The turboexpandergenerator arrangement is typically available in three configurations. Artificial demand is the excess volume of compressed air created for unregulated users as a. In addition to our built to order expander compressors, atlas copco gas and process also offers a standardized expander compressor off of the shelf ecots. Us4477223a sealing system for a turboexpander compressor. Expandercompressors an overview sciencedirect topics. Turbo expanders support systems ngl pumps cold boxes demethanizers utilities gas ngl. The shaft speed of a typical turboexpander in hydrocarbon service is typically around 5,000 to 10,000 rpm for large machines and 50,000. This secondary generator produces waste heat that can be used to offset the cooling effect of the turboexpander. Contents introduction application of turbo expanders primary sizing calculations expander compressor performance curves important points from api 617 8th edition, chapter 4 materials accessories references. With inlet temperatures up to 760c 1,400 f, inlet pressures of up to 25 bar and power outputs up to 30 mw, man energy solutions expanders are suitable for a broad variety of applications such as nitric acid, therephthalic acid, fluid catalytic cracking. Extracted power from the expander is transmitted through rotor, supported by oil or magnetic bearings to compressor wheel. Turbo expanders have a range of applications, but this template focuses on the use of turbo expanders for energy recovery and power generation. Cryostar have manufactured thousands of turbo expanders since the early 70s. Expandercompressor units to provide an oilfree solution with reduced maintenance and reduced plot plan.
Sometimes, the turboexpander and compressor are packaged in a single unit on a single shaft. As high pressure gas is expanded across the turbine, the majority of the energy potential in the gas is extracted and transferred through the shaft and to the compressor. Reliability improvement for turboexpandercompressor system. In cryogenic ngl recovery processes, the turboexpander achieves two different but. With over 60 years of experience, our global installed base includes the industrys first turboexpandercompressor used for gtl, first nacecompliant active magnetic bearings amb, and first amb installed on an fpso. Dew point turboexpander process a solution for high pressure fields author. Atlas copco turboexpanders are available in a number of models that can handle pressures up to 200 bar and are offered in booster compressor, expander generator, integrallygeared generator or hydraulic brake configurations. Pipeline centrifugal compressors siemens provides a wide range of compressors and compressor packages for natural gas transmission and distribution. Process gas enters the compressor where the pressure and temperature are raised by the compressor wheel.
This symbiosis between the turboexpander and secondary generator increases the net efficiency of the entire. A conical defuser is often used to recover remaining velocity. The efficiency inherent in the turboexpander compressor makes it the preferred turboexpander for natural gas and cryogenic gas processing within the petrochemical industry and other industrial processes requiring refrigeration. Atlas copco turboexpanders are available in a number of models that can handle pressures up to 200 bar and are offered in booster compressor, expander generator. Selection and conversion of turbocharger as turboexpander. Turbo expander operation, performance, maintenance. The turboexpander is essentially consist of a centrifugal compressor and a radial inflow turbine connected. I am trying to select the adequate control of two turboexpander for natural gas working in parallel. Exterran is the rst choice for gas processing plants. These highspeed rotating turboexpandercompressor machines are typically used in cryogenic applications including natural gas, petrochemical, and air separation industries. The plant currently processes 83 mmscfd and is in the process of expanding its capacity to 5 mmscfd. This gas is then ready to be sent to pipeline or to a final sales compression train for delivery to pipeline. The term turboexpander refers to an expandercompressor machine as a single unit.
It consists of two primary components, the radial inflow expansion turbine and a centrifugal compressor integrated as a single assembly. As described, when compared with a traditional mechanical refrigeration unit, this process offers fewer pieces of equipment. Driving turboexpander technology brochure atlas copco. Turbo expander system behavior improvement sing an adaptive.
