Application and selection of compressors for air separation equipment

The compressors used in the slogan air separation plant can be simply divided into raw material air compression, supercharger (circulation machine), product gas compressor and instrument gas compressor. There are many types of compressors, and centrifugal compressors, piston compressors, screw compressors and axial compressors are used in air separation plants.

For raw material air compressors: Generally, the raw material gas should be centrifuged at 5000Nm3/h550000Nm3/h (for compressor displacement); axial flow-centrifugation or axial flow above 550,000 Nm3/h; small selection below 5000Nm3/h The screw or piston of the flow, of course, with the large-scale development of air separation equipment, the market demand for air separation equipment below 1000Nm3/h is almost very small, so it is generally rare to use screw or piston as the main air compressor. At present, the main air compressor is mainly centrifugal compressor, the product gas compressor piston and centrifugal type, and the instrument gas compressor are all three.

1. The compressors for air separation equipment and compressor air separation equipment are the most widely used in centrifugal applications. The centrifugal compressors have various structural forms. There are three typical structures. These three types of centrifugal compressors are among the air separation. The application is more extensive. The efficiency of the compressor is very important, and the isothermal compressor has the characteristics of high isothermal efficiency and low power consumption of the whole machine. Therefore, the compressor suppliers of all air separation equipments use isothermal compressors.

The first type is a single-shaft type structure, and the single-shaft type structure is characterized in that the impeller of the same cylinder is mounted between two support bearings on the same main shaft, and rotates at the same rotational speed. There are many types of single-axis type, among which the single-axis isothermal type is one-stage one-cooling, and the final pressure required for obtaining gas is less compressed, which is generally preferred; the single-axis multi-stage compressor is characterized by two cooling. The number of stages is more than one level. It is suitable for gas compression that is smaller than the heat or limited by the speed of sound. It is suitable for working conditions with large volume flow and small pressure ratio, such as air compressor.

The second type is an integral gear type structure. The overall gear type structure is generally two-axis or three-axis. It is characterized by one shaft and one speed, which can make each impeller have the best specific speed and the best line speed. Play the ability of each impeller. The axial air intake also improves the efficiency of the impeller. In recent years, the development of the overall gear compressor has been fast, and it is suitable for relatively large working conditions, such as a supercharger.

The third type is a multi-axis type structure. The multi-axis type compressor is similar to the integral gear type compressor, but it has no volute and integrates the gas cooler on the exhaust structure to make the overall structure more compact.

It is also applied to piston compressors and screw compressors.

The piston type compressor is a volumetric compressor. The structure is relatively simple. When the pressure is high, the number of configuration stages is large. When the medium has no speciality, it can generally meet the requirements of small flow and high pressure.

The screw compressor is a relatively new type of compressor. Its development time is short, and its application is extremely wide. It is widely used in gas compression with a small flow rate and pressure below 12 bar. Its efficiency is generally higher than that of the piston type, and it is continuous. Long running time, more and more favored by the market, but not much application in air separation equipment, generally only used as instrument gas compressor.

The following table shows the general compressor selection range: the inlet pressure of the raw air compressor is local atmospheric pressure -3kpa, the inlet temperature is the hottest month average temperature, the inlet humidity (locally supplied) is 80%, and the exhaust pressure requires the check valve. Exhaust gas temperature w1 ° C, flow general air separation equipment basic requirements for raw air compressor is: A, continuous operation time is not less than two years; B, has a relatively high isothermal efficiency; C, relatively stable exhaust pressure ; D, to meet the flow can be adjusted in different seasons.

The advantages of the single-shaft isothermal raw material air turbine compressor are: A. The structure of the simple supported beam is adopted, and the dynamic characteristics of the rotor are very good, so the stability of the operation is very good; the split structure of the B and the meter is very safe to use and maintain. Convenient; C, isothermal compression, less power consumption; D, impeller has lower line speed and less noise.

Disadvantages are: A, the structure of the casing is complex, the manufacturing cost is high; B, each stage is radial intake, the flow field of the intake air is not very uniform, affecting the efficiency; C, the compression of each stage is relatively low, so the same pressure is required More levels.

