US20210040958A1 - Centrifugal compressor achieving high pressure ratio - Google Patents

Centrifugal compressor achieving high pressure ratio Download PDF

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US20210040958A1
US20210040958A1 US16/965,684 US201816965684A US2021040958A1 US 20210040958 A1 US20210040958 A1 US 20210040958A1 US 201816965684 A US201816965684 A US 201816965684A US 2021040958 A1 US2021040958 A1 US 2021040958A1
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Prior art keywords
process fluid
inlet
compressor
molecular weight
stage
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Inventor
James M. Sorokes
Mark J. Kuzdzal
El Mostafa El Ghazzani
Pascal Lardy
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Siemens Energy Inc
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Dresser Rand Co
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Assigned to Dresser-Rand SAS reassignment Dresser-Rand SAS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EL GHAZZANI, El Mostafa, LARDY, PASCAL
Assigned to DRESSER-RAND COMPANY reassignment DRESSER-RAND COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUZDZAL, MARK J., SOROKES, JAMES M.
Publication of US20210040958A1 publication Critical patent/US20210040958A1/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/40—Casings; Connections of working fluid
    • F04D29/42—Casings; Connections of working fluid for radial or helico-centrifugal pumps
    • F04D29/44—Fluid-guiding means, e.g. diffusers
    • F04D29/441—Fluid-guiding means, e.g. diffusers especially adapted for elastic fluid pumps
    • F04D29/444—Bladed diffusers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D17/00—Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps
    • F04D17/08—Centrifugal pumps
    • F04D17/10—Centrifugal pumps for compressing or evacuating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D17/00—Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps
    • F04D17/08—Centrifugal pumps
    • F04D17/10—Centrifugal pumps for compressing or evacuating
    • F04D17/12—Multi-stage pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D21/00—Pump involving supersonic speed of pumped fluids
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D25/00—Pumping installations or systems
    • F04D25/16—Combinations of two or more pumps ; Producing two or more separate gas flows
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
    • F04D29/284—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for compressors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
    • F04D29/284—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for compressors
    • F04D29/286—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for compressors multi-stage rotors

Definitions

  • the invention relates to centrifugal compressors. More particularly, in some embodiments, the invention relates to centrifugal compressors and methods of their operation, which in a single compressor stage, is capable of achieving high-pressure ratios of greater than, or equal to 2.5:1 on process fluids having a molecular weight range of 12-20, such as natural gas. In other embodiments, the invention relates to two-stage centrifugal compressors and methods of their operation, which are capable of achieving throughput pressure ratios of greater than or equal to 5:1 on process fluids having a molecular weight of 12-20, such as natural gas.
  • compressors have been developed and are utilized in a myriad of industrial processes (e.g., petroleum refineries, offshore oil production platforms, and subsea-process control systems).
  • conventional compressors are utilized to compress gas or gas/liquid mixture process fluids, which are also referred to as “working fluids”.
  • working fluids gas or gas/liquid mixture process fluids
  • compression is achieved by applying mechanical energy to the process fluid gas in a low-pressure environment and transporting the gas to and compressing the gas within a high-pressure environment, such that the compressed gas may be utilized to perform work or for operation of one or more downstream process components.
  • At least one known proposed solution to the above-mentioned constraints of conventional compact compressors has been the utilization of supersonic compressors to achieve higher compression ratios while maintaining a compact structure.
  • At least some of the known supersonic compressors utilize a compressor rotor that imparts supersonic velocity, greater than Mach 1, on the process fluid, to achieve greater single-stage pressure ratios than conventional compressors that impart velocities less than Mach 1.
  • Exemplary compressor embodiments described herein achieve high-pressure ratios of at least 2.5:1 in a single compressor stage, on process fluids having molecular weights of 12-20.
  • Exemplary process or working fluids within the 12-20 molecular weight range include natural gas, comprising methane, and other hydrocarbons, with or without other non-hydrocarbon constituents.
  • the compressor is configured to impart a pressure ratio of at least 5:1 on the process fluid having a molecular weight of 24-27.99; or at least 4:1 on the process fluid having a molecular weight of 20-24; or at least 3:1 on the process fluid having a molecular weight of 16-20; or at least 2.5:1 on the process fluid having a molecular weight of 10-16; or at least 2:1 on the process fluid having a molecular weight less than 10.
  • Other exemplary compressor embodiments described herein include first and second single-stage compressors serially in communication within a common housing structure or as separate housing structures, where both stages are commonly driven by a driver, such as an electric motor or a turbine engine.
