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04_Rotating_Equipment-1.pdf
1.
Rotating Equipment: Pumps, Compressors,
& Turbines/Expanders Chapters 2 & 9
2.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Topics Fundamentals ▪ Starting relationships • Thermodynamic relationships • Bernoulli’s equation ▪ Simplifications • Pumps – constant density compression • Compressors – reversible ideal gas compression ▪ Use of PH & TS diagrams ▪ Multistaging Efficiencies ▪ Adiabatic/isentropic vs. mechanical ▪ Polytropic Equipment ▪ Pumps • Centrifugal pumps • Reciprocating pumps • Gear pumps ▪ Compressors • Centrifugal compressors • Reciprocating compressors • Screw compressors • Axial compressors ▪ Turbines & expanders • Expanders for NGL recovery • Gas turbines for power production o What is “heat rate”? 2
3.
Updated: January 4,
2019 Copyright © 2017 John Jechura (jjechura@mines.edu) Fundamentals
4.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Review of Thermodynamic Principals 1st Law of Thermodynamics – Energy is conserved ▪ (Change in system’s energy) = (Rate of heat added) – (Rate of work performed) ▪ Major energy contributions • Kinetic energy – related to velocity of system • Potential energy – related to positon in a “field” (e.g., gravity) • Internal energy – related to system’s temperature o Internal energy, U, convenient for systems at constant volume & batch systems o Enthalpy, H = U+PV, convenient for systems at constant pressure & flowing systems 4 Ê Q W = − = + + 2 ˆ ˆ 2 c c u g E U h g g = + + 2 ˆ ˆ 2 c c u g E H h g g
5.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Review of Thermodynamic Principals 2nd Law of Thermodynamics ▪ In a cyclic process entropy will either stay the same (reversible process) or will increase Relationship between work & heat ▪ All work can be converted to heat, but… ▪ Not all heat can be converted to work 5
6.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Common Paths for Heat and Work 6 Isothermal constant temperature ΔT = 0 Isobaric constant pressure ΔP = 0 Isochoric constant volume ΔV = 0 Isenthalpic constant enthalpy ΔH = 0 Adiabatic no heat transferred Q = 0 Isentropic (ideal reversible) no increase in entropy ΔS = 0
7.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) 1st Law for steady state flow Equation 1.19a (ΔH ΔU for flowing systems) For adiabatic, steady-state, ideal (reversible) flow (using WS as positive value) ▪ The work required is inversely proportional to the mass density 7 2 ˆ 2 c c u g H z Q W g g + + = − 2 1 2 2 1 1 2 2 ˆ ˆ 2 ˆ 2 ˆ ˆ s c c P c c P P P s P P u g W H z g g u g V dP z g g dP W V dP = + + = + + =
8.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Thermodynamics of Compression Work depends on path – commonly assume adiabatic or polytropic compression Calculations done with: ▪ PH diagram for ΔH ▪ Evaluate integral using equation of state • Simplest gas EOS is the ideal gas law • Simplest liquid EOS is to assume incompressible (i.e., constant density with respect to pressure) 8 = = 2 1 P s P W VdP H − = = = 2 2 1 1 2 1 1 P P s P P dP P P W dP
9.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Liquid vs. Vapor/Gas Compression Can compress liquids with little temperature change 9 GPSA Data Book, 13th ed. ΔH for gas compression much larger than for liquid pumping