The advantages of the integral gear type raw material air turbine compressor are: A, each stage is axial intake, the inlet flow field is relatively uniform, which is beneficial to the improvement of the stage efficiency; B, no special large complex parts, making casting and processing It is easier; C, the number of stages can be increased or decreased, making it easy to adapt to changes in pressure; D, the line speed of each stage of the impeller can reach a higher level, giving full play to the potential of the material, and the number of stages can be higher. pressure.

The disadvantages are: A, gear processing accuracy requirements; B, rotor dynamic design is more difficult; C, the number of stages has a certain limit, it is difficult to achieve high pressure; D, more external leakage points, Toxic gases and chemical gases with high compression pressure and absolutely no leakage are not suitable.

1.2 Supercharger The current internal compression air separation equipment generally needs to be equipped with a supercharger as a heat source for heat exchange with high pressure liquid. The reheating medium is generally air or nitrogen, and the pressure of the supercharger can be up to 100 bar. Due to continuous use and high pressure, centrifugal type is generally selected. The flow rate is generally; the pressure is generally 20barGw100barG range can be satisfied; the general requirements of the air separation equipment supercharger are: A, very stable running performance; B does not cause secondary pollution to the medium; C, continuous running time is not less than 3 years; , has a relatively high isothermal efficiency; E, relatively stable exhaust pressure.

There are four types of supercharger structures, namely single-axis isothermal type, integral gear type, single-axis multi-stage type and multi-axis type. Due to the similarity between the supercharger and the raw material air turbine compressor medium, it has four combinations with the air compressor: A, integrated with the raw air compressor unit, the so-called one machine. This combination is generally suitable for integral gear type, the first 3 stages of compressed raw air, the latter several stages of pressurized reheating or product gas (generally nitrogen); when the charge air pressure is high, you can choose three axes or More axes. Because the inlet volume flow rate of the raw material air and the pressurized working medium is different, and the degree of difference between the different processes is large, the matching of the rotation speed of each shaft is difficult for the process in which the volumetric flow rate of the inlet gas is largely different. However, the biggest advantage of this combination is that the two machines are combined, the floor space is small, and the investment is small. This combination is only suitable for small air separation or liquid air separation.

B. Share one drive machine with the raw material air compressor. While driving the air compressor, the drive machine drags the booster and changes the speed of the compressor through different speed increasers to meet the flow requirements. The drive machine is generally a steam turbine.

C. Share one drive machine with the raw material air compressor. However, in the same shaft extension direction, the air compressor is dragged by the drive machine, the shaft is extended while dragging the supercharger, and the speed increaser is used to increase the speed of the supercharger to meet the flow requirement, and the drive machine is generally a steam turbine. This method is applied less.

D. For the two units with complementary coherence, this combination is generally driven by a motor and has many applications. 1.3 Nitrogen compressor product nitrogen can be pumped from the top of the upper tower, or can be pumped from the lower tower nitrogen (need to compare energy consumption); from the upper tower is generally around 15KPa (inhalation pressure loss 10kpa), need to pass through the nitrogen turbine The compressor is pressurized or the piston nitrogen compressor is pressurized to meet product pressure requirements.

The general flow rate of the piston nitrogen compressor is also large; the pressure can generally meet the requirements, and the small flow can meet the filling pressure of 150 barG; the disadvantage of the piston compressor is that there are many wearing parts, and it needs to be replaced after two or three months of operation. There is a backup machine.

The typical structure of a nitrogen turbine compressor has a single-shaft isothermal type; a single-shaft multi-stage type; an integral gear type and a multi-axis type. The single-axis isothermal type is suitable for low pressure applications; the single-axis multi-stage type is suitable for high pressure applications; the integral gear type can meet different pressure type nitrogen requirements, and the pressure range can be changed within a wide range, and the number of stages can be up to Up to 6 or more; multi-axis type can also meet the high pressure.

Generally, the compressor that can satisfy the air can meet the requirements of the nitrogen working fluid.

1.4 Oxygen compressor pressure loss 10kpa); oxygen turbine compressor working medium is oxygen. Oxygen is a strong combustion-supporting gas. The flow rate and temperature of oxygen during compression and transportation need to be strictly controlled.

