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he refrigeration station of the MEK-benzene dewaxing (UV-501) used the suction pressure of the first stage inlet
(2)
(3)
where:
A is the flow measuring device constant.
∆p1 is the differential pressure across flow measuring
device at compressor suction.
ρ1 is the gas density at compressor suction conditions.
M is gas molecular weight.
Z1 is the gas compressibility factor at compressor suc-
tion conditions.
R0 is the universal gas constant.
From formula (2) and (3) we get the following equation:
Figure 2. Antisurge control diagram of compressor
C-501 after retrofit. (4)
P2/P1
(1) (6)
Rc is the compression ratio.
Suppose:
nised motor. Removal of 10 control and switching panels with November 1998, reduced by 288 760 kWh.
for the synchronised motors. Removal of five synchro- The power consumption of December 1999 compared
nised motor ventilation systems and five synchronised with December 1998, reduced by 238 080 kWh.
motors. Removal of two auxiliary power switching panels The energy reduction was also due to the removal of the
and original power and control cables. original auxiliary equipment, such as the ventilator, excitation
Installation of five sets of induction motors, each with equipment, starting devices, etc. The synchronised motors
1600 kW rated power. Installation of seven new power were replaced by more efficient induction motors (the original
switching panels, two operating consoles, installation of a synchronised motor was rated 1500 kW at 179 A. The new
new lighting switching panel, installation of 6000 V induc- induction motor was 1600 kW at 182 A. Thus the rated power
tion motor power cables 500 m, and 5000 m instrumenta- increased by 100 kW, while the maximum current only
tion cables etc. increased by 3 A.)
The MEK/Benzen dewaxing unit had an average pro-
Conclusion cessing capacity of 600 000 tpy. Calculating using the cost of
This retrofit was implemented in July 1999. The units were in electricity as 0.55 Yuan/kWh. The refrigeration station can
operation at once. It was in continuous operation for more reduce the power consumption by 1.56kWh per t of material.
than one year. The annual saving will be 1.56 x 600 000 x 0.55 = 514 800
The refrigeration station load optimisation and compres- yuan (1 US$ = 8.26 Yuan).
sors antisurge control system were in fully automatic control Another key benefit from retrofit is the avoidance of an
and the compressors and station operation were smooth. unscheduled shutdown. Before the retrofit, annual unsched-
According to the compressor operating curve display, the uled shutdown ranged between 5 - 10 times. Effectively, there
compressors’ operating status can be observed very clearly has been no unscheduled shutdown after the retrofit. The
and easily. They reduced the workload of the operators, and economic benefit is certainly more significant than the energy
increased compressor reliability for safe operation and savings alone.
process stability.
Great economical benefits were achieved by using a vari- References
1. GUO QING TONG, BAI SHOU SAN, ZHAO WEI XIN, Cryogenics
able limiting flow control solution, effectively controlling the
Engineering Manual, Published by China Construction Industry
recycle flow of the ammonia gas and greatly reducing energy Publishing House, Beijing, 1985.
consumption of the compressors. 2. LU DE MIN, Petrochemical Automation Control Design Manual, 3rd
Edition, Published by Chemical Industry Publishing House, Beijing, 1993.
The process unit electrical power consumption was
3. JIANG MAO SUN, YU QUAN SHOU, Process Control Engineering,
greatly reduced: SINOPEC Publishing House, Beijing, 1988.
The power consumption of October 1999 compared with 4. ‘Using the Series 4 Antisurge Controller’, Publication UM4102 (3.3),
Compressor Controls Corporation, 2001.
October 1998, reduced by 194 660 kWh. 5. ‘Using the Series 4 Performance Controller’, Publication UM4104 (3.1.1),
The power consumption of November 1999 compared Compressor Controls Corporation, 1999.
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Publication #MS123 Reprinted from HYDROCARBON ENGINEERING NOVEMBER 2003