  • a multi-stage compressor of four stages constructed and operated in accordance with embodiments described herein, is capable of compressing natural gas within a mole weight range of 12-20 to a commercially desirable pressure ratio of 39:1 or higher.
  • Embodiments of the compressor stages described herein are of modular structure, which achieve maximum pressure ratios within a range of between 2.0:1-11:1 proportionally for 10-44 mole weight (MW) process fluids.
  • Each single-stage compressor constructed in accordance with embodiments described herein, includes a housing having an inlet defining an inlet passage, and an outlet defining an annular diffuser passage.
  • the process fluid in the inlet passage has an inlet pressure (P 1 ) and the process fluid discharged from the annular diffuser passage has a discharge pressure (P 2 ) greater than the inlet pressure, such that a pressure ratio (r) of the discharge pressure divided by the inlet pressure is greater than unity.
  • a shaft-mounted centrifugal impeller is oriented between the inlet and the outlet.
  • the impeller includes a plurality of three-dimensional impeller blades projecting outwardly from a hub.
  • the hub has an axial length (A x ), and a hub outer diameter (D 2 ) extending radially at a radius (R 2 ) relative to the shaft axis.
  • Each of the impeller blades has a leading edge facing the inlet passage at a blade sweep angle ( ⁇ ), a trailing edge facing the annular diffuser passage at a back sweep angle ( ⁇ ) and having a tip width (b 2 ), and a blade tip having a radius of curvature (R C ), which defines an outer periphery of the centrifugal impeller.
  • the impeller blades are configured to impart energy to the process fluid, upon rotation of the rotary shaft, and discharge the process fluid therefrom at a flow angle ( ⁇ ) into the annular diffuser passage.
  • the annular diffuser passage has a leading or shroud wall and a trailing or hub wall, which define a diffuser passage height (b 3 ) there between.
  • a plurality of diffuser vanes is oriented in the annular diffuser passage.
  • the respective diffuser vanes extend axially from the shroud wall towards the hub wall of the diffuser passage.
  • the diffuser vanes have a vane height (b 3R ), and they are circumferentially disposed about the periphery of the centrifugal impeller.
  • Each diffuser vane respectively defines curved, opposing vane pressure and vane suction sides, a vane leading edge proximate the periphery of the centrifugal impeller at a radial distance (R 3 ) relative to the shaft axis and conjoining the suction side, a vane trailing edge facing the outlet and conjoining the suction side, and a vane radial extent between the vane leading and trailing edges.
  • the vane radial extent defines a length (RE). Dimension ranges of the annular diffuser passage, the centrifugal impeller, and the diffuser vanes vary as a function of pressure ratio (r).
  • a x /D 2 varies between 0.1-0.4; 1/R C varies between 0.5-0.15; 0; and 0 varies between 40-86.
  • the angular bandwidth of minimum and maximum angles for the back sweep angle ⁇ vary between 20-60 degrees and 35-45 degrees, and the ratio of RE/R 2 varies from 0.1-0.5.
  • Dimension ranges of the annular diffuser passage and the diffuser vanes vary as a function of flow coefficient ( ⁇ ) of the process fluid flowing between the inlet and the outlet of the compressor. When ⁇ is in the range of 0-0.030, the ratio of b 3R /b 3 is 1.0.
  • the ratio of b 3R /b 3 is 0.5-1.0.
  • the ratio of b 3R /b 3 is 0.3.
  • Aforementioned dimensions of the modular construction housing, impeller, diffuser passage, diffuser vanes and outlet are selectively matched, within the aforementioned ranges, to achieve desired pressure ratios for given molecular weight process fluids. Achievable pressure ratios within any given stage are limited by ultimate mechanical stress limit of the impeller.
  • exemplary embodiments of the invention feature methods for compressing natural gas, having a molecular weight (MW) of 12-20.
  • the methods are practiced by utilizing a single-stage, centrifugal compressor with a compressor casing having therein an inlet for receipt of a process fluid.
  • the single-stage compressor includes a single, unshrouded, rotatable, centrifugal impeller defining a plurality of impeller blades for imparting kinetic energy into the process fluid.
  • Each of the respective impeller blades has a leading edge for receiving process fluid from the inlet and a trailing edge for discharging process fluid.
  • the single-stage compressor also has a diffuser, which defines an annular diffuser passage, for receiving the process fluid discharged from the respective trailing edges of the impeller blades in the annular diffuser passage and increasing static pressure of the process fluid therein.
  • the compressor has an outlet for receiving process fluid discharged from the annular diffuser passage.