The piston oxygen compressor generally has a flow rate of 200Nm3/h5000Nm3/h. When the pressure is high, the number of stages is required. Because of the high pressure and high temperature fire, the pressure is generally below 30 bar, and the small flow rate of several hundred can satisfy the filling pressure of 150 barG. The disadvantage of the piston compressor is that there are many wearing parts, and it needs to be replaced after two or three months of operation.

Oxygen turbine compressors are not very high in compression ratio per section due to flow rate and temperature limitations. Generally, the uniaxial rotor balance is relatively stable, so the uniaxial type is preferred. According to the different requirements of oxygen pressure, it is generally required to be designed in single cylinder, double cylinder and triple cylinder.

Due to the particularity of the oxygen medium, generally the compressor body with oxygen contact, the separator is made of cast iron, the oxygen flow channel and the surface of the sealing cavity are copper-plated; the other inner parts are made of nickel-copper alloy or copper. Effectively prevents oxygen from catching fire. All manufacturing processes require degreasing, while setting up a safe nitrogen gas, and diluting the oxygen concentration at the time of failure.

1.5 Instrument air compressor air separation equipment instrument air requirements are oil-free, dust-free and dry. Generally 6000Nm3/h class air separation equipment instrumentation gas 120Nm3/h; 15000 grade 360Nm3/h; 20,000 grade 500Nm3/h; 40,000 grade air separation equipment requires instrument 1000Nm3/h, discharge pressure is required to be around 7barG; instrument gas General requirements: Filtration particle size: Foreign compressor suppliers and characteristics Air separation equipment supporting main air compressors and superchargers are centrifugal compressors, generally imported units occupy a large share (about 60%), domestic machine technology Because the device is still not mature, the efficiency and stability are both poor, but it accounts for a small share.

Centrifugal compressors play an important role in various sectors of the national economy, especially in the metallurgical, petrochemical, natural gas transmission, refrigeration and power industries. In the past ten years, in the context of economic globalization and fierce competition, foreign centrifugal compressor manufacturing has also undergone continuous mergers and acquisitions. In 2000, EBARA Japan purchased all the shares of ELLIOTT in the United States and formed ELLIOTT-EBARA Turbomachinery. In 2001, the German MAN Group reorganized GHHBOSIG and Sulzer to form MAN Turbo MANTURBO; SIEMENS acquired DEMAG DELEVAL and reorganized into SIEMENS Turbomachinery. Since 1994, GE (General Electric) has acquired compressor manufacturing plants such as New Billund and AC, and has become a leader in the compressor industry. Domestic compressor manufacturers also carried out mergers and acquisitions. Shenyang Blower Factory reorganized Shenyang Gas Compressor Factory, and Jinxi Chemical Machinery Co., Ltd. was acquired by SIEMENS and became SIEMENS Huludao Turbine Company. After reorganization and integration, some famous compressor manufacturers in the past, such as Sulzer, DEMAG, GHH, etc., have changed their doors. Foreign large centrifugal compressor manufacturers have formed instrument air compression applied in GE, SIEMENS and MAN air separation plants. Screw compressors and centrifugal compressors that are commonly used in machines are also mostly imported, and are generally supplied by the above companies. The main suppliers of foreign compressors and their respective characteristics are as follows: Ingersoll Rand was founded in 1871 and is called "Ingersoll Rand Corporation". Ingersoll Rand's CENTAC centrifugal air compression is a fully assembled motor-driven, single-layer, single-stage, single-stage, centrifugal air that provides 100% oil-free air (naturally oil-free) Compressor unit. The flow range can be from 25~850m3/min, and the exhaust pressure ranges from 0.8~4.0MpaG. The compressor and motor are connected by flange and coupling. The whole unit includes cooling system, control system, oil lubrication system and other auxiliary equipment. They are all installed on a common chassis, which can meet the requirements of air separation equipment with a capacity of 50000Nm3/h or less. Small models have a large advantage.

Founded in 1873, Atlas Copco is one of the world's largest multinational industrial groups, headquartered in Sweden, producing reciprocating, screw and centrifugal compressors for air and other industrial gases. And its associated dryers, filters, coolers, energy recovery systems and control systems. The Belgian AIRPOWER plant is the world's largest screw compressor production plant with an annual production capacity of tens of thousands. The ENERGAS branch in Germany specializes in special process gas compressors, and the centrifugal air compressors are manufactured by COMPTEC and ROTOFLOW in California. Machines, process compressors and expanders. It can be matched to meet the air separation equipment below 40,000.

