NGL工厂可靠性、灵活性和效率的交易风险

T. Patel, Sami Tabaza
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引用次数: 0

摘要

天然气处理厂需要应对多变且常常不确定的条件。美国北达科他州天然气处理厂的运营商通常面临着操作模式(乙烷排出或乙烷回收)和原料气不确定性(富气或贫气)的挑战。在设备可靠性、灵活性和效率方面,这些情况也对所使用的压缩机技术提出了很高的要求。本案例研究将讨论使用商业级丙烷(95%至98.5%丙烷,其余为重碳氢化合物或HD5或更高等级丙烷)的机械制冷循环的部署。在可用于此类应用的不同压缩机技术(包括油浸螺杆、整体齿轮离心式或在线离心式)的背景下,作者研究了应用于天然气加工厂的整体齿轮传动压缩机技术的性能特征。从本质上讲,油浸螺杆压缩机系统需要定期维护,以确保无油工艺气体的可用性。反过来,当密封或聚结过滤器没有得到维护或没有达到预期的效果时,油可能会随着工艺气体流动到下游。这些事件需要大量的清洁,并可能导致工厂停机。相比之下,整体齿轮传动压缩机和在线离心压缩机100%无油(压缩室/过程中无油),提供更高的可靠性,同时需要更少的维护。此外,整体齿轮传动技术可以提供倾斜垫推力轴承,允许这些丙烷制冷压缩机在更高的吸入压力下启动(即在炎热的夏季沉降条件下启动),从而提供卓越的转子稳定性,同时节省丙烷,因为不需要燃烧气体来降低系统沉降压力(Patel和Struck 2017)。关于灵活性的参数,作者将讨论可变扩散导叶(vdgv)如何帮助提供过程灵活性,从而在不循环的情况下将压缩机的转速提高到50%。vdgv可以保持所需的和随后设计的排放压力,使操作人员能够灵活地适应不同的摩尔重量和水头要求。vdgv还有助于在制冷过程等高沉降条件下启动。结果表明,整体齿轮压缩机的效率比油浸螺杆压缩机高10%左右。由于每个叶轮都有自己的壳体和密封,因此可以方便地调节侧流。此外,整体传动装置可以匹配叶轮几何形状所需的速度,从而产生更高的压缩效率,而干气密封减少过程气体泄漏,提高工厂的可靠性。最后,研究发现,整体齿轮传动制冷剂压缩机每年可节省超过20万美元的运营成本,此外还可降低约20%的资本支出(基于对200 MMSCFD工厂的研究)。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
Trading Risk for Reliability, Flexibility and Efficiency in NGL Plants
Gas processing plants need to cope with varying and often uncertain conditions. Operators of gas processing plants in North Dakota (USA) typically face challenges with the mode of operation (ethane rejection or ethane recovery) and feed gas uncertainty (rich gas or lean gas). In terms of equipment reliability, flexibility and efficiency, these circumstances also place significant requirements on the compressor technology used. This case study will discuss the deployment of a mechanical refrigeration cycle using commercial-grade propane (95 to 98.5% propane, with the rest being heavy hydrocarbons, or HD5, or higher-grade propane). In the context of different compressor technologies available for such applications (this includes oil flooded screw, integrally geared centrifugal or inline centrifugal, the authors examine the performance characteristics of integrally geared compressor technology applied in gas processing plants. Inherently, oil-flooded screw compressor systems require regular maintenance to ensure the availability of oil-free process gas. In turn, when seals or coalescing filters are not maintained or do not perform as expected, oil may carry over with the process gas and flows to downstream. These events require extensive cleaning and can lead to plant downtime. By comparison, integrally geared compressors and inline centrifugal compressors are 100% oil-free (no oil in compression chamber / process), providing increased reliability while requiring less maintenance. Also, integrally geared technology can be supplied with tilting pad thrust bearings which allow these propane refrigeration compressors to start at a higher suction pressure (i.e., settle out conditions on hot summer days), thus providing superior rotor stability while saving the propane because there is no need to flare the gas to reduce the system settle out pressure (Patel and Struck 2017). With regards to the parameter of flexibility, the authors will discuss how the variable diffuser guide vanes (vDGVs) are helping to provide the process flexibility, thereby extending compressor turndown up to 50% without recycle. vDGVs can maintain a required and subsequently designed discharge pressure that gives operators flexibility with varying mole weight and head requirements. vDGVs also help with start-up during high settle-out conditions like those in refrigeration processes. It was found that integrally geared compressors are about 10% more efficient than oil-flooded screw compressors. As each impeller has its own casing and seals, it will allow for easy accommodation of side streams. Also, integral gearing can match the impeller geometry to the required speed which results in higher compression efficiency, while dry gas seals reduce process gas leakage to improve plant reliability. Lastly, it was found that an integrally geared refrigerant compressor delivers more than USD 200 000 per year in OPEX savings, in addition to lower CAPEX of up to approximately 20% (based on the study done for a 200 MMSCFD plant).
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