  • the centrifugal impeller is driven at a rotational speed (N), so that the trailing edges of the respective impeller blades achieve a rotational velocity (U 2 ) of greater than or equal to 1400 feet/second: this imparts kinetic energy into the first process fluid.
  • the diffuser passage receives the first process fluid discharged by the trailing edges of the centrifugal impeller blades, which converts the kinetic energy imparted in the first process fluid by centrifugal impeller into a pressure increase.
  • the first process fluid is discharged from the annular diffuser passage at a discharge pressure (P 2 ) greater than the inlet pressure (P 1 ) thereof, such that a pressure ratio (r) of the discharge pressure divided by the inlet pressure is greater than or equal to 2.5:1.
  • exemplary embodiments of the invention feature methods for compressing process fluids.
  • the methods are practiced by utilizing a single-stage, centrifugal compressor with a compressor casing having therein an inlet for receipt of a process fluid.
  • the single-stage compressor includes a single, unshrouded, rotatable, centrifugal impeller defining a plurality of impeller blades for imparting kinetic energy into the process fluid.
  • Each of the respective impeller blades has a leading edge for receiving process fluid from the inlet and a trailing edge for discharging process fluid.
  • the single-stage compressor also has a diffuser, which defines an annular diffuser passage, for receiving the process fluid discharged from the respective trailing edges of the impeller blades in the annular diffuser passage and increasing static pressure of the process fluid therein.
  • the compressor has an outlet for receiving process fluid discharged from the annular diffuser passage.
  • the diffuser passage receives the first process fluid discharged by the trailing edges of the centrifugal impeller blades, which converts the kinetic energy imparted in the first process fluid by centrifugal impeller into a pressure increase.
  • the first process fluid is discharged from the annular diffuser passage at a discharge pressure (P 2 ) greater than the inlet pressure (P 1 ) thereof, such that a pressure ratio (r) of the discharge pressure divided by the inlet pressure is:
  • the first process fluid has a molecular weight of 24-27.99;
  • the first process fluid has a molecular weight of 20-24;
  • the first process fluid has a molecular weight of 16-20;
  • the first process fluid has a molecular weight of 10-16;
  • the first process fluid has a molecular weight less than 10.
  • FIG. 1 is a schematic view of an exemplary compressor, operatively coupled to a driver, in accordance with an embodiment as described herein;
  • FIG. 2 is a quartered cross-sectional, perspective view of an exemplary, single-stage compressor, in accordance with another embodiment as described herein;
  • FIG. 3 is a quartered, axial cross-sectional view of an exemplary, multi-stage, center-hung compressor; in accordance with another embodiment as described herein;
  • FIG. 4 is an axial cross-sectional view of another exemplary single-stage compressor in accordance with another embodiment as described herein;
  • FIG. 5 is a front elevational or radial, cross-sectional view of the compressor of FIG. 4 , taken along 5 - 5 thereof, showing a portion of its centrifugal impeller and a modular, annular static diffuser within its annular diffuser passage;
  • FIG. 6 is an alternate embodiment of the impeller of FIGS. 4 and 5 ;
  • FIGS. 7A-C respectively are axial cross-sectional alternative embodiments of annular diffuser passages and diffuser vanes, where dimensional ranges b 3R /b 3 vary as a function of flow coefficient ( ⁇ ) of the process fluid flowing between the inlet and the outlet of the compressor, in accordance with embodiments of the invention;
  • FIG. 8 is an axial elevational view of an exemplary impeller, in accordance with embodiments of the invention.
  • FIG. 9 shows graphically the interrelationship of compressor impeller speed (in feet/second) and compressor pressure ratio (r) for process fluids having molecular weights (also referred to as mole weight or MW) between 10 and 44;
  • FIG. 10 shows graphically the interrelationship of the ratio of axial length (A x ) and corresponding outer diameter (D 2 ) and compressor pressure ratio (r), of exemplary centrifugal impellers, in accordance with embodiments of the invention
  • FIG. 11 shows graphically the interrelationship of curvature of the blade tip of the exemplary three-dimensional blades of the centrifugal impeller of FIG. 10 (expressed as the inverse of the radius of curvature, 1/R C ) and compressor pressure ratio (r), in accordance with embodiments of the invention;
  • FIG. 12 shows graphically the interrelationship of blade sweep angle ( ⁇ ) of the leading edge of exemplary three-dimensional blades of the centrifugal impeller of FIG. 10 and compressor pressure ratio (r), in accordance with embodiments of the invention
  • FIG. 13 shows graphically the interrelationship of the back sweep angle ( ⁇ ) of the trailing edge of exemplary three-dimensional blades of the centrifugal impeller of FIG. 10 and compressor pressure ratio (r), in accordance with embodiments of the invention
  • FIG. 14 shows graphically the interrelationship of the ratio of the radius of the diffuser vane leading edge to the outer hub radius of the impeller hub (expressed as R 3 /R 2 ) and the exit flow angle ( ⁇ ) of process fluid off the impeller, of the exemplary impeller and diffuser vane of FIGS. 7A and 7B , in accordance with embodiments of the invention;
  • FIG. 15 shows graphically the interrelationship of the exit flow angle ( ⁇ ) of process fluid off the impeller, of the exemplary impeller and diffuser vane of FIGS. 7A and 7B and the corresponding ratio of the length of the vane radial extent to the radius of the impeller hub (expressed as RE/R 2 ), in accordance with embodiments of the invention.
