Maximise customer-specific potential savings in reciprocating compressors

Selecting modern components helps save energy

Andreas Zeiff Hoerbiger Compression Technology

eciprocating compressors are true largescale energy consumers. Much of the driving energy is used to perform physical work and cannot be stored. A further not inconsiderable proportion of this energy is, however, wasted on inadequate technology and can therefore be significantly reduced. In addition to the primary savings on the actual compressor, further potential savings are possible by exploiting additional effects, such as reduced energy consumption during re-expansion to decrease gas discharge. The use of modern components and systems, adapted to individual conditions, is now opening up enormous potential for savings compared with previous solutions. In this age of CO2 levies and rising energy prices, sophisticated optimisation or modernisation of equipment can quickly pay for itself due to improved energy efficiency, while making operation more reliable. In many sectors, reciprocating compressors are the centerpiece of production. If the compressor stops, so does production. This means that the compressors must be able to combine long service lives with the utmost reliability. At the same time, the driving energy used must be utilised as efficiently as possible, as that is the only way to minimise operating costs. The compression technology specialist Hoerbiger is offering a new approach with its energy optimisation service for compressors. Instead of expensive new investments, it is often sufficient to make relatively minor changes in selected components in order to achieve significant savings. At the start of a renovation project, a thorough inventory analysis is carried out and a list of possible potential improvements drawn up. Following the upgrade and system restart, a final analysis is carried out, which includes an evaluation of the savings achieved.

Large savings potential

During compressor operation, the largest amounts of energy are wasted in relatively few areas. On the one hand, under partial-load operation, conventional installations with step or bypass control systems convert a not insignificant proportion of expensive operating energy into (waste) heat. Introducing stepless control of the suction volume can result in significant savings being achieved, while, at the same time, being able to optimally adapt compressor output to production. On the other hand, the efficiency of most of the components found in older compressors leaves a lot to be desired. New components with optimised flow, reduced friction and longer service lives ie, longer operation with optimal performance can improve both the compressors energy efficiency and reliability. The savings potential can be calculated from the reduction of the input power in kW multiplied by the operating hours to give the energy saved in kWh. This amount multiplied by the energy price per kWh (plus any CO2 levies) gives the savings income in Euro. Even ostensibly minimal savings of only 3% per component quickly add up with multi-cylinder installations and over long periods of operation to produce considerable savings on energy bills. If we compare this with the cost of a full compressor analysis and upgrading with new components, the expenditure involved is usually exceeded by the savings in the first year.

Hotspots for savings

Surprisingly, most of the energy losses occur in places that can be upgraded to a state-of-the-art standard by relatively simple conversion work (Figure 1). Thus, on average, 2% to 7% of the energy used is lost at the drive shaft due to

www.digitalrefining.com/article/1000668

November 2012 1

increased from 0-(10%) to 100%. Instead of older plate valves, Hoerbigers new CE, CM or CP valves are capable of further reducing losses during the gas exchange. Savings of 5% to 8% are thus quite realistic. The main reasons for the increase in efficiency are the aerodynamically improved flow channels and a design that largely excludes deposit build-ups which impede the gas exchange. Since pressurFigure 1 Energy balance for a typical 1-4 MW reciprocating compressor ised gases are also energy carriers, leaks always go hand in hand with energy losses. Modern piston and packing sealing rings such as the cut BCD ring help to improve efficiency. The BCD ring can be easily retrofitted, minimises gas leakage as well as wiping losses, and improves reliability thanks to its long service life. In practice, given an energy price of 110 EUR/MWh (2011 industry price according to Eurostat), this approach means the following for a 962 kW reciprocating compressor that operates 8.253 hours a year: annual savings of approximately 235.799 Euro are possible as a result of a realistic reduction of losses related to the Figure 2 The compact HydroCOM actuator control system, the valves and the packing sealing rings from 35% to friction. The valves cause further losses of 3% to approximately 8% (-27%). 10%. Piston rings and packings cause 1% losses due to leakage of gas and additional losses of 1% to 3% due to friction. The biggest energy guzzler, Links however, is an inadequate flow control. For More articles from: Hoerbiger Compression Technology instance, a bypass control system usually wastes between 12% and 50% of the energy used. In More articles from the following categories: such cases, the use of the stepless HydroCOM Emissions Control control system should be considered (Figure 2). Energy Efficiency/Energy Management With a reverse flow control, energy is used to Gas Processing/Treatment compress only as much gas as is actually Reliability & Asset Management required by the process. The control system can Revamps, Shutdowns and Turnarounds be dynamically adapted to the process; within Rotating Equipment just three revolutions, the capacity can be

2 November 2012

www.digitalrefining.com/article/1000668