He recently retired after 33 years with ge rotoflow where he last served as. Turboexpandercompressors for air separation facilities. The device has a shaft carried in a housing on bearings with a compressor wheel on one side and an expander wheel on the other side. Turbo expanders, also referred to as expansion turbines, provide a way to capture the energy lost in natural gas facilities and refineries. Conversion of an automotive scroll compressor into a scroll expander for research 110 kw application conversion of a compressor into a turboexpander verdicorp company 20 115 kw 0. A turboexpander, also referred to as a turbo expander or an expansion turbine, is a centrifugal or axialflow turbine, through which a highpressure gas is expanded to produce work that is often used to drive a compressor or generator. The shaft spins the compressor wheel, which shoves air into the engines combustion chamber. The compressor end will boost up the expanded process fluid to the needed fuel gas pressure. Development of high efficiency hot gas turbo expander for. The turboexpander uses the energy removed from the gas due to the pressure drop to drive a compressor, which helps recompress the gas to sales pressure. These expanders offer the same reliability and efficiency of our customengineered units, but use readily available components such as housings, fittings and frame sizes. Driving expander technology atlas copco 112017 printed in. The turbo expander is essentially consist of a centrifugal compressor and a radial inflow turbine connected. Development of a high efficiency hot gas turboexpander and low cost heat exchangers for optimized csp supercritical co 2 operation 1.
Expandercompressors, an introduction turbomachinery. These expanders are either connected to a generator or directly to a compressor train. In the oil brake and the expander compressor configurations both. I am trying to select the adequate control of two turbo expander for natural gas working in parallel. Cryostar was the first company to develop the hydrocarbon expander compressor with active magnetic bearings in the 90s. Expander compressors for hydrocarbons, petrochemicals atlas. A turboexpander compressor for use in a gas processing system has a seal system that avoids communication of gas with the oil being pumped through the bearings.
Turboexpandercompressor system reliability improvement for turboexpandercompressor system compressor discharge expander suction compressor suction expander discharge mechanical center section. Expander compressors for hydrocarbons, petrochemicals. Turbo expander compressor natural gas turboexpander l. Conventional control systems limit speed by limiting the opening of the expander guide vanes which limits the torque delivered by the expander. In the case of our hydrocarbon turboexpander compressors, this means greater liquid recovery and extra compression power. Please provide internet sites for reference if any. Ii1 turboexpander magnetic bearings cpf gt 28 ii2 overview of turboexpander 29 ii3 turboexpander image 30 ii4 the different parts of turboexpander 31 ii5 the detailed diagram of the turboexpander 32 ii6 the detailed diagram of the joule thompson valve 38 iii1 distribution of natural gas reserves in the world 42. Compressor loaded expanders turbo expander compressor tc series tc2000 tc3000 tc4000 tc6000 tc9000 tc12000 performance expander ns range 40 140 expander efficiency up to the low 90%s expander pressure ratio up to 24. The radial and thrust bearings discussed herein are thus located between the expander and compressor impellers, as in figure 1. Turboexpander turbine, expansion turbine all industrial. Consult ge steam turbiness entire turboexpandercompressors catalogue on directindustry. Other forms of turboexpanders, such as those in which the expander drives a generator, are similar in design, as shown in figure 2. Turboexpanders have a range of applications, but this template focuses on the use of turboexpanders for energy recovery and power generation.
Driving expander technology atlas copco 112017 printed. Driving expander technology atlas copco gas and process. Enhanced control techniques for cryogenic turboexpander. Over 550 amb expandercompressors are installed and in service as of 2015, in gas.
The expander wheel in compressordrive applications connects to a matching centrifugal compressor which works just like the turbo expander, but backward via a shaft. The gas is compressed, cryogenically separated, and fractionated to yield residue gas. Turbomachine layout options option generator compressor turbine rpm high speed, optimal a. Preliminary design and simulation of a turbo expander for small. Benefit from the multistage integralgearing advantage as one of the industrys most efficient and compact designs, integral gear technology enables optimal aerodynamic speeds at. The torque delivered by the compressor remains relatively constant. The energy extracted from a gas expanding across the turbine can be converted into electric power by connecting the load side of the expander shaft to a generator.
Turboexpanders, also referred to as expansion turbines, provide a way to capture the energy lost in natural gas facilities and refineries. We quickly deliver reliable plants designed and manufactured inhouse to maximize your control over project schedules. This energy is transferred to the compressor side of the turbo expander compressor via a rigid shaft where it is used to recompress the gas for delivery to its next stage etc. Using demand expanders in compressed air systems by. Find your turboexpander turbine easily amongst the 17 products from the leading brands baker hughes, deprag schulz, ge power. With complexity comes greater information access and equipment reliability, together with the need for a.
