Hybrid Compressor Train Control Under Low Steam Supply
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Solution Overview
Problem
In chemical plants like ammonia plants, insufficient steam generation can lead to unstable rotational speed and pressure fluctuations in the compression units, particularly when the rated rotational speed is increased or steam generation decreases.
Innovation Solution
A compressor train system incorporating a steam turbine driven by process gas-generated steam, a motor to assist rotation, a frequency conversion unit for motor control, and a vacuum pump to manage pressure, with a method involving evacuation, motor starting, and controlled steam inflow to stabilize the process gas pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the rated rotational speed of the compression unit is increased or the amount of steam generated is decreased, then the steam supply to the steam turbine becomes insufficient, but the rotational speed of the compression unit becomes unstable and the process gas pressure fluctuates
Solution Approach 1:
The patent combines the steam turbine and motor into a hybrid drive system where the motor assists the steam turbine during startup and low-steam conditions. This merging of two different power sources (steam thermal energy and electrical energy) allows the system to maintain stable compression unit operation even when steam supply is insufficient, resolving the contradiction between speed requirements and operational stability.
Solution Approach 2:
The motor acts as an intermediary device that bridges the gap between insufficient steam supply and the required rotational speed for stable operation. By introducing the motor as a mediating power source, the system can achieve stable compression unit performance without requiring adequate steam supply, thus resolving the stability issue under steam-deficient conditions.
2Adaptability or versatility
If a motor is added to assist the steam turbine, then the system can operate with insufficient steam, but the device complexity increases
Solution Approach 1:
The motor is designed to serve multiple functions: it assists the steam turbine during startup, provides supplemental power during low-steam conditions, and can operate independently when steam supply is insufficient. This multi-functionality justifies the added complexity by providing versatile operation across various steam supply scenarios, enhancing the system's adaptability without requiring separate dedicated devices for each function.
3Ease of operation
If the steam turbine is evacuated before motor starting, then the motor can start smoothly, but the operating procedure becomes more complex
Solution Approach 1:
The system performs preliminary evacuation of the steam turbine before motor starting to create favorable conditions for smooth motor operation. By preparing the steam turbine environment in advance (removing excess steam and pressure), the motor can start without resistance or overload, ensuring smooth operation. This preliminary action sequence, while adding procedural steps, prevents more serious operational problems during motor startup.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system stabilizes the pressure of the compressed process gas, allows for compact and cost-effective design, reduces the need for auxiliary boilers, and enhances energy efficiency by managing steam supply and rotational speed.
Implementation Method 1
a vacuum pump which is driven to be able to reduce the pressure inside the steam turbine
Implementation Method 2
a motor which is able to assist a rotation of the steam turbine
Implementation Method 3
a steam turbine which is rotated by steam generated in accordance with the processing of the process gas
Data Source
AI summary
A compressor train of chemical plants includes: a compression unit which is driven to compress a process gas of the chemical plants; a steam turbine which is rotated by steam generated in accordance with the processing of the process gas of the chemical plants to drive the compression unit; a motor which is able to assist the rotation of the steam turbine; and a frequency conversion unit which is connected to an electric power system and controls the rotation of the motor.