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CRU

Nitrogen+Syngas 2015

Hilton Bomonti

Istanbul, Turkey

26.02.2015

Aleksandr Liubimov leading specialist on compressors

Increase of Capacity by 35% and


Efficiency Raise of the Technological Air
Centrifugal Compressor 101J
in Ammonia Production

Contents
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 103J
3.2 Natural gas compr. item 102J 3.4 Ammonia compr. item 105J

4. Air compressor item 101J


4.1 Original compressor
4.2 1700 t/day Modernization

4.3 1800 t/day Modernization


4.4 1950 t/day Modernization

5. Conclusion
3

Contents

1 About us

1 About us
23 years on turbo-compressor market

Improving the efficiency and reliability of the turbocompressor units - a priority of the company
5

1 About us
Production

Manufacture takes place in 4 main production facilities with


modern machine tool equipment
6

1 About us
New machine tools
Components and parts for turbo-compressor modernizations are
made on our own production facilities

Contents

2 Experimental and calculation


methods

2 Experimental and calculation methods


Experimental method
Good results of turbo-compressor flow part modernizations are
achieved by an unique experimental data base.

2 Experimental and calculation methods


-2, , , , 2-4

Experimental gasdynamic characteristics of the model stage


1
0.8
0.6

0.4
0.2
0
0.1

0.15

0.2

0.25

0.3

r2
0.35
10

2 Experimental and calculation methods


CFD calculations

1. Surge

2. Optimal

3. Choke
11

Contents

3 Examples of performed works


(ammonia production)

12

3 Examples of performed works (NH3)


Entechmach RPC LLC has successfully completed a number of
compressor modernizations for large-scale ammonia productions.
Air

1290-121-1

item 101J
Natural Gas

item 102J

Synthesis Gas

item 103J

Ammonia

item 105J
13

Contents

3.1 Air compressor item 402

14

3.1 Air compressor item 402


Air compressor item 402 (1290-121-1)
3 modernizations are already performed with increased capacity
+21% and increased efficiency.
In 2014 2015 4 more modernization will be put into operation.

Turbine

LPC

HPC
15

3.1 Air compressor item 402


Modernized rotors

LPC

HPC
16

Contents

3.2 Natural gas compressor item 102J

17

3.2 Natural gas compressor item 102J


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.

Turbine

LPC

HPC
18

3.2 Natural gas compressor item 102J


After the modernization

Turbine

HPC

19

Contents

3.3 Synthesis gas compressor item 103J

20

3.3 Synthesis gas compressor item 103J


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.

HPC

MPC

Turbine

LPC
21

3.3 Synthesis gas compressor item 103J


Modernized MPC and HPC rotors (1750 t/day)

22

Contents

3.4 Ammonia compressor item 105J

23

3.4 Ammonia compressor item 105J


Ammonia compressor item. 105J
1 modernization is already performed with increased capacity +30%
and increased efficiency.

LPC

HPC

Turbine
24

3.4 Ammonia compressor item 105J


The LPC modernization was done on Hitachi (2MCL808+MCL806)
compressor in the existing cases with existing turbine.

LPC

HPC

Turbine

25

Contents

4 Air compressor item 101J

26

Contents

4.1 Original Compressor

27

4.1 Original Compressor


Air compressor item 101J
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.

LPC

HPC

Turbine
28

4.1 Original Compressor

Turbine

LPC

HPC

29

4.1 Original Compressor


Compressor scheme
Turbine

LPC
2

HPC

1
3

atm.
atm.

30

4.1 Original Compressor


LPC cross-section

31

4.1 Original Compressor


HPC cross-section

32

Contents

4.2 1700 t/day Modernization

33

4.2 1700 t/day Modernization


1700 t/day Modernization
In 2005 Entechmach RPC LLC worked on the 1st air compressor
modernization to raise its capacity to obtain 1700 t/d of ammonia.
8 modernizations are already performed with increased capacity
+16% and increased efficiency.
Naming
Performance at the discharge at normal
conditions Qg, Nm3/h
Discharge pressure p, kgf/sm2, a.
Rotor speed n, rpm: LPC/HPC
Overall shaft power Nshaft, kW

Hitachi
1360 t/day

Entechmach
1700 t/day

52000

60500

37,6
5250
10700
10260

35,0
5150
9967
11290
34

4.2 1700 t/day Modernization


Design features (1700 t/day)
LPC

HPC

35

4.2 1700 t/day Modernization


Modernized LPC rotor (1700 t/day)

LPC
36

4.2 1700 t/day Modernization


Modernized HPC rotor (1700 t/day)

HPC

HPC
37

4.2 1700 t/day Modernization


The intermediate cooler sections were changed to new ones with heat
exchange surface increased by 25%.

38

4.2 1700 t/day Modernization

Qg

Capacity

Shaft
power

+ 10%

+16%

Results, 1800 t/day

39

Contents

4.3 1800 t/day Modernization

40

4.3 1800 t/day Modernization


1800 t/day Modernization
In 2012 Entechmach RPC LLC worked on the 1st air compressor
modernization to raise its capacity to obtain 1800 t/d of ammonia.
3 modernizations are already performed with increased capacity
+21% and increased efficiency.
Naming
Performance at the discharge at
normal conditions Qg, Nm3/h
Discharge pressure p, kgf/sm2, a.
Rotor speed n, rpm: LPC/HPC
Overall shaft power Nshaft, kW

Hitachi
1360 t/day

Entechmach
1700 t/day

Entechmach
1800 t/day

52000

60500

63000

37,6
5250
10700
10260

35,0
5150
9967
11290

35,0
5200
10035
11290
41

4.3 1800 t/day Modernization


Design features
1700 t/day

1800 t/day

LPC
New gearbox couple
HPC
New HPC

42

4.3 1800 t/day Modernization


130
120

(1)
(2)