  • FIG. 16 shows graphically the interrelationship of the ratio of the diffuser vane height and the diffuser passage height (expressed as b 3R /b 3 ) and the flow coefficient ( ⁇ ) of the process fluid flowing between the inlet and the outlet of the compressor, of the exemplary annular diffuser of FIGS. 7A and 7B .
  • Exemplary embodiments of the invention are utilized in compressors, and methods of their operation. These exemplary embodiments achieve, in a single compressor stage, between the inlet and outlet of the stage, a high pressure ratio (r) of at least 5:1 on the process fluid having a molecular weight of 24-27.99; or at least 4:1 on a process fluid having a molecular weight of 20-24; or at least 3:1 on a process fluid having a molecular weight of 16-20 or at least 2.5:1 on a process fluid having a molecular weight of 10-16 or at least 2:1 on a process fluid having a molecular weight less than 10.
  • r high pressure ratio
  • an exemplary embodiment achieves a pressure ratio (r) of greater than or equal to 2.5:1 on a process fluid having a molecular weight of 12-20, such as natural gas.
  • Natural gas in that molecular weight range typically comprises methane, other hydrocarbons, and non-hydrocarbon constituents, such as water, and carbon dioxide.
  • the process fluids pressurized, circulated, contained, or otherwise utilized in the supersonic compression system are a liquid phase, a gas phase, a supercritical state, a subcritical state, or any combination thereof.
  • compressor embodiments described herein include first and second single-stage compressors, serially in communication within a common housing structure or as separate housing structures, where both stages are commonly driven by a driver, such as an electric motor or a turbine engine.
  • a driver such as an electric motor or a turbine engine.
  • the outlet of the first-stage compressor, downstream of its diffuser passage is in fluid communication with the inlet of the second-stage compressor.
  • the inlet of each successive stage is downstream of the outlet of the prior stage.
  • one or more compressor stages incorporate known intercooling structure, for extracting heat from the process fluid.
  • the compressors are modular compressors, with a plurality of modular housings, respectively including annular diffuser passages and diffuser vanes; and a plurality of modular impellers. Internal dimensions of the respective modular housings and impellers are matched for imparting desired pressure ratios in selected process fluids respectively having varying molecular weight range properties during compressor design.
  • the diffuser vanes are also modular, annular diffuser vanes having varying vane height. Exemplary internal dimensions of the modular housings, modular diffuser vanes, and the modular centrifugal impellers are described in detail herein.
  • FIGS. 1 and 2 illustrate, a schematic view of an exemplary compression system 100 including a compressor 102 , according to one or more embodiments.
  • the compressor 102 imparts a supersonic velocity (i.e., greater than or equal to Mach 1) on a process or working fluid to increase the compressor's pressure ratio.
  • the compressor 102 is alternatively referred to herein as a supersonic compressor.
  • a driver 104 such as any one or more of an electric motor, hydraulic motor, internal combustion engine or a turbine engine of known construction, is operatively coupled to the supersonic compressor 102 via a drive shaft 106 .
  • the drive shaft is integral with or coupled with a rotary shaft 108 of the supersonic compressor 102 .
  • Drive shaft 106 is coupled with the rotary shaft 108 via a gearbox 109 of known construction, including a plurality of gears configured to transmit the rotational energy of the drive shaft 106 to the rotary shaft 108 of the supersonic compressor 102 , such that the drive shaft 106 and the rotary shaft 108 alternatively spin at the same speed, substantially similar speeds, or disparate speeds.
  • the rotary shaft 108 spins about its central rotational axis 108 A.
  • the compressor 102 is a direct-inlet, or axial-inlet, single-stage, centrifugal compressor, with an overhung rotor configuration.
