Sidestream Mixing Layout for Uniform Compressor Inlet Flow
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Solution Overview
Problem
Beam-style, multi-stage centrifugal compressors used in hydrocarbon processing face challenges in achieving uniform temperature and pressure fields for sidestream flows, leading to performance degradation and difficulties in installing movable geometry for process adjustments.
Innovation Solution
A system and method for mixing and pressurizing process fluid streams using a network of compressors and drivers, with a junction configuration that allows for efficient mixing and minimizes pressure and temperature stratification, enabling the installation of movable geometry for performance tuning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sidestream flows are introduced through additional flanges with inlet plenums and scoop vanes, then the compressor can handle multiple process streams, but pressure and temperature stratification occurs leading to performance degradation
Solution Approach 1:
The patent applies preliminary action by introducing a flow conditioning device upstream of the compressor inlet that pre-mixes sidestream flows with the main process stream before they enter the compressor. This preliminary mixing prevents pressure and temperature stratification from occurring within the compressor, thereby maintaining reliable performance while still allowing multiple process streams to be handled.
Solution Approach 2:
The flow conditioning device acts as an intermediary element between the sidestream inlets and the compressor inlet. It provides a dedicated mixing zone with flow distribution elements that condition the combined flow before it enters the compressor, eliminating the harmful stratification effect while preserving the ability to accept multiple streams.
2Adaptability or versatility
If movable geometry is installed for performance tuning, then the compressor can be adjusted to match process requirements, but the limited space in beam-style compressors makes installation challenging
Solution Approach 1:
The patent extracts the flow conditioning and mixing function from the compressor internal geometry and places it in a separate, upstream flow conditioning device. This extraction eliminates the need for complex movable geometry installations within the tight compressor space, while still providing performance tuning capability through the external flow conditioning elements.
Solution Approach 2:
The patent replaces the traditional mechanical approach of installing movable inlet guide vanes or diffuser vanes within the compressor with a flow conditioning device that uses fixed geometry and flow distribution elements. This substitution achieves performance tuning through flow management rather than mechanical adjustment, simplifying installation while maintaining adaptability.
3Productivity
If mixing occurs in the inlet guide immediately upstream of the impeller, then sidestream flows are combined with working fluid, but improper mixing leads to non-uniform pressure and temperature fields
Solution Approach 1:
The patent applies preliminary action by performing the mixing operation upstream of the compressor inlet rather than at the inlet guide. The flow conditioning device provides a dedicated mixing zone where sidestream and main stream are thoroughly combined and homogenized before entering the compressor, ensuring uniform pressure and temperature fields without relying on the limited mixing capability of the inlet guide.
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 achieves uniform temperature and pressure fields, enhancing compressor performance and allowing for flexible adjustments to meet varying process requirements.
Implementation Method 1
The diffuser is configured to convert the velocity of the gas received from the impeller to potential energy in the form of increased static pressure, thereby resulting in the compression of the gas.
Implementation Method 2
The gas is drawn into the impeller from the first inlet guide and driven (or propelled) to a tip of the impeller, thereby increasing the velocity of the gas.
Data Source
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AI summary
Systems and methods are provided for sidestream mixing. The system may include a first junction formed from a plurality of conduits. The plurality of conduits may include a first conduit fluidly coupled to a compressor, the first conduit forming a first conduit diameter and configured to flow therethrough a first process fluid stream of a plurality of process fluid streams. The plurality of conduits may also include a second conduit fluidly coupled to the first conduit and the compressor, and configured to flow therethrough a second process fluid stream of the plurality of process fluid streams. The first junction may be disposed a first distance at least three times the first conduit diameter upstream of the compressor, such that the first process fluid stream and the second process fluid stream are mixed and form a first combined process fluid stream prior to being fed into and pressurized in the compressor.