This manual is designed to familiarize users
with applications for axial flow fans,
velocity recovery stacks, seal discs, and
variable flow fans. Calculations are provided
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Course in Pune University Mechanical Engineering ppt based on Engineering Fundamentals
of the
Internal Combustion Engine
Willard W. Pulkrabek
University of Wisconsin-· .. Platteville
Course in Pune University Mechanical Engineering ppt based on Engineering Fundamentals
of the
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University of Wisconsin-· .. Platteville
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moisture, it could reduce its total cooling water intake
requirement. One of the most practical way to recover water
from flue gas is to use a condensing heat exchanger. The power
plant could also recover latent heat due to condensation as well
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Additionally, harmful acids released from the stack can be
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heat and mass transfer processes. A computer program for
numerical simulations of water (H2O) and sulfuric acid (H2SO4)
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Institution:
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Methodology:
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Ethylene Unit Cracked Gas Compressor Case Studies on Fouling.pdf
1. Ethylene Unit Cracked Gas Compressor
Case Studies on Fouling
Visagaran Visvalingam - Presenter
Cyron Anthony Soyza
Sew Nyit Tong
Karl Kolmetz
2. Outlines
? Overview of Equipment and Setup
? CGC Fouling Experiences
? Identification of Turbine Fouling
? Impacts of Compressor-Turbine fouling
? Turnaround Inspections
? Countermeasures for Fouling Control
? Future Improvements
? Conclusions
3. Overview of Equipment & Setup
• CGC is a five stages centrifugal compressor
• Caustic wash and drying are facilitated between 4th
and 5th stage
• 5th stage is a heat pump for DeC3 system where C4
and heavier are removed
• CGC is driven by a SHP steam turbine
• Turbine extracts HP steam while condensing is
controlled by CGC power demand
4. Compressor System Flow Diagram
Cracked Gas
Caustic
& Dryers
Stage 1 Stage 2 Stage 3 Stage 4
Stage 5
To
Recovery
Section
HP DeC3
Acetylene Converters
Wash Oils
10. Identification of Turbine Fouling
? Unable to maintain speed at max steam flow
? HP and LP valve fully open
? Backpressure from LP turbine
HP
Valve
SHP
LP
Valve
P1 P2
HP Steam
Extraction
Exhaust
Steam
HP Casing LP Casing
11. Causes of Turbine Fouling
• BFW quality upset
– High Sodium / Silica due to capacity overrun or
improper regeneration of demin train
• Water Carry-over
– Steam drum level control high
• Steam contamination
– Attemporating water
high in sodium or silica
Water level
12. Impacts of Compressor-Turbine
Fouling
£ Throughput limited due to maximum driver governor
valve opening
£ Increased suction pressure
£ Energy inefficient due to higher steam rate
£ Short run length, 3 years down for cleaning
13. Turnaround Inspections
• Inspection done during TA99 and TA 2001
• 1st and 5th stage - relatively clean
• 2nd, 3rd & 4th stage - heavily fouled
• Polymer deposits and most samples were organic
component
• Inter-coolers fouled with polymers and tars
• Discharge piping layered with polymer
21. Anti-foulant Injection
• Trail run at 4th stage
• Start of run - 9 May 02
• Co-injection with the existing wash oil
• Injection rate at 2-5 ppm by weight
• Monitoring parameters :
− Polytropic Efficiency
− Suction / Discharge Temperatures
− Pressure Drop Across Inter-cooler
− Steam Consumption
− Vibrations
22. Antifoulant Trial Run
Cracked Gas
Caustic
& Dryers
Stage 1 Stage 2 Stage 3 Stage 4
Stage 5
To
Recovery
Section
HP DeC3
Acetylene Converters
Wash Oils
Antifoulant : 2-5
ppm wt based on the
4th stage charge rate
23. • Polytropic efficiency improved - 4-5%
• Comp discharge temperature reduced - 3-4oC
• Delta T reduced
• Pressure drop across inter-cooler maintained
• Vibration normal
Antifoulant Trial Run Findings
26. Future Improvements
Wash oil quality
– C8+ High aromatics, low gums & higher FBP
– Intermittent or Continuos - 0.5% wg
– High volume flush - 2% wg
Wash oil and Antifoulant injection to casing
– Revamp or TA modification
Wash water injection
– max 1% throughput to minimize rotor erosion
Inter-coolers
– Antifoulant injection facilities for online cleaning
High efficiency 3D impeller blades (new service)
– More efficient and larger gas passage
27. Conclusions
? A review of equipment and maintenance records are
essential to each producer
? Part of this review should include turbine and
compressor fouling
? Adequate wash oil selection and antifoulant injection
enables cracker extension of cracked gas compressor
run lengths by reducing the amount of polymer
fouling.
? Any review should also include future optimizations