Gas compressors have new measures to reduce reliability

In 2007, US Anrun Long made a notable appearance at the Asia PTC exhibition by launching new compressor oils designed to reduce downtime and enhance return on investment. These innovative lubricants have become a key focus in the ongoing efforts to improve energy efficiency and lower consumption across industries. Compressors play a critical role in the petrochemical sector, with gas compressors being essential in most plants. The two primary types are centrifugal and reciprocating compressors. As the industry continues to grow, there's an increasing emphasis on improving energy efficiency, reliability, and operational performance. Centrifugal compressors are evolving toward larger scale, greater energy efficiency, and enhanced reliability. Technological advancements now focus on boosting efficiency, reducing energy use, and optimizing production processes. The application of ternary flow theory in impeller blade and diffuser design has led to higher unit efficiency, while parameterized working characteristics allow for better stage and system matching. Early fault detection, noise control, and advanced control systems are becoming standard features. Thanks to these improvements, modern centrifugal compressors can achieve up to 88% overall efficiency, operate stably, and maintain reliable performance for 3 to 4 years. Shenyang Blower Group is currently developing a cracking gas compressor for Tianjin’s 1 million-ton ethylene project, featuring an inlet flow of 341,494 standard cubic meters per hour and a shaft power of 51,106 kW. Meanwhile, Shaanxi Blower Group has introduced axial compressor technology from Swiss company Sulzer, successfully designing and manufacturing main and standby fans for Dalian Petrochemical Company’s 3.5 million-ton catalytic cracking unit. This includes the largest axial compressor in China, with a flow rate of 300,000 standard cubic meters per hour and a power of 40,000 kW. On the reciprocating compressor side, global developments in refining, ethylene, and fertilizer industries have driven significant progress. Modern large reciprocating compressors now handle piston loads exceeding 1,250 kN and shaft power over 10,000 kW. The current trend in reciprocating compressor design emphasizes larger capacity, higher pressure, compact structure, lower energy consumption, reduced noise, improved efficiency, and enhanced reliability. Advanced software tools for thermodynamics, dynamics, and process simulation are used to refine designs and predict real-world performance. New valve technologies are extending service life, while electromechanical integration allows for automated control, real-time monitoring, and optimized energy-saving operation. These innovations ensure smoother operations, timely alerts, and effective protection against abnormal conditions.

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