Ful-Vane Gas Compressor

More compression, less energy

Developed from Fuller design and technology, FLSmidths Ful-Vane Gas Compressors provide more compression with less energy: -- Large inlet area provides efficient capture of large gas flows -- Only three moving parts for minimal mechanical losses -- Constant blade-to-cylinder contact results in constant compression efficiency -- Shaft and bearing design minimizes drive losses -- Inlet/outlet configuration eliminates internal compression losses -- Suited for operation with variable frequency drive

Cylinder head casting: ASTM 278 gray iron or ASTM 536 ductile iron Inlet / outlet flange: ANSI 150# drilling pattern (250# drilling available on some models)

Fixed (drive) end bearing: Cylindrical roller Expansion end bearing: Cylindrical roller Lubrication: Integral lube fittings with check valves

9 3 Cooling jacket: Integral in cylinder and heads (also in bearing retainer in some models) 4 Rotor and shaft: Single piece ASTM 536 ductile iron 5 Blades: B3000 Carbon fiber

10 Drive options: Direct, belt,

or gearbox. Shaft suited for maximum HP in all arrangements

laminate
6

Shaft seals: Single mechanical or double mechanical

8
2

7 6 10 4

Ful-Vane Gas Compressor Packages

Single-stage and Two-stage compressor packages FLSmidth offers a full range of single stage and two-stage compressorsfrom critical parts to complete selfcontained packages. Packages may be custom built to project specifications or FLSmidth standards. Additional auxiliary components are available upon request.

FLSmidth standard packages include: Drive Synchronous belt Direct Gear box Driver Electric motor Engine Pressurized lubrication system Reservoir Pumping unit Tubing Capacity control Variable frequency drive Automatic gas bypass Structure Steel base ANSI gas piping ASME scrubbers Ancillaries PLC control panel Closed loop cooling system Condensate removal Intercooler / aftercooler Instrumentation

Hydrocarbon service

Ful-Vane compressors are proven for a wide range of hydrocarbon services on both low and high molecular weight gases, and vacuum or pressure service. Ful-Vane compressors are also well suited for saturated, corrosive, and sour gas service. LPG loading / unloading Vapor recovery Casing head gas Natural gas Flare gas recovery Stock tank vapor recovery Sweet / sour gases Gas gathering Fuel gas boosting

SINGLE STAGE PERFORMANCE1 MSCFD 200 350 500 750 1000 1250 1500 2000 2500 3500 MODEL CC30 CC60 CC80 CC120 CC150 CC200 CC225 CC300 C400 C608 BHP 31 49 70 94 124 154 185 247 306 427 NAMEPLATE HP 40 60 75 100 150 200 200 250 350 450 VE3 75.1% 77.1% 77.1% 81.8% 81.8% 81.8% 81.8% 81.8% 81.8% 81.8% AE4 77.2% 81.6% 82.7% 85.6% 86.8% 86.3% 86.4% 86.2% 88.4% 88.5% MODEL CC30-30H CC60-60H CC80-80H CC120-120H CC150-150H CC200-200H CC225-225H CC300-300H C350-350H -

TWO STAGE PERFORMANCE2 BHP 51 80 112 152 201 242 291 386 481 NAMEPLATE HP 60 100 125 200 250 250 300 400 500 VE3 74.7% 76.5% 76.6% 80.6% 80.7% 83.1% 83.1% 83.2% 83.2% AE4 76.3% 81.1% 81.2% 85.0% 85.8% 86.2% 86.3% 86.5% 86.6% -

Performance based on Natural gas with the following properties: MW = 19.460, SG = 0.670, CP/CV = 1.270, T1 = 90F, Elev. = 500 FASL
1 2

P1 = 0 psig, P2 = 50 psig P1 = 0 psig, P2 = 140 psig

3 4

VE = Volumetric Efficiency AE = Adiabatic Efficiency

Landfill gas service

Built with rugged construction and suited for harsh environments, Ful-Vane compressors provide low energy consumption, high volumetric efficiency, reliability and durability. Ful-Vane compressors also feature rebuildable housings and rotors and are field repairable, minimizing downtime and reducing maintenance and ownership costs. Ful-Vane compressors are well suited for high CO2 applications such as landfill gas. FLSmidth offers a variable scope of supply meeting project needs ranging from critical components to complete packaged systems.

