Compressor Thermodynamics

Methods and Alternatives

Background

Calculating Volume, SI
The basic equation is 𝑃𝑉 = 𝑛𝑅𝑇𝑍
Where
Z=Compression factor, (no units)
T=Absolute Temperature
R=0.083145, m3 bar/(mol K) (Volume Units)
P=Absolute pressure, bar
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General Energy Balance

Work

Output Fluid @ Po,To

Mixture @ Pi,Ti

F Process

Heat

1st Law  DH=Q+W/e

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General Energy Balance
Work=??

F Process
Pi= 35 bar Po= 110 bar
Ti= 30 oC To= ??

Efficiency = 80%

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Calculating Discharge Conditions:
Ideal Gas Single Phase
• Note Inlet Pi, Ti
• Calculate Volume (Vi), and Cp, Cv and k=Cp/Cv
Step 1

• Estimate To
𝑘−1
𝑃
Step 2
𝑘
• 𝑇𝑜 = 𝑇𝑖 𝑃𝑜
𝑖

• Estimate Ideal Work

𝑘−1
1 𝑘 𝑍𝑖 𝑅𝑇𝑖 𝑃0 𝑘 𝑘𝐽
Step 3 •𝑊≈ 𝜖 𝑘−1 𝑀𝑊 𝑃𝑖
− 1 𝑤ℎ𝑒𝑟𝑒 𝑅 = 8.3145 𝑘𝑚𝑜𝑙 /𝐾

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Example: First Calculating Mol Wt

𝑍𝑖 𝑀𝑊𝑖 Feed Component MW Zi*mwi

𝑀𝑊 =
Component mol%
Water 0.00 18.02 0.00

𝑍𝑖
H2S 0.00 34.08 0.00
CO2 0.95 28.01 26.61
N2 8.85 44.01 389.56
Methane 78.96 16.04 1266.70
Ethane 7.75 30.07 233.11
Propane 2.51 44.10 110.78
i-Butane 0.30 58.12 17.35
n-Butane 0.49 58.12 28.50
i-Pentane 0.08 72.15 5.84
n-Pentane 0.07 72.15 5.07
Benzene 0.00 78.11 0.00
Toluene 0.00 92.14 0.00
e-Benzene 0.00 106.17 0.00
o-Xylene 0.00 106.17 0.00
m-Xylene 0.00 Density 106.17 0.00
p-Xylene 0.00 mw kg/m3 106.17 0.00
Hexane 0.02 84.40 670 84.40 1.70
Heptane 0.01 92.60 734 92.60 1.08
Octane 0.00 105.20 760 105.20 0.47
Nonane 0.00 117.70 781 117.70 0.14
Decane 0.00 171.50 800 171.50 0.05
100.00 Stream MW, S 20.87

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Calculating Ideal Gas Version

Step 1 efficiency 0.80 mw kg/kmol 19.64

Pi bar 35.00 Ti C 60.00
Zi - 0.95 Hi J/mol 10516.77
Vi m /kmol 0.76 k=Cpi/Cvi - 1.33
Step 2 Po bar 110.00 To C 169.35
Ideal Work 178.4 info

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Compressor Modeling

L
The Polytropic Analysis of Centrifugal Compressors
John M. Schultz, Trans. Of the ASME, ASME J. of Engineering for Power, Jan 1962 pp 69-82
The real-gas equations of polytropic analysis are derived in terms of compressibility functions X and Y which
supplement the familiar compressibility factor, Z. A polytropic head factor, f, is introduced to adjust test results
for deviations from perfect-gas behavior. Functions X and Y are generalized and plotted for gases in
corresponding states.
The thermodynamic design and test evaluation of centrifugal compressors is frequently based upon a
polytropic analysis employing perfect-gas relations. In many instances real-gas relations would be more
accurate, but these are virtually unknown. The purpose of this paper is to derive the real-gas equations of
polytropic analysis and to show their application to centrifugal compressor testing and design.