10.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Mechanical Energy Balance Differential form of Bernoulli’s equation for fluid flow (energy per unit mass) ▪ Frictional loss term is positive ▪ Work term for energy out of fluid – negative for pump or compressor If density is constant then the integral is straight forward – pumps If density is not constant then you need a pathway for the pressure-density relationship – compressors 10 ( ) ( ) ( ) 2 ˆ ˆ 0 2 s f d u dP g dz d w g d h + + + + = ( ) 2 ˆ ˆ 0 2 s f u P g z w g h + + + + = ( ) 2 1 2 ˆ ˆ 0 2 P s f P u dP g z w g h + + + + =
11.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump equations Pumping requirement expressed in terms of power, i.e., energy per unit time Hydraulic horsepower – power delivered to the fluid ▪ Over entire system ▪ Just across the pump, in terms of pressure differential or head: Brake horsepower – power delivered to the pump itself 11 ( ) ( ) ( ) ( ) ( )( ) ( )( ) ( )( ) = − = + + + = + + + 2 hhp 2 ˆ ˆ 2 1 ˆ 2 s f f u P W m w V g z g h V P V g z V g h V u ( ) = = hhp hhp or W V P W V gH = hhp bhp pump W W
12.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump equations for specific U.S. customary units U.S. customary units usually used are gpm, psi, and hp Also use the head equation usually using gpm, ft, specific gravity, and hp 12 = 3 f hhp 2 f 2 f in 231 gal lb gal hp min in ft lb / sec sec in 60 12 550 min f lb 1 gal 1714 min in t hp W = m 2 hhp m f 2 f lb ft 8.33719 32.174 gal gal sec hp ft lb ft min f 1 gal ft 39 t lb / sec sec 32.174 60 550 lb sec min 58 hp min o o W
13.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Static Head Terms 13 Fundamentals of Natural Gas Processing, 2nd ed. Kidnay, Parrish, & McCartney
14.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump Example Liquid propane (at its bubble point) is to be pumped from a reflux drum to a depropanizer. ▪ Pressures, elevations, & piping system losses as shown are shown in the diagram. ▪ Max flow rate 360 gpm. ▪ Propane specific gravity 0.485 @ pumping temperature (100oF) ▪ Pump nozzles elevations are zero & velocity head at nozzles negligible What is the pressure differential across the pump? What is the differential head? What is the hydraulic power? 14 GPSA Data Book, 13th ed.
15.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump Example Pressure drop from Reflux Drum to Pump inlet: Pressure drop from Pump outlet to Depropanizer: 15 ( ) ( )( ) ( ) piping inlet 0.485 62.3665 20 0.5 0.2 144 3.5 psi 203.5 psia c g P z P g P = − + − = − + − − = = ( ) ( )( ) ( ) piping outlet 0.485 62.3665 74 3.0 2.0 1.2 13.0 1.0 9.0 144 44.7 psi 264.7 psia c g P z P g P = − + = − − + + + + + = − =
16.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump Example Pump pressure differential: Pump differential head: Hydraulic power: 16 ( ) outlet inlet pump 264.7 203.5 61.2 psi P P P = − = − = ( ) ( ) ( ) ( ) ( )( ) ( ) pump pump pump 144 61.2 291 ft 0.485 62.3665 c c o water P P g g h g g = = = − = ( )( ) ( )( )( ) hhp hhp 360 gpm 61.2 psi 360 gpm 0.485 291 ft 12.85 hp OR 12.84 hp 1714 3958 W W = = = =
17.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Gas Compression: PH Diagrams 17 Ref: GPSA Data Book, 13th ed.
