Gas Compression Stages – Process Design & Optimization
Jayanthi Vijay Sarathy, M.E, CEng, MIChemE, Chartered Chemical Engineer, IChemE, UK
The following tutorial demonstrates how to
estimate the required number of compression
stages and optimize the individual pressure
ratio in a multistage centrifugal compression
system. A schematic of a 2-Stage compressor
unit is as follows,
Fig 1. Two Stage Compressor Unit
A schematic of a 3-Stage Compressor Unit is
as follows,
Fig 2. Three Stage Compressor Unit
General Notes
1. When vapours are compressed, its
temperature increases & therefore
requires provisions for gas cooling.
2. High gas temperatures can affect lube oil
characteristics causing them to carbonize
and turn in sludge. This results in fouling
causing the bearing pads and seals to wear
out and performance degradation.
3. As per API 617 (7th Edition, 2002), Clause
2.7.1.3, it states, As a design criteria,
bearing metal temperatures shall not
exceed 100°C (212°F) at specified
operating conditions with a maximum inlet
oil temperature of 50°C (120°F). Vendors
shall provide bearing temperature alarm
Page 1 of 4
and shutdown limits on the datasheets.
However clause No. 2.7.1.3.1 of the said
document also says, In the event that the
above design criteria cannot be met,
purchaser and vendor shall mutually agree
on acceptable bearing metal temperatures.
4. During gas recycling, (either by cold
recycling or hot recycling), the compressor
discharge temperature rises above the
temperature pertaining to normal running
conditions. Quantitatively, the rise in
temperature depends on the pressure ratio
of each stage. The maximum discharge
temperature is typically limited to, in the
range of 1500C to 1600C to avoid damage
to the bearings and seals. To ensure these
limits are not crossed, the compressor
discharge temperature at normal running
conditions must be operated at lower
temperatures with a margin of 200C to
250C. This means typical compressor
discharge temperatures (under normal
running conditions) should be limited to
the range of 1200C to 1350C.
5. Individual compressor pressure ratios
must also be optimized to obtain the
lowest amount of power required to meet
the final discharge pressure. This also
enables to reduce the suction scrubber
volumes and air cooler duties to save on
material and operating costs.
Case Study
A multistage compression system receives 30
MMScfd of hydrocarbon vapours at 2 bara,
300C and is required to be raised to 15 bara.
The Polytropic efficiency [] for all
compressors is assumed to be 82%. An
optimization study is performed for a 2-Stage
and 3-Stage centrifugal compression system.
The vapour composition is as follows,
 Table 1. Gas Composition Therefore considering a maximum number of
Components Mole Fraction [-] stages of 3, for a two stage compressor unit,
the first compressor discharge pressure [P1]
Methane [C1] 0.5232
and Pressure ratio [R] is,
Ethane [C2] 0.3001 15
𝑙𝑛[ ]
2
Propane [C3] 0.1096 𝑛= = 1.83 ~ 2 𝑆𝑡𝑎𝑔𝑒𝑠 (6)
𝑙𝑛[3]
iso-Butane [iC4] 0.0106 15
1⁄
2
𝑅=[ ] = 2.7386 (7)
n-Butane [nC4] 0.0346 2

Iso-Pentane [iC5] 0.0076 𝑃1 = 2 × 2.73861 = 5.48 𝑏𝑎𝑟𝑎 (8)

n-Pentane [nC5] 0.0092 For a three stage compressor unit, the LP

compressor discharge pressure [P1] and MP
n-Hexane [C6] 0.0052
compressor discharge pressure [P2] is,
Total 1.0000 1⁄
15 3
MW [kg/kmol] [PR EoS] 26.53 𝑅=[ ] = 1.9574 (9)
2

Density [1 atm, 15.60C] [kg/m3] 1.128 𝑃1 = 2 × 1.95741 = 3.91 𝑏𝑎𝑟𝑎 (10)

𝑃2 = 2 × 1.95742 = 7.66 𝑏𝑎𝑟𝑎 (11)