2.3 Cameron (CAMERON) Cameron (CAMERON) is the original Cooper Turbo Compressor Co., Ltd. The company began manufacturing centrifugal compressors in the early 1950s. The company's current centrifugal compressors are available in horizontal splits in the form of RB-S, RC-S, RD-S, RE-S, RF-S, etc. The high exhaust pressure is 44.49~8.5MPa, which can meet the air separation equipment below 35,000.

In 2001, the German MAN Group reorganized GHHBOSIG and Sulzer to form MANTURBO. MANTURBO is a subsidiary of the Man AG group, one of the world's top 500 companies, and the world's largest manufacturer of turbomachinery and compressor equipment.

The horizontally split centrifugal compressor produced by MAN Turbo's newly developed high-flow model RIKT subsidiary Sulzer has a flow range of 4000~220000m3/h and a maximum outlet pressure of 70barG. It is mainly used in oxygen compression, refrigeration units and petroleum. Transportation of various medium gases in the chemical and chemical industries. The vertical split barrel type centrifugal compressor (6 types) has a flow range of 3000~45000m3/h and an outlet pressure of 700barG. It is mainly used for high pressure oxygen, synthetic ammonia gas compression, hydrocarbon gas compression, refinery gas compression, gas delivery, Natural gas uses gas and so on. The former German GHHBORSIG Turbo Machinery Co., Ltd. was merged by GHH and BORSIG in March 1996 to form a new company, which is widely used in various fields of petroleum and chemical industry around the world. The products include axial compressors, centrifugal compressors, and industrial Gas screw compressors, large-flow models of RIKT expansion machines (for energy recovery), industrial steam turbines, industrial gas turbines, etc. The company's compressor design meets the following international standards: API, PNEUROP, ASME, BS, DIN, etc. 2.5 Siemens Turbomachinery (formerly Demag-Drava) Siemens acquired the Demag-Drava DEMAGDELEVAL turbine company in 2001 to form the SIEMENS Turbine Machinery Division. It can produce various types of centrifugal compressors and steam turbines. Its main products are: centrifugal compressors, multi-axis gear speed-increasing centrifugal compressors, axial compressors, mixed-flow compressors, gas expanders, industrial steam turbines, etc. The compressors produced by Demag in Germany include: AX series centrifugal compressors, AR series mixed flow compressors, RR series high-flow centrifugal compressors, MH series horizontal split-core compressors, MV series vertical split-core compressors, H (VK) series multi-axis (high pressure) gear speed-increasing centrifugal compressor, PRT series process gas compressor, SEI/SEE series single-stage centrifugal compressor.

2.6 In other years, GE has acquired GE General Electric Power Units for compressor manufacturing plants such as New Billund and AC. Other compressor suppliers include DRESSER-RAND, Mitsubishi Heavy Industries (MHI), Japan. Hitachi Co., Ltd., as well as emerging compressor companies such as South Korea's Samsung TECHWIN Co., Ltd., Sullair (Japan's company acquisition, IHI) and so on.

In short, the imported unit is characterized by the world's leading air compressor, supercharger is a multi-axis compressor, high efficiency, but the shaft system is complex, difficult to control, high daily maintenance requirements; strong operation and coordination; large unit performance Strong set of capabilities; less spare parts, high reliability, high after-sales service costs, and poor timeliness.

Domestic compressor suppliers have many domestic small compressors, and the types are complete, but they have not yet formed brand competitiveness. They are far from mature enough in terms of technology and market compared with foreign suppliers.

The large-scale centrifugal compressor suppliers supporting the air separation of more than 20,000 grades in China are mainly Shaanxi drums and Shen drums. Among them, Shaanxi drum and Man Turbo are cooperating, and the machine technology is guaranteed. Low, its centrifugal unit can reach the operating requirements of air separation equipment below 60,000 level (axial flow + centrifugal can meet the requirements of 100,000 grades), the disadvantage is that the shaft temperature is high; the cooperation between the drum and Siemens can also meet the air separation of less than 60,000. The equipment (axial flow + centrifugation can meet the 100,000 level matching), the shortcoming of the unit is that the shaft vibration is large, the energy consumption of the Shaanxi drum is lower than that of the sun drum, but the price is slightly higher. At present, both Shaanxi Drum and Shen Drum are starting to make gear-type compressors, but they are still immature. Many high-pressure and medium-draw working conditions require that the supercharger cannot be satisfied.