18.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) TS Diagram 18
19.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Thermodynamics of Ideal Gas Compression Choices of path for calculating work: ▪ Isothermal (ΔT = 0) • Minimum work required but unrealistic ▪ Adiabatic & Isentropic (ΔS = 0) • Maximum ideal work but more realistic ▪ Polytropic – reversible but non-adiabatic • Reversible work & reversible heat proportionately added or removed along path • More closely follows actual pressure-temperature path during compression 19 = = = 2 2 1 1 2 1 ln P P s P P dP P W VdP RT RT P P
20.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Thermodynamics of Compression Ideal gas isentropic (PV = constant) where = CP/CV ▪ Molar basis ▪ Mass basis Can also determine discharge temperature 20 ( ) ( ) − = − − 1 / 2 1 1 1 1 s P W RT P ( ) − = = − − 1 / 1 2 1 ˆ 1 1 s s W RT P W M M P ( ) − = 1 / 2 2 1 1 P T T P
21.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Thermodynamics of Compression Calculation of for gas mixture Use the ideal gas heat capacities, not the real gas heat capacities Heat capacities are functions of temperature. Use the average value over the temperature range 21 , , , , i p i i p i i V i i p i x C x C x C x C R = = −
22.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Example Calculation: Ideal Gas Laws For methane: ▪ = 1.3 ▪ M = 16 ▪ T1 = 120oF = 580oR ▪ P1 = 300 psia ▪ P2 = 900 psia ▪ R = 1.986 Btu/lb.mol oR 22 ( ) ( ) ( )( )( ) ( )( ) ( ) ( ) ( ) − − − = − = − = − − = = 1 / 1.3 1 /1.3 1 2 1 1.3 1 /1.3 2 1.3 1.986 580 900 1 1 90 Btu/lb 1 16 1.3 1 300 900 580 747°R 287°F 300 s RT P W M P T
23.
440 BTU/lb 525 BTU/lb Enthalpy
Changes: 𝑊 = ∆𝐻 = 525 − 440 = 85 𝐵𝑇𝑈 𝑙𝑏 Outlet temperature: 280°F Compress methane from 300 psia & 120°F to 900 psia
24.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Example Calculation: Using a Simulator Work Btu/lb Outlet oF HYSYS Peng-Robinson 86.58 281.8 HYSYS Peng-Robinson & Lee-Kesler 87.34 280.5 HYSYS SRK 87.71 281.2 HYSYS BWRS 87.04 281.1 HYSYS Lee-Kesler-Plocker 87.40 280.6 Aspen Plus PENG-ROB 86.61 282.4 Aspen Plus SRK 87.82 281.8 Aspen Plus BWRS 87.10 281.6 24
25.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Multi-Stage Gas Compression If customer wants 1,000 psig (with 100 psig & 120oF inlet)… ▪ Then pressure ratio of (1015/115) = 8.8 ▪ Discharge temperature for this ratio is ~500oF For reciprocating compressors the GPSA Engineering Data Book recommends ▪ Pressure ratios of 3:1 to 5:1 AND … ▪ Maximum discharge temperature of 250 to 275oF for high pressure systems To obtain higher pressure ratios higher must use multistage compression with interstage cooling 25
26.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Multistaging To minimize work need good interstage cooling and equal pressure ratios The number of stages is calculated using To go from 100 to 1000 psig with a single-stage pressure ratio of 3 takes 2 (1.98) stages & the stage exit temp ~183oF (starting @ 120oF) 26 ( ) ( ) 1/ 2 1 2 1 ln / ln m P P P P P m P = = R R ( ) ( ) ( ) ( ) ( ) ( ) ( ) − − = = = = = = + = = 1 / 1.3 1 /1.3 1/ 1/2 0.2308 2 2 1 1 1015 ln ln 8.8 115 1.98 2 ln 3 ln 3 1015 120 460 580 2.97 746°R 286°F 115 m m m P T T P
27.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Multistaging Work for a single stage of compression Work for two stages of compression (interstage cooling to 120oF) ▪ Intermediate pressure ▪ Total work – 13% less work 27 ( ) ( ) ( )( )( ) ( )( ) ( ) 1 / 1.3 1 /1.3 1 2 1 1.3 1.986 580 1015 ˆ 1 1 204 Btu/lb 1 16 1.3 1 115 s RT P W M P − − = − = − = − − ( )( ) int 2 1 1015 115 341.7 psia P P P = = = ( )( )( ) ( )( ) ( ) ( ) 1.3 1 /1.3 1.3 1 /1.3 1.3 1.986 580 341.7 1015 ˆ 1 1 16 1.3 1 115 341.7 178 Btu/lb s W − − = − + − − =