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The problem in 1962
• Needed a convenient model for the fluid

• Little General Access to Process Simulation Tools

• Limitations in Equations of State Methods
• BWR  1940, complex solution
• RK  1949, limited application to mixtures
• NGA  1958, Equilibrium Ratio Data for Computers

Needed an alternative which could be handled using a slide rule

• Ie: Simple log-log relationships
• Utilize Corresponding States Models

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Classic Algorithm
Flange to Flange Feed at
P,T
Outputs

Hi,Si,ri,CPi,Cvi
Inputs Flash at
Pi,Ti V/F
• Efficiency
• Composition Isentropic Hos,Sos,Tos
Flash at Po

Ho=Hi+(Hos-His)/h

Isenthalpic Ho,So,To,W
Flash at Po V/F
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Schultz Algorithm: Wheel by Wheel
Feed at Outputs
P,T
Inputs
• Efficiency Flash at Hi,Si,Vi,CPi,Cvi
Pi,Ti V/F,X,Y,n,m,
• Composition
Calculate To
To,Po,Vo

Done Ho,So,To,W

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Compressor Modeling

Classic Compressor Algorithm: Polytropic

• 𝑃𝑉𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑃𝑚
• = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑇
𝑛−1
𝑃 𝑛 −𝑚
• = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑍

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Schultz shortcut: Linearization
𝐶𝑝
𝑘=
𝐶𝑣
hp= polytropic efficiency

𝑑𝑃 𝑉
h𝑝 = 𝑉 =
𝑑𝐻 𝜕𝐻 𝑑𝑇
+ 𝐶𝑝
𝜕𝑃 𝑇 𝑑𝑃

𝑇 𝜕𝑉
𝑋= − 1 Z-Factor Charts
𝑉 𝜕𝑇 𝑃

𝑃 𝜕𝑉
𝑌= − 13
𝑉 𝜕𝑃 𝑇 GE Title or job number
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Schultz Calculation Strategy:
Single Phase
• Note Inlet e, Pi, Ti
• Calculate Volume (Vi), k= (Cp/Cv)
Step 1
• Estimate Outlet Temperature, To
𝑘−1
𝑃𝑜 𝑘
Step 2 • 𝑇𝑜 = 𝑇𝑖
𝑃𝑖

• Estimate Average Pressure, 𝑃

𝑃𝑜 𝑃𝑜 +𝑃𝑖
• 𝑃 = 𝑃𝑖 𝑜𝑟 𝑃 =
Step 3 𝑃𝑖 2

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Example: Continue from Previous

Step 1 efficiency 0.80 mw kg/kmol 19.64

Pi bar 35.00 Ti C 60.00
Zi - 0.95 Hi J/mol 10516.77
Vi m /kmol 0.76 k=Cpi/Cvi - 1.33
Pbar from Geometric Mean Pbar from Arithmetic Mean
Step 2 Po bar 110.00 To C 169.35
Ideal Work 178.4 info
Step3 Pbar bar 62.05 Pbar bar 72.50

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Schultz Calculation Strategy:
Single Phase
• Estimate Average Temperature, 𝑇
𝑇𝑜 +𝑇𝑖
Step 4 • 𝑇=
2

• Estimate Average Heat Capacity Ratio, 𝑘

𝑘𝑖 +2𝑘𝑇,𝑃 +𝑘𝑜
Step 5 • 𝑘=
4

• Estimate 𝑋
𝑇 𝜕𝑉
• 𝑋= − 1 𝑎𝑡 𝑃, 𝑇
Step 6 𝑉 𝜕𝑇 𝑃

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Next Steps: Same Example

Look at effect of averaging models

Pbar from Geometric Mean Pbar from Arithmetic Mean
Step 4 Tbar C 114.68
Step 5 ko - 1.30
ktbar,pbar - 1.31 ktbar,pbar - 1.33
kbar - 1.32 kbar - 1.32
Step 6 dv/dt m /kmol/bar 0.0016 dv/dt m /kmol/bar 0.0014
T/V K*kmol/ m 770.23 T/V K*kmol/ m 902.98
Xbar 0.22 Xbar 0.25

