 140 160 180 200 220 240
О т н о ш е н и е д а в л е н и й ε
Объемный расход по условиям всасывания Qвс, м3/мин
(2) - n т
= 5200 об/мин;
(1) - nт = 5300 об/мин; (3) - nт= 5100 об/мин;
(4) - nт= 5000 об/мин;
Начальные условия: R= 289,0 Дж/(кг·К); z = 1,0; k = 1,4; t н = 49,0 C
- режим работы по ТЗ
0.55
0.6
0.65
0.7
0.75
0.8
0.85
60 70 80 90 100 110 120
П о л и т р о п н ы й К П Д η п о л
1.4
1.6
1.8
2
2.2
2.4
2.6
60 70 80 90 100 110 120
О т н о ш е н и е д а в л е н и й ε
Объемный расход по условиям всасывания Qвс, м3/мин
(2) - n т
= 5200 об/мин;
(1) - nт = 5300 об/мин; (3) - nт= 5100 об/мин;
(4) - nт= 5000 об/мин;
Начальные условия: R= 289,0 Дж/(кг·К); z = 1,0; k = 1,42; t н = 49,0 C
- режим работы по ТЗ
0.65
0.7
0.75
0.8
0.85
0.9
800 900 1000 1100 1200 1300 1400 1500 1600
П о л и т р о п н ы й К П Д η п о л
800 900 1000 1100 1200 1300 1400 1500 1600
1.6
2.0
2.4
2.8
3.2
3.6
800 900 1000 1100 1200 1300 1400 1500 1600
О т н о ш е н и е д а в л е н и й ε
Объемный расход по условиям всасывания Q вс, м3/мин
(2) - n т
= 5150 об/мин;
(1) - nт = 5300 об/мин; (3) - nт= 5000 об/мин;
(4) - nт= 4850 об/мин;
Начальные условия: R = 289,0 Дж/(кг·К); z = 1,0; k = 1,4; t н = 29,5 C
- режим работы по ТЗ
0.65
0.7
0.75
0.8
0.85
0.9
300 350 400 450 500 550 600
П о л и т р о п н ы й К П Д η п о л
1.7
1.9
2.1
2.3
2.5
2.7
2.9
3.1
3.3
3.5
300 350 400 450 500 550 600
О т н о ш е н и е д а в л е н и й ε
Объе мный расход по условиям всасыв ания Qвс, м3/мин
(2) - n т
= 5150 об/мин;
(1) - nт = 5300 об/мин; (3) - nт= 5000 об/мин;
(4) - nт= 4850 об/мин;
Начальные условия: R= 289,0 Дж/(кг·К); z = 1,0; k = 1,401; t н = 49,0 C
- режимработы по ТЗ
LPC (1700 t/day) HPC (1950 t/day)
4 3 1800 t/day Modernization
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4.3 1800 t/day ModernizationResults, 1800 t/day
Q
g
Capacity
N
Shaftpower + 2 1 %
+ 1 0 %
Contents
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4.4 1950 t/day Modernization
Contents
4 4 1950 t/day Modernization
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4.4 1950 t/day Modernization
In 2013 Entechmach RPC LLC worked on the 1st air compressormodernization to raise its capacity to obtain 1950 t/d of ammonia.
1 modernization is already performed with increased capacity +35%and increased efficiency.
1950 t/day Modernization
NamingHitachi
1360 t/day
Entechmach
1700 t/day
Entechmach
1800 t/day
Entechmach
1950 t/day
Performance at the discharge at
normal conditions Qg, Nm
3
/h
52000 60500 63000 70 870
Discharge pressure pк, kgf/sm2, a. 37,6 35,0 35,0 37,4
Rotor speed n, rpm: LPC/HPC5250
1070051509967
520010035
520010035
Overall shaft power Nshaft, kW 10260 11290 11290 13200
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationDesign features
LPC
1800 t/day 1950 t/day
HPC
1700 t/day
New gearbox couple
New LPC
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationModernized LPC (1950 t/day)
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationModernized HPC (1950 t/day)
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationGasdynamic calculations (Numeca) 1st stage LPC
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationGasdynamic calculations (Numeca) 1st stage LPC
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationModernized LPC rotor (1950 t/day)
LPC
4 4 1950 t/day Modernization
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4.4 1950 t/day Modernization1st stage LPC (1950 t/day)
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationModernized HPC rotor (1950 t/day)
HPC
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationExperimental data (1950 t/day)
Compressor item 101J is tested and shown to be effective close to theproject level.
LPC (1980 t/day) HPC (1980 t/day)
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationPolytropic efficiency
Section № 1 2 3 4
Modernized (1980 t/day) 0.83 0.82 0.83 0.82
Modernized (1800 t/day) 0.83 0.81 0.83 0.82
Modernized (1700 t/day) 0.83 0.81 0.77 0.74
Original(1360 t/day) 0.79 0.78 0.76 0.725
LPC HPC
4 4 1950 t/day Modernization
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4.4 1950 t/day Modernization101JT turbine exhaust, 1950 t/day
4 4 1950 t/day Modernization
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4.4 1950 t/day ModernizationResults, 1950 t/day
Q
g
Capacity
N
Shaftpower + 3 5 %
+ 2 5 %
Contents
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5 Conclusion
Contents
5 Conclusion
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5 ConclusionEntechmach RPC LLC has all the necessary means to perform
work on the compressor modernizationsin ammonia and urea production :
o highly qualified specialists;
o experimental data base;o experience in the design and manufacture of flow parts;o modern software;o own production base;o new high-precision machine tools.
Happy Anniversary!
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Happy Anniversary!Reprintsev Anatoly Ivanovich - 70 years
Chief specialist on compressors
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Thank you for attention!
Welcome to cooperation!Visit exhibition stand №12
66d, ul.Ovcynskaya, poselok im.Sverdlova,Vsevolozhskiy r-n, Leningradskaja obl.,
188682, RussiaTel./fax +7 (812) 331-16-20
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