28.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Compression Efficiency Compression efficiencies account for actual power required compared to ideal ▪ Isentropic (also known as adiabatic) efficiency relates actual energy to fluid to energy for reversible compression ▪ Mechanical efficiency relates total work to device to the energy into the fluid 28 ( ) ( ) 0 0 IS IS S S fluid fluid H W W H = = = = Total Energy To Device Energy Lost To Environment Minimum Energy for Compression Energy to Overcome Mechanical Inefficiencies – Goes Into Fluid & Increases Temperature { Total Energy Into Fluid 0 mech mech mech IS fluid fluid S total total W W W W W = = = =
29.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Compressor Efficiency – Discharge Temperature GPSA Engineering Data Book suggests the isentropic temperature change should be divided by the isentropic efficiency to get the actual discharge temperature 29 ( ) ( ) ( ) 1 / 1 / 2 2 1 1 1 0 1 1 1 S P P T T T T P P − − = = − = − ( ) ( ) ( ) ( ) ( ) 1 / 2 1 0 1 IS IS 1 / 2 1 2, 1 1 IS 1 So: 1 1 S act act act P T P T T P P T T T T − = − − = = − = + = +
30.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Example Calculation: 75% isentropic efficiency ΔS =0 Work Btu/lb ΔS =0 Outlet oF =0.75 Work Btu/lb =0.75 Outlet oF Ideal Gas Equations 90 287 120 343 PH diagram 85 280 113 325 HYSYS Peng-Robinson 86.58 281.8 115.4 325.2 HYSYS SRK 87.71 281.2 116.9 325.2 HYSYS BWRS 87.04 281.1 116.1 325.1 HYSYS Lee-Kesler-Plocker 87.40 280.6 116.5 324.8 30
31.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Polytropic Compression & Efficiency Definition of polytropic compression (GPSA Data Book 14th ed.): A reversible compression process between the compressor inlet and discharge conditions, which follows a path such that, between any two points on the path, the ratio of the reversible work input to the enthalpy rise is constant. In other words, the compression process is described as an infinite number of isentropic compression steps, each followed by an isobaric heat addition. The result is an ideal, reversible process that has the same suction pressure, discharge pressure, suction temperature and discharge temperature as the actual process. 31
32.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Polytropic Efficiency Polytropic path with 100% efficiency is adiabatic & is the same as the isentropic path ▪ Polytropic efficiency, p, is related to the isentropic path In general P > IS Polytropic coefficient from discharge temperature 32 ( ) ( ) − = = − 1 2 1 2 2 1 1 2 1 ln / 1 where 1 ln / T T P T T P P P ( ) ( ) − = − P 1 / 1 /
33.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Polytropic Efficiency Actual work is calculated from the polytropic expression divided by its efficiency Note: 33 ( ) 1 / 1 2 1 ˆ 1 ˆ 1 1 p act p p W RT P W M P − = = − − 0 ˆ ˆ ˆ p S act p IS W W W = = =
34.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Why Use Polytropic Equations? Polytropic equations give consistent P-T pathway between the initial & discharge conditions 34
35.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Effect of Internal Pressure Drops Pressure drops at the inlet & outlet give an apparent inefficiency of compression ▪ Assume isenthalpic pressure drops before & after the actual compression 35
36.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Effect of Internal Pressure Drops Pressure Reductions Before Compression psia After Compression psia Work Btu/lb Outlet °F Efficiency 0% 300 900 86.58 281.8 100% 1% 297 909 88.36 284.7 98% 5% 285 947 95.76 296.8 90% 10% 270 1000 105.7 313.0 82% 15% 255 1059 116.5 330.2 74% 36
37.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Compression vs. Expansion Efficiency Work to compressor is greater than what is needed in the ideal case ▪ Work to the fluid ▪ Total work to the device Work from expander is less than what can be obtained in the ideal case ▪ Work from the fluid ▪ Total work from the device 37 ( ) ( ) 0 0 IS IS S S fluid fluid H W W H = = = = mech 0 mech mech IS fluid total fluid S total W W W W W = = = = ( ) ( ) ( ) IS IS 0 0 fluid fluid S S H W W H = = = = mech mech mech IS 0 total fluid total fluid S W W W W W = = = =
38.