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Schultz Calculation Strategy:
Single Phase
• Estimate 𝑌
𝑃 𝜕𝑉
•𝑌=− 𝑎𝑡 𝑃, 𝑇
Step 7 𝑉 𝜕𝑃 𝑇

• Estimate 𝑚
𝑘−1 1
+𝑋 𝑌
Step 8
𝑘 𝜖
•𝑚=
1+𝑋 2

• Estimate 𝑛
1+𝑋
•𝑛=
Step 9 𝑌
1 1
𝑘 𝜖
+𝑋
1
− −1
𝜖

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More Steps

Pbar from Geometric Mean Pbar from Arithmetic Mean

Step 7 dv/dp m /kmol/K -0.01 dv/dp m /kmol/K -0.01
P/V bar*kmol/ m 123.23 P/V bar*kmol/ m 168.80
Ybar 1.02 Ybar 1.02
Step 8 mbar - 0.24 mbar - 0.24
Step 9 nbar - 1.38 nbar - 1.38

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Schultz Calculation Strategy:
Single Phase
• Estimate To
𝑃𝑜 𝑚
• 𝑇𝑜 = 𝑇𝑖 𝑃
Step 10 𝑖

• Estimate Vo
1
𝑃𝑜 −𝑛
Step 11 • 𝑉𝑜 = 𝑉𝑖 𝑃
𝑖

• Verify n from EOS

ln 𝑃𝑜 𝑃
𝑖
•𝑛=
Step 12 ln
𝑉𝑖
𝑉𝑜

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Closing Up First Iteration

Pbar from Geometric Mean Pbar from Arithmetic Mean

Step 10 To C 166.18 C 164.56
Step 11 Vo calc m /kmol 0.33 m /kmol 0.33
Step 12 Zo EOS - 0.99 - 0.99
Vo Eos m /kmol 0.33 m /kmol 0.33
nbar - 1.38 - 1.37

Previous Estimate To C 169.35

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Schultz Calculation Strategy:
Single Phase
• Compare n-values
• Adjust To estimate or subdivide steps and return to step 4
Step 13

• Estimate Work
𝑛−1
1 𝑛 𝑍𝑖 𝑅𝑇𝑖 𝑃0 𝑛 𝑓 𝑛 𝑅
Step 14 •𝑊≈ −1 ≈ 𝑍𝑜 𝑇𝑜 − 𝑍𝑖 𝑇𝑖
𝜀 𝑛−1 𝑀𝑊 𝑃𝑖 𝜀 𝑛−1 𝑀𝑊

• Done
Step 15

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End of First Iteration

Both Schultz
Pbar from Geometric Mean Pbar from Arithmetic Mean
Step 13 New To C 166.18 C 164.56
Step 14 Work kJ/kg 226.72 Work kJ/kg 226.18

Relations
Work kJ/kg 226.72 Work kJ/kg 226.18
Ho J/mol 14942.93 Ho J/mol 14857.41
Work kJ/kg 225.38 Classic kJ/kg 221.03

Difference between “Classic” work and Predicted work is

related to effect of efficiency on Schultz temperature model

Slight difference between relations

Iterate Further to Close
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Next Iteration
Pbar from Geometric Mean Pbar from Arithmetic Mean
Step 2 Po bar 110.00 To C 165.37
Step 3 Pbar bar 62.05 Pbar bar 72.50
Step 4 Tbar C 112.68
Step 5 ko - 1.31
ktbar,pbar - 1.32 ktbar,pbar - 1.33
kbar - 1.32 kbar - 1.33
Step 6 dv/dt m /kmol/bar 0.0016 dv/dt m /kmol/bar 0.0014
T/V K*kmol/ m 771.12 T/V K*kmol/ m 904.17
Xbar 0.23 Xbar 0.26
Step 7 dv/dp m /kmol/K -0.01 dv/dp m /kmol/K -0.01
P/V bar*kmol/ m 124.01 P/V bar*kmol/ m 169.90
Ybar 1.02 Ybar 1.02
Step 8 mbar - 0.24 mbar - 0.24
Step 9 nbar - 1.38 nbar - 1.39
Step 10 To C 166.46 C 164.81
Step 11 Vo calc m /kmol 0.33 m /kmol 0.33
Step 12 Zo EOS - 0.99 - 0.99
Vo Eos m /kmol 0.33 m /kmol 0.33
nbar - 1.38 - 1.37
Step 13 New To C 166.46 C 164.81
Step 14 Work kJ/kg 226.81 Work kJ/kg 226.27
Work kJ/kg 226.81 Work kJ/kg 226.27
Ho J/mol 14958.04 Ho J/mol 14870.88
Work kJ/kg 226.15 kJ/kg 221.71