Methodology
The number of compressors can be chosen by Using these preliminary values, to arrive at
first estimating preliminary discharge optimized discharge pressures, the following
pressures based on equal pressure ratio as, iterative procedure is adopted.
𝑃𝐿𝑎𝑠𝑡 1. Keeping all preliminary estimated
𝑋𝑛 = [ ] (1)
discharge pressures fixed, the LP
𝑃𝐹𝑖𝑟𝑠𝑡
Where, compressor discharge pressure is varied
PFirst = First Compressor Pressure [bara] for a range to obtain total absorbed power
& total cooler duty of all compressors, and
PLast = Last Compressor Pressure [bara]
sizing each suction scrubber. Making a plot
n = Number of stages [-] of the above values, the discharge pressure
X = Maximum number of Stages [-] corresponding to the lowest duty is chosen
Rewriting the expression, [1st Iteration of LP Compressor].
𝑃𝐿𝑎𝑠𝑡 2. The LP compressor initial estimated
𝑛 × 𝑙𝑛𝑋 = 𝑙𝑛 [ ] (2)
𝑃𝐹𝑖𝑟𝑠𝑡 discharge pressure is now replaced with
𝑃
𝑙𝑛[ 𝐿𝑎𝑠𝑡 ] the 1st Iteration’s optimized pressure.
𝑃𝐹𝑖𝑟𝑠𝑡
Or, 𝑛 = (3) 3. Following further, the MP compressor
𝑙𝑛𝑋
The separation ratio is computed as, discharge pressure is also varied for a
1⁄
given range to similarly obtain an
𝑃𝐿𝑎𝑠𝑡 𝑛
𝑅=[ ] (4) optimized discharge pressure
𝑃𝐹𝑖𝑟𝑠𝑡
corresponding to the lowest total
The intermediate pressure is computed as, compressor duty and cooler duty. [1st
𝑃𝑖 = 𝑃𝑓𝑖𝑟𝑠𝑡 × 𝑅𝑖 (5) Iteration of 2nd stage].

Where, 4. The MP compressor initial estimate

pressure is now replaced with the
Pi = Intermediate Pressure at Stage ‘i’
optimized value, [1st Iteration of 2nd stage].
Page 2 of 4
5. With the 1st iteration optimized pressures, Based on the optimized compression ratios,
calculations are repeated similar to Step 2 the savings on the total compressor duty and
Step 3 & Step 4, i.e., 2nd Iteration and so total air cooler duty is 1.59% and 1.68% for 2
forth, until a converged solution is reached. stages respectively. For 3 stages, the
respective savings is 1.86% and 2.03%.
Results
Table 3. Savings on Compressor & Air Cooler Duty
With the procedure applied for the calculated
initial estimates, the optimized results of 2- Parameter 2 Stage 3 Stage
Stage & 3-stage system [ = 82%] is, Before Optimization
Table 2. Optimized Compressor Stage Pressures
Total Comp. Duty [kW] 3,000 2,930
Discharge Pressure
Stages-Pressure
Pressure Ratio Total Cooler Duty [kW] 2,786 2,717
- [bara] [-] After Optimization
2 Stage LP [2S-LP] 8.12 4.060 Total Comp. Duty [kW] 2,952 2,876
2 Stage HP [2S-HP] 15.00 1.847 Total Cooler Duty[kW] 2,739 2,663
3 Stage LP [3S-LP] 6.15 3.075 % Savings [Compressor] 1.59% 1.86%
3 Stage MP [3S-MP] 8.25 1.341 % Savings [Air Cooler] 1.68% 2.03%
3 Stage HP [3S-HP] 15.00 1.818
Based on the optimized compression ratios,
The plots of total compressor absorbed the suction scrubber sizes for both cases are,
power, total cooler duty for two stage design Table 4. Suction Scrubber Sizes
and three stage design is as follows, Suction Head Design [2:1 Elliptical]
Scrubber D H Vessel
[H/D = 3.0] [mm] [mm] Volume [m3]
2S-LP/3S-LP 2,400 7,200 34.08

Before Optimization

2S-HP 1,900 5,700 17.11

3S-MP 2,100 6,300 22.98

3S-HP 1,800 5,400 14.59

After Optimization
Fig 3. Two Stages –Total Compressor & Cooler Duty
2S-HP 1,800 5,400 14.59

3S-MP 1,900 5,700 17.11

3S-HP 1,800 5,400 14.59

For 2S-HP & 3S-MP cases, the vessel volume

decreases by 14.7% and 25.5% respectively.
References
1. “Example problems for the calculation and
selection of compressors”, Intech GMBH,
Fig 4. Two Stages – Total Compressor & Cooler Duty
(intech-gmbh.com/compr_calc_and_selec_examples/)
2. www.checalc.com
Page 3 of 4
Appendix A

Appendix B

Page 4 of 4