Updated: January 4,
2019 Copyright © 2017 John Jechura (jjechura@mines.edu) Equipment: Pumps, Compressors, Turbines/Expanders
39.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump & Compressor Drivers Internal combustion engines ▪ Industry mainstay from beginning ▪ Emissions constraints ▪ Availability is 90 to 95% Electric motors ▪ Good in remote areas ▪ Availability is > 99.9% Gas turbines ▪ Availability is > 99% ▪ Lower emissions than IC engine Steam turbines ▪ Uncommon in gas plants on compressors ▪ Used in combined cycle and Claus units 39
40.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Pump Classifications 40 Fundamentals of Natural Gas Processing, 2nd ed. Kidnay, Parrish, & McCartney
41.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Centrifugal Pump Performance Curves 41 Fundamentals of Natural Gas Processing, 2nd ed. Kidnay, Parrish, & McCartney
42.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Compressor Types Positive displacement – compress by changing volume ▪ Reciprocating ▪ Rotary screw ▪ Diaphragm ▪ Rotary vane Dynamic – compress by converting kinetic energy into pressure ▪ Centrifugal ▪ Axial 42
43.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressors Workhorse of industry since 1920’s Capable of high volumes and discharge pressures High efficiency – up to 85% Performance independent of gas MW Good for intermittent service Drawbacks ▪ Availability ~90 to 95% vs 99+% for others, spare compressor needed in critical service ▪ Pulsed flow ▪ Pressure ratio limited, typically 3:1 to 4:1 ▪ Emissions control can be problem (IC drivers) ▪ Relatively large footprint ▪ Throughput adjusted by variable speed drive, valve unloading or recycle unless electrically driven 43
44.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressors - Principle of Operation Double Acting – Crosshead Typical applications: ▪ All process services, any gas & up to the highest pressures & power Single Acting - Trunk Piston Typical Applications: ▪ Small size standard compressors for air and non-dangerous gases 44 Courtesy of Nuovo Pignone Spa, Italy
45.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressors - Compression Cycle 45 Suction Discharge 1 1 2 2 3 3 4 5 4 5 p0 Pressure Volume Courtesy of Nuovo Pignone Spa, Italy
46.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressors - Main Components 46 Pulsation Bottles Crosshead Cast Steel Crankcase Cast Iron Distance Pieces Slide Body Connecting Rod (die forged steel) Forged Cylinder Crankshaft Forged Steel Cast Cylinder Main Oil Pump Piston Rod Rod Packing Piston Cylinder Valve Counterweight for balancing Ballast for balancing of inertia forces Pneumatic Valve Unloaders for capacity control Oil Wiper Packing
47.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressors 47 https://www.youtube.com/watch?v=E6_jw841vKE
48.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Rotary Screw Compressor Left rotor turns clockwise, right rotor counterclockwise. Gas becomes trapped in the central cavity The Process Technology Handbook, Charles E. Thomas, UHAI Publishing, Berne, NY, 1997. 48 Courtesy of Ariel Corp
49.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Rotary Screw Compressors Oil-free First used in steel mills because handles “dirty” gases Max pressure ratio of 8:1 if liquid injected with gas High availability (> 99%) ▪ Leads to low maintenance cost Volumetric efficiency of ~100% Small footprint (~ ¼ of recip) Relatively quiet and vibration-free Relatively low efficiency ▪ 70 – 85% adiabatic efficiencies Relatively low throughput and discharge pressure Oil-injected Higher throughput and discharge pressures Has two exit ports ▪ Axial, like oil-free ▪ Radial, which permits 70 to 90% turndown without significant efficiency decrease Pressure ratios to 23:1 Tight tolerances can limit quick restarts Requires oil system to filter & cool oil to 140oF Oil removal from gas Oil compatibility is critical Widely used in propane refrigeration systems, low pressure systems, e.g., vapor recovery, instrument air 49
