H.P. Bloch - Turboexpanders Process Applications.pdf - aparatura przemysłowa - seithe

Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

CHAPTER 1

Why and How Turboexpanders Are Applied . . . . . . . . . . . . . . . . .1

Turboexpanders for Energy Conversion 2, Turboexpander

Applications 3, Power Recovery Turboexpanders 4, Power

Absorption Methods 8, Turboexpander Qualities 10,

Summary 15, Bibliography and Additional Reading 17

CHAPTER 2

Turboexpander Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Basic Applications 19, Gas Path Equations and Analysis 21,

Specific Cryogenic Applications 30, Future Applications 33,

Statistical Aspects of Turboexpander Requirements 33, Radial Reaction

versus Impulse Design 35, Efficiency and Sizing Calculations 36,

Summary 40, Bibliography and Additional Reading 41

CHAPTER 3

Application of Cryogenic Turboexpanders . . . . . . . . . . . . . . . . . .42

Methane (Natural Gas) Liquefaction 42, Ethylene Plant

Expanders 58, Gas Treating Methods 69, Summary 77,

Bibliography and Recommended Reading 82

CHAPTER 4

Application of Hot Gas Turboexpanders . . . . . . . . . . . . . . . . . . .85

Nitric Acid Plant Applications 85, Integrally Geared Process

Gas Radial Turbines 129, Turboexpanders in Geothermal Applications

136, Turboexpander Applications in Catalytic Cracking Units 141,

Microprocessor-based Turbomachinery Management Systems 196,

Material Selection for Power Recovery Turbines 233, Turboexpander

Testing 243, Solid Particle Erosion 246, Power Recovery and the Eddy

Current Brake 260, Bibliography and Recommended Reading 271

CHAPTER 5

Specifying and Purchasing Turboexpanders . . . . . . . . . . . . . . . .273

Cryogenic Expanders 273, Power Recovery Expanders for

FCC Units in Main Air Blower or Generator Drive Service 297

CHAPTER 6

Special Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .333

Active Magnetic Bearings and Dry Gas Seals 333, Squeeze

Film Dampers 359, Radial Fit Bolts 370, Controls 373,

Bibliography and Additional Reading 400

CHAPTER 7

Turboexpander Protection and Upgrading . . . . . . . . . . . . . . . . .401

Maintenance Strategies 401, PRT Load Shedding

Concerns 403, Rotor Dynamics and Vibration Analysis 419,

Optimized/Reengineered Design and Economics 428,

Nomenclature 437, Bibliography and Additional Reading 439

CHAPTER 8

Specific Applications and Case Histories . . . . . . . . . . . . . . . . . .440

Case 1: Cryogenic Technology Helps Optimize Productivity 440,

Case 2: Turboexpanders Installed at an Older Methanol Producing

Plant Provide Major Energy Savings 442, Case 3: Manufacture of

Copper and Molybdenum 444, Case 4: Nickel Smelter and Oxygen

Production 447, Case 5: LNG Parallel Expanders 448, Case 6: New

Gas Reservoir Production with Offshore Oil Site 450, Case 7: Natural

Gas “Straddle” Pipeline Application 452, Case 8: A New H 2 O 2 Plant

Design 455, Case 9: Use of Magnetic Bearings by Norske Shell in

an Onshore Application 456, Case 10: Gas Separation Plant in

Thailand 460, Case 11: Ethylene Plant in Kuwait 460, Case 12:

MTBE Plant in Texas 462, Case 13: More Energy for a Phenol

Plant 463, Case 14: Improving FCC Expander Reliability Under

Off-Design Conditions 464, Case 15: Generating Electricity from

Excess Energy with a Letdown Gas Compressor 471, Case 16: The

Use of Magnetic Bearings for Offshore Applications 481, Bibliography

and Additional Reading 483

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498

Dedication

To the Memory of Dr. Judson S. Swearingen,

January 11, 1907–September 5, 1999

Those who knew him well called Dr. Swearingen a man of many tal-

ents, a superb theoretician, and hands-on manager. He was one of the

rarest breed of individuals: An inventor and entrepreneur with a genius-

level feel for machine behavior.

His pioneering works, over one hundred mechanical and natural gas

and/or hydrocarbon processing patents and numerous articles, led the

way to a cryogenic expander technology that has become an inseparable

part of the gas processing industry.

vii

Preface

We planned this book to be an up-to-date overview of turboexpanders

and the processes where these machines are applied in a modern, cost-

conscious plant environment. Therefore, the text addresses construction

features, application criteria, functional parameters, and selection guide-

lines. It is clearly intended for the widest possible spectrum of engineer-

ing, technical support, maintenance, operating, and managerial personnel

in process plants, refineries, air liquefaction, natural gas separation, min-

ing, design contracting, and many other industries.

The book covers both cryogenic turboexpanders that are used to re-

cover power from extremely cold gases, and hot gas expanders that

recover power from gases reaching temperatures well in excess of

1,000°F. Because energy recovery applications ranging from 75–25,000

kW exist in virtually any process that uses high-temperature and/or high-

pressure gases, properly designed turboexpanders will play an increas-

ingly important role in modern industry. It is our hope that we have

managed to thoroughly explain why, when, and how to use these

machines—in both theory and practice. We, therefore, delve into issues

and guidelines, overview comments and details, procedures, and tech-

niques that most turboexpander owner/operators and specifying engi-

neers need to know.

To the best of our knowledge, this is the first comprehensive text that

elaborates on the rather skimpy treatment given to turboexpanders else-

where. It is clearly the first book explaining magnetic bearing applica-

tions for this machinery category.

In terms of audience, this book should be of unique interest to a very

wide spectrum of engineers, technicians, supervisors, operators and man-

agers in virtually every user plant environment. Recent technical gradu-

ates, experienced and advanced individuals from air separation facilities,

chemical plants, refineries, natural gas processing plants, mining, design

viii

contracting, and other industries will benefit from this highly practical,

well-illustrated text.

Written and compiled with the active assistance of industry experts and

experienced turboexpander users, the book covers theory to the extent nec-

essary to understand operating principles and overall application criteria.

The interaction of components and controls, auxiliaries, and subsystems is

given extensive coverage and provides continuity and readability.

The reader will find both chapter sequences and the index organized

for rapid retrieval of pertinent information. Referring to this text will

equip every turboexpander job level and job function with an under-

standing of technical matters relating to a wide variety of processes and

equipment types. It combines process and mechanical technology as it

applies to these machines and presents both “overview information” and

more detailed explanations for the various categories of readers and

interested parties.

The following are some examples of the book’s problem-solving potential.

A. JOB FUNCTION:

Equipment Selection Engineer

RESPONSIBILITY:

Bid Evaluation

PROBLEM:

Receives offers from bidders whose com-

ponent selections differ; needs to under-

stand the advantages and disadvantages

of certain design features

HOW SOLVED:

This text will provide guidance.

B. JOB FUNCTION:

Plant Manager

RESPONSIBILITY:

P&L, Plant Profitability, Safety

PROBLEM:

Receives contractor’s proposal for

an energy conservation project, which

includes a turboexpander driving

a generator.

HOW SOLVED:

Understands operating principles and rela-

tive complexity after reviewing this text.

C. JOB FUNCTION:

New engineer

RESPONSIBILITY:

Contact person between project group and

operations department.

PROBLEM:

Confronted with a machine he knows

nothing about; has no knowledge of a par-

ticular process that uses turboexpanders.

HOW SOLVED:

Finds a thorough explanation in this text.

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