Previous Estimate To C 165.37

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After 3 Iterations (Direct Substitution)
Pbar from Geometric Mean Pbar from Arithmetic Mean
Step 2 Po bar 110.00 To C 165.64
Step 3 Pbar bar 62.05 Pbar bar 72.50
Step 4 Tbar C 112.82
Step 5 ko - 1.31
ktbar,pbar - 1.32 ktbar,pbar - 1.33
kbar - 1.32 kbar - 1.33
Step 6 dv/dt m /kmol/bar 0.0016 dv/dt m /kmol/bar 0.0014
T/V K*kmol/ m 771.06 T/V K*kmol/ m 904.09
Xbar 0.23 Xbar 0.26
Step 7 dv/dp m /kmol/K -0.01 dv/dp m /kmol/K -0.01
P/V bar*kmol/ m 123.96 P/V bar*kmol/ m 169.82
Ybar 1.02 Ybar 1.02
Step 8 mbar - 0.24 mbar - 0.24
Step 9 nbar - 1.38 nbar - 1.39
Step 10 To C 166.44 C 164.80
Step 11 Vo calc m /kmol 0.33 m /kmol 0.33
Step 12 Zo EOS - 0.99 - 0.99
Vo Eos m /kmol 0.33 m /kmol 0.33
nbar - 1.38 - 1.37
Step 13 New To C 166.44 C 164.80
Step 14 Work kJ/kg 226.81 Work kJ/kg 226.26
Work kJ/kg 226.81 Work kJ/kg 226.26
Ho J/mol 14957.01 Ho J/mol 14869.96
Work kJ/kg 226.10 kJ/kg 221.67

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Converged

Step 13
Pbar from Geometric Mean
New To C 166.44
Pbar from Arithmetic Mean
C 164.80
Rigorous Model
Step 14 Work
Work
kJ/kg
kJ/kg
226.81
226.81
Work
Work
kJ/kg
kJ/kg
226.26
226.26 To=164.1oC
Ho
Work
J/mol
kJ/kg
14957.07
226.10
Ho J/mol
kJ/kg
14870.01
221.67 W=219.7kJ/kg

Arithmetic mean seems to agree better

with rigorous model, but all are within
modeling accuracy.

Note that enthalpy match is important for

process simulators
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If I Integrate Through the Compressor
Choose 7 wheels

Gas
Inlet T Inlet P Discharge P Discharge T Gas Rate Compressibility Gas Density Gas Mol Wt Gas Cp/Cv Enthalpy
o o
C bar bar C m3/d Z Tf c ,Pf c Tf c ,Pf c Tf c ,Pf c Change
1 60.00 35.00 41.22 73.8 31.5 0.95 26.11 19.64 1.33 27.28
2 73.76 41.22 48.55 87.9 27.9 0.96 29.47 19.64 1.33 28.60
3 87.92 48.55 57.19 102.5 24.7 0.96 33.24 19.64 1.32 29.97
4 102.48 57.19 67.35 117.4 21.9 0.96 37.49 19.64 1.32 31.42
5 117.43 67.35 79.33 132.8 19.5 0.97 42.24 19.64 1.32 32.94
6 132.77 79.33 93.43 148.5 17.3 0.97 47.56 19.64 1.32 34.55
7 148.49 93.43 110.00 164.5 15.4 0.98 53.49 19.64 1.31 36.18
Sum= 220.95

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