VACUUM / PRESSURE SERVICE1 SCFM 100 250 350 500 650 800 950 1200 1500 2000 2500
1 2

PRESSURE SERVICE2 AE4 71.9% 76.8% 77.5% 76.6% 78.7% 78.2% 78.6% 79.2% 84.0% 83.2% MODEL CC30 CC70 CC100 CC120 CC150 CC200 CC225 CC250 CC300 C450 C608 BHP 18 42 59 80 102 125 148 190 239 312 391 NAMEPLATE HP 25 50 75 100 125 150 150 200 250 350 400 VE3 81.7% 83.0% 83.0% 86.5% 86.5% 86.5% 86.5% 86.5% 86.5% 86.5% 86.5% AE4 83.4% 86.6% 87.1% 86.5% 87.9% 87.6% 87.8% 86.5% 85.6% 88.6% 88.6%

MODEL CC30 CC70 CC100 CC120 CC150 CC200 CC225 CC300 C450 C608 -

BHP 19 41 58 80 101 124 147 184 219 296 -

NAMEPLATE HP 25 50 60 100 125 150 150 200 250 300 3 4

VE3 83.4% 84.6% 87.8% 87.8% 87.8% 87.8% 87.8% 87.8% 87.8% 87.8% -

Performance based on Landfill gas with the following properties: MW = 30.015, SG = 1.040, CP/CV = 1.310, T1 = 100F, Elev. = 500 FASL P1 = -90WC, P2 = 25 psig P1 = 15WC, P2 = 45 psig VE = Volumetric Efficiency AE = Adiabatic Efficiency

Digester gas service

Ful-Vane compressors are designed for reliable, efficient operation over many years in the most aggressive atmospheres. Oil lubrication protects internal surfaces. Simple design minimizes maintenance. Widely used in digester gas applications, Ful-Vane compressors scope of supply is flexible to meet project requirements. Compressors include B3000 carbon fiber blades, rugged cast construction and simple design for easy inspection and maintenance. Available in a wide range of sizes.

LOW PRESSURE SERVICE1 SCFM MODEL 150 300 450 600 800 1000 1250 1500 1750 2000 2500 CC50 CC70 CC100 CC120 CC150 CC200 CC225 CC300 C350 C450 C608 BHP 13 27 41 52 68 85 107 125 143 159 199 NAMEPLATE HP 20 30 50 60 75 100 125 150 150 200 250 VE3 86.3% 86.9% 86.9% 89.9% 89.9% 89.9% 89.9% 89.9% 89.9% 89.9% 89.9% AE4 74.5% 71.8% 71.2% 71.5% 73.4% 72.6% 72.0% 73.7% 75.4% 80.9% 78.5% MODEL CC50 CC70 CC100 CC120 CC150 CC200 CC225 CC300 C350 C450 C608

MEDIUM PRESSURE SERVICE2 BHP 22 42 65 81 106 132 167 196 226 254 318 NAMEPLATE HP 25 50 75 100 125 150 200 200 250 300 350 VE3 81.0% 82.2% 82.2% 86.0% 86.0% 86.0% 86.0% 86.0% 86.0% 86.0% 86.0% AE4 82.0% 80.0% 79.6% 80.0% 81.5% 80.8% 80.3% 81.6% 83.0% 85.2% 85.3%

Performance based on digester gas with the following properties: MW = 17.429, SG = 0.599, CP / CV = 1.319, Elev. = 500 FASL, T1 = 90F
1 2