50.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Dynamic Compressors Centrifugal ▪ High volumes, high discharge pressures Axial ▪ Very high volumes, low discharge pressures Use together in gas processing ▪ Centrifugal for compressing natural gas ▪ Axial for compressing air for gas turbine driving centrifugal compressor 50
51.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Centrifugal compressors Single stage (diffuser) Multi-stage 51 Bett,K.E., et al Thermodynamics for Chemical Engineers Page 226
52.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Centrifigual Compressor 52 Siemens https://www.energy.siemens.com/br/en/compression- expansion/product-lines/single-stage/stc-sof.htm https://www.youtube.com/watch?v=s-bbAoxZmBg
53.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Centrifugal Compressor 53 Courtesy of Nuovo Pignone Spa, Italy
54.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Centrifugal vs. Reciprocating Compressors Centrifugal Constant head, variable volume Ideal for variable flow - MW affects capacity ++ Availability > 99% + Smaller footprint - ηIS = 70 – 75% CO & NOx emissions low - Surge control required ++ Lower CAPEX and maint. (maint cost ~1/4 of recip) Reciprocating Constant volume, variable pressure Ideal for constant flow + MW makes no difference - Availability 90 to 95% - Larger footprint + ηIS = 75 – 92% Catalytic converters needed ++ No surge problems ++ Fast startup & shutdown 54
55.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Turbines & Turboexpanders Utilize pressure energy to… ▪ Reduce temperature of gas & (possibly) generate liquids ▪ Perform work & provide shaft power to coupled equipment Similar principles to a centrifugal compressor except in reverse Most common applications: ▪ Turboexpander: NGL recovery ▪ Gas turbine: power to drive pumps, compressors, generators, … 55
56.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Turboexpander Cutaway 56 https://www.turbomachinerymag.com/expander-compressors-an-introduction/ Video (LA Turbine. 2:54 minutes): https://www.youtube.com/watch?v=f5Gz_--_NBM
57.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Turboexpanders GPSA Engineering Data Book, 14th ed.
58.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Methane Expansion – Isentropic vs. Isenthalpic 58
59.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Gas Turbine Engine 59 https://aceclearwater.com/product/case-study-ge-power-ducts/
60.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Gas Turbine Coupled to Centrifugal Compressor 60
61.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Industrial Gas Turbines 61 Ref: GPSA Data Book, 13th ed.
62.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) What is “heat rate”? Heat rate is the amount of fuel gas needed (expressed heating value) to produce a given amount of power ▪ Normally LHV, but you need to make sure of the basis Essentially the reciprocal of the thermal efficiency ▪ Example: Dresser-Rand VECTRA 30G heat rate is 6816 Btu/hp·hr Includes effects of adiabatic & mechanical efficiencies 62 ( ) = 2544 Thermal efficiency Btu LHV Heat rate, hp hr = = 2544 Thermal efficiency 0.3732 6816
63.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Combustion chamber Compressor Turbine Load Gas Turbine Engine From: F.W.Schmuidt, R.E. Henderson, and C.H. Wolgemuth, “Introduction to Thermal Sciences, second edition” Wiley, 1993 shaft shaft Atmospheric air Fuel Combustion products Assumptions To apply basic thermodynamics to the process above, it is necessary to make a number of assumptions, some rather extreme. 1) All gases are ideal, and compression processes are reversible and adiabatic (isentropic) 2) the combustion process is constant pressure, resulting only in a change of temperature 3) negligible potential and kinetic energy changes in overall process 4) Values of Cp are constant P1 P2 P3 P4 Gas Turbine Engine 63
64.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Temperature T Entropy S P2 = P3 Patm = P1 = P4 1 2 3 4 wS = -∆h = -CP∆T (9.1 and 1.18) Note the equations apply to both the compressor and the turbine,since thermodynamically the turbine is a compressor running backwards Neglecting the differences in mass flow rates between the compressor and the turbine, the net work is: wnet = wt – wc = CP(T3 – T4) – (T2 -T1) Since (T3 – T4) > (T2 – T1) (see T – S diagram) Since wnet is positive work flows to the load Gas Turbine Engine 64