Thanks to their unmatched reliability, these machines are a well proven design and have become a standard. Our turboexpanders provide a unique degree of efficient and reliable operation for air separation and liquefaction of cryogenic gases. Turbo expander system behavior improvement sing an. By using the recompressor recycle valve first, the expander guide vanes are allowed to remain in a more open position and these results in an increase in condensate production. Most orc systems have been developed with scroll and vane type expanders.
A turboexpander can generate low temperature gas far more efficiently than options such as a joulethomson jt valve or others in many refrigeration, cryogenic and low temperature gas services. Axial optimized for compressor high speed, expander only a. In the above, certain values were assumed for specific speed, efficiency, head coefficient, etc. The project is based on designing and testing of a small turboexpander for performance. Turbo expanders modern turbo expanders can achieve almost isentropic expansion resulting in much lower temperature drops than possible with a valve. Advanced multivariable control of a turboexpander plant. Jul 31, 2016 an expandercompressor, also referred to as a turboexpandercompressor or simply a turboexpander, refers to a machine with a common shaft, with a centrifugal expander wheel on one end, expanding gas with a temperature of less than 300 c 570f, and a centrifugal compressor wheel on the opposite end. A simple diagram of expander turbine system with nozzle control system and actuator is shown in fig. The gulf plains plant is a turboexpander plant originally designed to handle approximately 120 mmscfd of 3. Cryostar was the first company to develop the hydrocarbon expandercompressor with active magnetic bearings in the 90s. Elliott group is a global leader in the design, manufacture and service of. The expansion turbine is the power unit and the compressor is the driven unit. Turboexpander compressors baker hughes, a ge company. Advanced multivariable control of a turboexpander plant dan altena, michael howard.
The expander drops the pressure of the gas from high pressure to low and liquids drop out, during the decompression, pressure energy is converted to kinetic energy. Apr 23, 2019 sometimes, the turboexpander and compressor are packaged in a single unit on a single shaft. The expander wheel in compressor drive applications connects to a matching centrifugal compressor which works just like the turbo expander, but backward via a shaft. Labyrinth seals seal the wheels from the interior of the housing and the bearings. Turboexpanderscompressors baker hughes, a ge company. Acd has over 50 years of experience in the design and manufacturing of high efficiency turboexpanders. With over 60 years of experience, our global installed base includes the industrys first turboexpandercompressor used for gtl, first nacecompliant active magnetic. This work is used to drive a compressor to partially restore the gas pressure. A turboexpander, also referred to as a turboexpander or an expansion turbine, is a centrifugal or axialflow turbine, through which a highpressure gas is expanded to produce work that is often used to drive a compressor or generator because work is extracted from the expanding highpressure gas, the expansion is approximated by an isentropic process i. The extracted energy is used to drive another rotating machine such as compressor, generator or pump. These highspeed rotating turboexpander compressor machines are typically used in cryogenic applications including natural gas, petrochemical, and air separation industries.
Fundamentals of turboexpanders basic theory and design. The gulf plains plant is a turbo expander plant originally designed to handle approximately 120 mmscfd of 3 gpm gas using one train. For most compressors, increasing the flow rate leads to increasing the power needed to drive the compressor. The project is based on designing and testing of a small turbo expander for performance. The power extracted can then be used elsewhere in the process, such as a booster compressor. The turboexpander is essentially consist of a centrifugal compressor and a radial inflow turbine connected on a single rotating shaft. Our equipment is still proudly designed and manufactured in the usa in our facilities in santa ana california. Turboexpander compressors delivering reliable cryogenic service with ultrahigh energy efficiency in virtually any oil and gas application robust materials and advanced designs that result in smaller footprints and higher performance for the most demanding applications. Uncoupling the expander as a direct driver from the fcc process minimised the risk of process interruption. Scot foss, plant air technology increasing the amount of air in a system doesnt have to mean adding compressors. Turboexpandercompressors ge steam turbines pdf catalogs. Take advantage of turboexpanders chemical processing.
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