For domestically produced machines that are far behind in Europe and the United States, Shaanxi Drum, Shengu and Hangzhou Auto should also have greater development and progress in many aspects.

Hanging oxygen turbine and Kaifeng air separation below 20,000 can meet the matching, but the pressure of the supercharger can only be below 45barG. Hangyang turbine is the leader in oxygen turbine compressors. The price of imported oxygen is domestic. More than 2 times, so the domestic oxygen transmission market is almost filled by Hangyang Turbo. Up to now, there are nearly 900 types of centrifugal compressors designed and manufactured by the company (including nearly 470 centrifugal oxygen permeation). . Kaifeng air separation is dominant in the labyrinth seal piston oxygen compressor.

Jiaoda Saier is a rising star. With the slogan of foreigners such as Saier, and self-improvement, it vigorously promotes the superiority of its “controllable vortex”. The certain progress made in recent years has also occupied some low-end markets of large centrifugal compressors. The share, but also the long-term test of the market.

The characteristics of domestically produced units are that the air compressor technology is not mature; the supercharger technology is general; the shafting design and calculation technology is not mature; the operation is general and the coordination is general; the large-scale unit has general performance and complete set of capabilities; The after-sales service costs are low and the timeliness is good.

For large centrifugal compressors, there is still a certain gap between the domestically produced units and the imported units. The overall performance and efficiency of the machines are not as good as those of the imported units. However, the domestically produced units have a small investment, generally only half of the imported units, and the after-sales service is better. This is also the advantage of domestic units.

Other suppliers of centrifugal compressors, screw compressors and piston compressors have their own characteristics and have specific customers in the domestic market.

Turbine one to two conventional units are equipped with a rotary prime mover that uses steam with a certain temperature and pressure to work. Turbine can be divided into: according to the thermal process: A, condensing steam turbine: steam entering the steam turbine work, except for a small amount of gas leakage, all or most of which are discharged into the condenser to form condensed water.

B. Back-pressure steam turbine: After the steam is working in the steam turbine, it is discharged into the exhaust chamber at a pressure higher than atmospheric pressure to provide heating and industrial gas for heating users.

C. Adjusting the pumping steam turbine: pumping part of the steam that has been subjected to work under some pressure for industrial use or heating.

D. Intermediate reheat steam turbine: The steam that has been completed in the high pressure cylinder of the steam turbine is sent back to the boiler superheater to heat up to the new steam temperature, and the medium and low pressure cylinders continue to work.

Some steam turbines choose to import, for example, Siemens and Man Turbo also supply steam turbines themselves; there are also domestically produced, generally choose Hangzhou Auto, Hangzhou Auto Zhongneng or Qingdao Jieneng (below 30,000 grades), and the turbine applications are generally condensed and pumped. It is the most widely used in air separation equipment.

-General air separation equipment supporting compressor supplier Siemens: gear centrifugal compressor, air 200,000 class air separation equipment), divided into axial flow section (9 or so) + centrifugal section (2), gear, The supercharger can meet the air volume of the air compressor, and the pressure can reach 100barG. Man Turbine: the centrifugal compressor air compressor can meet the air separation equipment below 100,000 class, and the 100,000-200,000 air separation equipment adopts the axial current + Centrifugal structure; centrifuge minimum gas volume 80,000 Nm3 / h; axial flow + centrifugation (price is about 15% expensive), the supercharger can meet the air compressor air volume, pressure up to 100barG; sinking drum: air compressor displacement 1.5 Million Nm3/h-35 million Nm3/h centrifugal compressor; 350,000 Nm3/h-600,000 Nm3/h first-stage axial flow + centrifugation, the supercharger can meet the air compressor air volume treatment, the pressure can reach 100barG; the machine All are single-axis (the booster has developed a gear type, but it has not been promoted), and the pressure ratio is too large to be good.