65.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) GT - Principle of Operation 65 Simple Cycle Gas Turbine 4 3 2 A B Temperature °F Entropy 1 Theoretical Cycle Axial Compressor Combustion Chamber H.P./L.P. Turbine Fuel Gas Air Exhaust Gas (~950°F) 1 3 4 ~1800 - 2300°F ~650 - 950°F Ideal Cycle Efficiency Real Cycle Centrifugal Compressor 2 ( ) 1 / 4 1 1 3 2 2 1 1 id T T P T T P − − = − = − −
66.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Modeling Gas Turbine with Aspen Plus Basics to tune model ▪ Combine heat rate & power output to determine the fuel required ▪ Determine the air rate from the exhaust rate ▪ Adjust adiabatic efficiencies to match the exhaust temperature ▪ Adjust the mechanical efficiencies to match the power output 66
67.
Updated: January 4,
2019 Copyright © 2017 John Jechura (jjechura@mines.edu) Summary
68.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Summary Work expression for pump developed assuming density is not a function of pressure Work of compression is much greater than that for pumping – a great portion of the energy goes to increase the temperature of the compressed gas Need to limit the compression ratio on a gas • Interstage cooling will result in decreased compression power required • Practical outlet temperature limitation – usually means that the maximum compression ratio is about 3 There are thermodynamic/adiabatic & mechanical efficiencies • Heat lost to the universe that does affect the pressure or temperature of the fluid is the mechanical efficiency 68
69.
Updated: January 4,
2019 Copyright © 2017 John Jechura (jjechura@mines.edu) Supplemental Slides
70.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressors 70
71.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Propane Refrigeration Compressors 71
72.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Propane Compressors with Air-cooled Heat Exchangers 72
73.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Reciprocating Compressor at Gas Well 73 Courtesy of Nuovo Pignone Spa, Italy
74.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) 2 stage 2,000 HP Reciprocating Compressor 74 Courtesy of Ariel Corp
75.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Oil-Injected Rotary Screw Compressor 75 Courtesy of Ariel Corp
76.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Two-stage screw compressor 76 Courtesy of MYCOM / Mayekawa Mfg
77.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Centrifugal Compressors – Issues Surge • Changes in the suction or outlet pressures can cause backflow; this can become cyclic as the compressor tries to adjust. The resulting pressure oscillations are called SURGE Stonewall • When gas flow reaches sonic velocity flow cannot be increased. Inlet Volume Flow Rate Pressure Head S u r g e L i n e Stonewall Line Centrifugal Reciprocating Axial 77
78.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Air & Hot Gas Paths Gas Turbine has 3 main sections: A compressor that takes in clean outside air and then compresses it through a series of rotating and stationary compressor blades 78 EXHAUST FRESH AIR MECHANICAL ENERGY COMPRESSION
79.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Air & Hot Gas Paths Gas Turbine has 3 main sections: A combustion section where fuel is added to the pressurized air and ignited. The hot pressurized combustion gas expands and moves at high velocity into the turbine section. 79 EXHAUST FRESH AIR MECHANICAL ENERGY COMBUSTION COMPRESSION
80.
Updated: January 4,
2019 Copyright © 2019 John Jechura (jjechura@mines.edu) Air & Hot Gas Paths Gas Turbine has 3 main sections: A turbine that converts the energy from the hot/high velocity gas flowing from the combustion chamber into useful rotational power through expansion over a series of turbine rotor blades 80 EXHAUST FRESH AIR MECHANICAL ENERGY EXPANSION TURBINE COMPRESSION COMBUSTION
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