110

(3)

100

(4)

90

150
140
130
120

(2)

(3)

110

(4)

100

900

1000

1100

1200

1300

1400

1500

300

1600

350

400

450

500

550

0.8

0.75
0.7

0.85
0.8
0.75
0.7

1000

1100

1200

1300

1400

1500

3.6
3.2
2.8
2.4
2.0
1.6

800

900
1000 1100 1200 1300 1400 1500
Q , 3/

1600

: R = 289,0 /(); z = 1,0; k = 1,4; t = 29,5 C


(1) - n = 5300 /;
(2) - n = 5150 /;

(3) - n = 5000 /;
(4) - n = 4850 /;

180

200

220

350

400

450

500

550

0.7

600

: R = 289,0 /(); z = 1,0; k = 1,401; t = 49,0 C


(1) - n = 5300 /;
(2) - n = 5150 /;

(3) - n = 5000 /;
(4) - n = 4850 /;

LPC (1700 t/day)

(1)
(2)

90

(3)
(4)
60

70

80

90

100

110

120

60

70

80

90

100

110

120

0.8

0.7
0.65
0.6
0.55

120

140

160

180

200

220

240

2.6

2.4

2.2
2
1.8

2.4
2.2
2
1.8
1.6
1.4

1.6
350
400
450
500
550
Q, 3/

100

0.75

2.6

300

110

0.85

0.75

600

3.5
3.3
3.1
2.9
2.7
2.5
2.3
2.1
1.9
1.7

120

240

0.65
300

1600

160

0.8

900

800

130

80

140

0.85

0.65

0.65

(1)
(2)

(3)
(4)

80

120

0.85

90

600

0.9

0.9

100

70

90

800

(1)

110

T,

140

150

160

140

120

160

170

T,

T,

T,

170

80

Experimental data (1800 t/day)


130

180

180

120

140
160
180
200
220
Q , 3/

240

: R = 289,0 /(); z = 1,0; k = 1,4; t = 49,0 C


(1) - n = 5300 /;
(2) - n = 5200 /;

(3) - n = 5100 /;
(4) - n = 5000 /;

60

70
80
90
100
110
Q , 3/

120

: R = 289,0 /(); z = 1,0; k = 1,42; t = 49,0 C


(1) - n = 5300 /;
(2) - n = 5200 /;

(3) - n = 5100 /;
(4) - n = 5000 /;

HPC (1950 t/day)

43

4.3 1800 t/day Modernization

Qg

Capacity

Shaft
power

+ 10%

+21%

Results, 1800 t/day

44

Contents

4.4 1950 t/day Modernization

45

4.4 1950 t/day Modernization


1950 t/day Modernization
In 2013 Entechmach RPC LLC worked on the 1st air compressor
modernization to raise its capacity to obtain 1950 t/d of ammonia.
1 modernization is already performed with increased capacity +35%
and increased efficiency.
Naming
Performance at the discharge at
normal conditions Qg, Nm3/h
Discharge pressure p, kgf/sm2, a.

Rotor speed n, rpm: LPC/HPC


Overall shaft power Nshaft, kW

Hitachi Entechmach Entechmach Entechmach


1360 t/day 1700 t/day 1800 t/day 1950 t/day
52000

60500

63000

70 870

37,6
5250
10700
10260

35,0
5150
9967
11290

35,0
5200
10035
11290

37,4
5200
10035
13200
46

4.4 1950 t/day Modernization


Design features
1700 t/day

1800 t/day

1950 t/day
New LPC

LPC

HPC

New gearbox couple


47

4.4 1950 t/day Modernization


Modernized LPC (1950 t/day)

48

4.4 1950 t/day Modernization


Modernized HPC (1950 t/day)

49

4.4 1950 t/day Modernization


Gasdynamic calculations (Numeca) 1st stage LPC

50

4.4 1950 t/day Modernization


Gasdynamic calculations (Numeca) 1st stage LPC

51

4.4 1950 t/day Modernization


Modernized LPC rotor (1950 t/day)

LPC
52

4.4 1950 t/day Modernization


1st stage LPC (1950 t/day)

53

4.4 1950 t/day Modernization


Modernized HPC rotor (1950 t/day)

HPC
54

4.4 1950 t/day Modernization


Experimental data (1950 t/day)

LPC (1980 t/day)

HPC (1980 t/day)

Compressor item 101J is tested and shown to be effective close to the


project level.
55

4.4 1950 t/day Modernization


Polytropic efficiency
LPC
Section

HPC

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

56

4.4 1950 t/day Modernization


101JT turbine exhaust, 1950 t/day

57

4.4 1950 t/day Modernization

Qg

Capacity

Shaft
power

+ 25%

+35%

Results, 1950 t/day

58

Contents

5 Conclusion

59

5 Conclusion
Entechmach RPC LLC has all the necessary means to perform
work on the compressor modernizations
in ammonia and urea production :
o
o
o
o
o
o

highly qualified specialists;


experimental data base;
experience in the design and manufacture of flow parts;
modern software;
own production base;
new high-precision machine tools.

60

Happy Anniversary!
Reprintsev Anatoly Ivanovich - 70 years
Chief specialist on compressors

61

Thank you for attention!


Welcome to cooperation!
Visit exhibition stand 12
66d, ul.Ovcynskaya, poselok im.Sverdlova,
Vsevolozhskiy r-n, Leningradskaja obl.,
188682, Russia
Tel./fax +7 (812) 331-16-20
www.entechmach.com

etm@entechmach.com