10,000 Nm3/h centrifugal compressor; 350,000 Nm3/h-600,000 Nm3/h first-stage axial flow + centrifugation; the supercharger can meet the air compressor air volume treatment, the pressure can reach 100 barG; the machine is all single-axis (increased The press has developed a gear type, but it has not been promoted. If the pressure ratio is too large, it is not easy to do. The energy consumption is lower in the drums, but the investment is slightly higher.

Jiaoda Saier: air compressor single shaft (pressure ratio is small), supercharger gear, gas volume 50,000 Nm3 / h -300,000 Nm3 / h, supercharger developed a three-axis six-stage gear type, gas volume 250,000 Below Nm3/h, the pressure is below 120barG, and the energy consumption is dominant (the energy consumption is equivalent to that of the imported unit). However, domestic processing technology has a gap compared with foreign countries, and it still needs long-term test of the market.

Hang Oxygen Turbine: Air compressor single-axis and gear type machine are also single-axis or multi-axis gear type, flow: 6,000~66,000Nm3/h, discharge pressure can be), full isothermal efficiency: 68%; oxygen Turbine compressor is a single-shaft type, flow Atlas: air compressor volume is less than 300,000 Nm3 / h, pressure is 6.2 bar (A), supercharged air volume is less than 180,000 Nm3 / h, pressure can reach 80 bar (A ); Cooper (Cameroon): air compressor gas compressor volume below 100,000 NmVh, pressure up to 70bar (A); US Sullair: air compressor volume 75,000 Nm3 / h, pressure 6.2bar (A), unit Four-stage compression, supercharger pressure below 40bar (A); opening air separation: air compressor single axis, flow (A) below; South Korea Samsung: air compressor air volume up to 100,000 Nm3 / h, pressure 6.2bar ( A); supercharger (according to Ingersoll Rand: air compressor gas volume up to 4.5 conclusions general large air separation equipment compressors, imports are mainly Man Turbo and Siemens, and more than 60,000 level can only choose these two Home; below 60,000 level, Shaanxi drum and Shen drum can also meet the requirements, the efficiency of air compressor is about 2%, the efficiency of supercharger is about 10%, but Less than half of the capital, there is a certain market share in the domestic market; 2-4 million grades of Cooper (Cameron) and Atlas Jiaotai Saier and Hangyang Turbine can meet the matching, small size below 20,000 The compressors are generally equipped with Atlas, Cooper, Kaifeng Air Separation, Ingersoll Rand, Sullair, South Korea Samsung, etc. The machine types have their own characteristics, performance and efficiency are similar, and more mature. There are many choices of compressors, but the overall performance and efficiency are not as good as imports, and the price does not take much advantage; the small oil-free screw machine is mainly Atlas, Ingersoll Rand, Sullair, and domestically produced relative Not mature, the price/performance advantage is not big.

The large-scale air separation plant is the key equipment for the development of three major chemical industries (large-scale chemical fertilizer, large-scale ethylene, large-scale coal chemical industry), metallurgical industry and centralized oxygen supply in industrial parks, and the compressor is an indispensable cardiac device in the air separation plant. Generally, it accounts for more than half of the investment in the entire air separation plant. Among the operating costs of the air separation plant, the energy consumption of the drive compressor accounts for almost 80% of the operating cost of the air separation plant, so it is chosen to meet the investment and operation. The contradiction and correlation of factors (usually the investment of large-scale imported units is twice that of domestic investment, but it can be recovered by operating expenses in about 7 years), which is essential for a set of air separation equipment and also an air separation. The primary problem faced by equipment investors. d: Jiang Xu, male, assistant engineer, graduated from Xi'an Jiaotong University, majoring in process equipment and control engineering. Now working in the design and research institute of Kaifeng Air Separation Group Co., Ltd. Shanxi Natural Gas CBM Demonstration Park will be put into operation at the end of the year. On the workers, construction is under intense construction. The project will be put into operation at the end of the year, which will fully utilize the CBM, coal mine gas and pipeline natural gas resources in the region. The comprehensive utilization of gas resources will reach 1 billion cubic meters per year, and the annual comprehensive output value will reach 2 billion yuan, making it the first in China. A natural gas coalbed methane comprehensive utilization demonstration park. Letters on natural gas and pipeline networks)

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