P1 = 0 psig, P2 = 15 psig P1 = 0 psig, P2 = 30 psig

3 4

VE = Volumetric Efficiency AE = Adiabatic Efficiency

Ammonia service

The Original Fuller Low Stage Ammonia Boosters designed and built by FLSmidth. FLSmidth manufacturers the original low stage boosters including all A and CA sizes from 30 through 300, and more. OEM parts, including: -- Bearings -- B3000 carbon fiber blades -- Replacement seals Also available: Replacement check valves Replacement lubrication systems Other OEM parts upon request Factory authorized service and rebuilds with new factory warranty

COMPRESSOR MODEL CA30 CA40 CA50 CA60 CA70 CA80 CA100 CA120 CA135 CA150 CA175 CA200 CA250 CA300

NOMINAL SPEED (RPM) 1760 1760 1760 1180 1180 1180 1180 880 880 880 705 705 705 705

40F SATURATED SUCTION TEMPERATURE AND +10F DISCHARGE TEMPERATURE

20F SATURATED SUCTION TEMPERATURE AND +20F DISCHARGE TEMPERATURE

TONS OF REFRIGERATION 21.8 27.9 32.1 35.2 42.2 50.0 59.6 74.4 84.2 95.0 103.8 122.4 163.1 187.8

ICFM 200 246 294 322 386 457 595 680 770 867 949 1119 1491 1717

BHP 31 38 42 43 49 59 69 79 88 97 108 127 168 193

TONS OF REFRIGERATION 39.4 48.6 58.0 62.7 75.3 89.3 106.3 130.8 148.3 167.1 182.9 215.7 287.3 330.7

ICFM 214 264 315 391 409 489 578 711 806 908 994 1172 1561 1797

BHP 36 43 49 50 58 70 82 93 105 115 128 151 200 230

FLSmidth manufactures all compressors at its Manheim, PA facility, ensuring that each and every compressor is built and tested to the most rigorous standards. In addition, FLSmidth has a 24/7 emergency breakdown service for customers, a reconditioning and exchange program, and offers on site training for rebuilding compressors. We also have a customer consignment inventory management program. In addition to our Manheim facility FLSmidth has factory-certified independent service centers and parts warehouses on all continents.

Compressor Exchange Program The FLSmidth Compressor Exchange Program is designed to replace the cylinder assemblies on existing FLSmidth rotary compressors. The program minimizes downtime for replacement and is a highly economical method for restoring compressors to original performance standards. This program is for those customers that require: Reduced downtime New and extended warranty Decreased maintenance hours Increased reliability

B3000 Compressor Blades FLSmidths B3000 compressor blades last up to four times longer than conventional blades. Their carbon graphite construction repels abrasive particles for less wear and tear. B3000 blades reduce man hours and maintenance costs, provide smooth operation and durability, and extend the life of the compressor.

B3000 Compressor Blades - Actual Test Results: Location 1. Raw Mill 1 1a. Raw Mill 1 System Compressor Blade pressure Size Type PSI C300 C300 15-20 15-20 Kevlar B3000 Std. Lube Rate DPM* 49 49
*

Lube Rate DPM 49 49

Length of Test 15 months 22 months

Total Blade Wear 1/8 3/32

Expected Blade Life Hours 16,000 60,000

Bore Condition** Test End Slight Corrugation No Corrugation

Total Hours of Operation 4,000 10,800

Notes: 1. All of the tested compressors were running at 590 RPM. 2. Maximum allowable blades wear is .

DPM Drops per minute lubrication rate

** Results based on no previous corrugation. Prior to installation cylinder must be checked for previous corrugation. Total Hours of Operation at the time measurements were taken

Project Centre Denmark FLSmidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 3618 1000 Fax: +45 3630 1820 E-mail: info@flsmidth.com

Project Centre USA FLSmidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com

Project Centre India FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai, Chennai) Tamil Nadu 603 103 Tel: +91-44-4748 1000 Fax: +91-44-2747 0301 E-mail: indiainfo@flsmidth.com

www.flsmidth.com

Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

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