Integrated Charge Gas Compression Train for Ethylene Without Gearbox
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ethylene charge gas compression trains are bulky, costly, and unreliable due to the presence of a gearbox and separate casings for low-pressure and high-pressure compressors, which increases the footprint and maintenance needs.
Innovation Solution
Directly coupling a steam turbine to a group of low-pressure compressors and integrating them in a common casing, eliminating the need for a gearbox and reducing the overall size and complexity of the compression train.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a gearbox is used to couple the steam turbine to the compressors, then the rotation speed can be increased to 5000 RPM, but the device complexity and footprint increase
Solution Approach 1:
The patent removes the gearbox from the system entirely, directly coupling the steam turbine to the compressors. This extraction of the intermediate mechanical transmission component eliminates the associated complexity, maintenance needs, and space requirements while the turbine itself operates at the required high rotation speed to drive the compressors directly
Solution Approach 2:
The patent merges the steam turbine and compressors into a single integrated assembly where the turbine shaft is directly connected to the compressor shafts. This direct coupling eliminates the need for separate gearbox housing, mounting structures, and alignment mechanisms, thereby reducing device complexity and footprint
2Adaptability or versatility
If separate casings are used for low-pressure and high-pressure compressors, then each compressor can be optimized independently, but the footprint and device complexity increase
Solution Approach 1:
The patent combines multiple compressor stages (both low-pressure and high-pressure compressors) into a single common casing. The compressors are arranged radially or axially around a shared drive mechanism, allowing them to share common structural support, sealing systems, and maintenance access points. This integration reduces the overall footprint by eliminating redundant casing walls, mounting flanges, and alignment features that would be required for separate casings
Solution Approach 2:
The common casing serves multiple functions simultaneously: it houses both low-pressure and high-pressure compressors, provides structural support for all rotating elements, contains the sealing systems for multiple compression stages, and facilitates unified maintenance access. This multi-functionality reduces the total component count and space requirements compared to separate dedicated casings for each compressor
3Power
If a gearbox is used in the compression train, then power transmission is achieved, but reliability decreases due to additional failure points
Solution Approach 1:
The patent eliminates the gearbox from the power transmission system, creating a direct-drive configuration where the steam turbine shaft is mechanically coupled directly to the compressor shafts. This removal of the gearbox eliminates gear teeth, bearings, lubrication systems, and coupling mechanisms that are potential failure points, thereby significantly improving system reliability while maintaining full power transmission capability through direct mechanical connection
Solution Approach 2:
The patent merges the power transmission function directly into the rotational coupling between the turbine and compressors. The turbine shaft and compressor shafts are aligned and connected through a common bearing support structure, eliminating the need for intermediate power transmission components. This integrated power transmission path reduces the number of moving parts and potential failure modes while maintaining efficient torque and power delivery
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
This configuration enhances reliability, reduces costs, and minimizes space usage while maintaining efficient compression performance, achieving higher rotating speeds and pressures without the need for a gearbox, thus improving the overall system reliability and efficiency.
Implementation Method 1
a steam turbine (2), a first compressor (60), a second compressor (61) and a third compressor (62) arranged on the same shaft line
Implementation Method 2
The first compressor (60) receives an input gas flow at a first input pressure (e.g., 1.5-2 bar) and outputs a first output flow at a first output pressure (e.g., 2.5-4 bar)
Data Source
AI summary
A charge gas compression train for ethylene including a first compressor including a first group of compression stages, a second group of compression stages, and a third group of compression stages. The first group of compression stages includes an outlet configured to be connected to a first intercooler inlet. The second group of compression stages includes a second compressor inlet configured to be connected to a first intercooler outlet, and a second compressor outlet configured to be connected to a second intercooler inlet. The third group of compression stages includes a third compressor inlet configured to be connected to a second intercooler outlet. The first, the second, and the third group of compression stages are integrated in a first common casing and operate at the same rotation speed. The first compressor includes a plurality of unshrouded and shrouded impellers, where an unshrouded impeller is positioned upstream to a shrouded impeller.