  • the compressor 102 A is a multi-stage, center-hung compressor, having a radial inlet.
  • Three stages, referenced as SI, SII, and SIII, are substantially similar in construction to the single stage of the compressor 102 .
  • each of the respective stages SI, SII, and SIII is constructed and functions in a substantially similar manner as the single stage of the compressor 102 .
  • the inlet of each successive stage is in communication with the outlet of the prior stage.
  • the outlet of SI is upstream of and is in direct fluid communication with the inlet of SII
  • the outlet of SII is upstream of and is in direct fluid communication with the inlet of SIII.
  • Pressurized throughput of process fluid in the compressor 102 A is from the inlet 102 B of SI to the outlet 102 C of SIII.
  • one or more stages SI-S N are cooled by a known intercooler(s) (not shown).
  • the single-stage compressor 102 embodiments respectively include a housing 120 having an inlet 122 defining an inlet passage 124 , and an outlet 130 defining an annular diffuser passage 140 .
  • the process fluid in the inlet passage 124 has an inlet pressure P 1 and the process fluid discharged from the diffuser passage 140 into the outlet 130 has a discharge pressure P 2 greater than the inlet pressure, such that a pressure ratio r of the discharge pressure divided by the inlet pressure is greater than unity.
  • a rotary shaft 108 defining a shaft axis 108 A, is oriented in the housing 120 between the inlet and the outlet thereof, driven by the driver 104 .
  • one or more optional inlet guide vanes 126 guide and direct incoming process fluid flow a centrifugal impeller 160 .
  • the inlet guide vanes 126 are configured to condition the process fluid flowing therethrough to include one or more predetermined parameters, such as a circumferential swirl, a velocity, a mass flow rate, a pressure, a temperature, and/or any suitable flow parameter to enable the supersonic compressor 102 to function as described herein.
  • the inlet guide vanes 126 are static or they are adjustable.
  • a plurality of inlet guide vanes 126 are arranged about a circumferential inner surface of the inlet 122 in a spaced apart orientation. The spacing of the inlet guide vanes 126 may be equidistant or may vary depending on the predetermined, desired flow conditioning parameter for the process fluid.
  • the shaft-mounted centrifugal impeller 160 is oriented between the inlet 122 and the outlet 130 .
  • the impeller 160 includes a plurality of three-dimensional impeller blades 162 projecting outwardly from a hub 164 .
  • the hub 164 is concentric with the rotational axis 108 A of the shaft 108 .
  • the hub 164 has an axial length A x , and a hub outer diameter D 2 extending radially at a radius R 2 relative to the rotational axis 108 A.
  • the each of the impeller blades 162 has: a leading edge 166 facing the inlet passage 124 at a blade sweep angle ⁇ ; a trailing edge 168 facing the diffuser passage 140 at a back sweep angle ⁇ , and having a tip width b 2 ; and a blade tip 170 having a radius of curvature R C , which defines an outer periphery of the centrifugal impeller.
  • the radius of curvature R C is measured along a circle 171 that is coplanar with the leading edges 166 of the blades 162 ; the circle is concentric with the rotational axis 108 A, and has a diameter that is equal to the diameter D 2 of hub 164 .
  • the hub diameter D 2 is equal to twice the radius of the hub R 2 .
  • the plurality of blades 262 include one or more splitter blades 263 , configured to reduce choking conditions that may occur in the supersonic compressor 102 depending on the number of blades 262 employed with respect to the centrifugal impeller 260 .
  • a splitter blade 263 includes a leading edge 263 A that is not coplanar with at least one other leading edge 262 A of the centrifugal impeller 260 .
  • the impeller blades 162 are curved in three dimensions, such that upon rotation of the shaft 108 , the process fluid flowing into the inlet 122 is drawn into the centrifugal impeller 160 and accelerated in a tangential and radial direction by the centrifugal force imparted by the impeller 160 .
  • the accelerated process fluid is discharged from the blade trailing edges 168 in radial directions that extend 360 degrees around the periphery of the centrifugal impeller, thereby increasing the velocity and static pressure of the process fluid.
  • the velocity of the process fluid at the trailing edges 168 of the blades 162 is about Mach 1 or greater.
  • the velocity of the process fluid at the same trailing edges 168 position is a between about Mach 1.5 and about Mach 3.5, although wider ranges are certainly possible within the teachings hereof, within strength limits of material forming the impeller 160 and geometric constraints of the impeller.
  • the process fluid is discharged from the trailing edges 168 at a flow angle ⁇ into the diffuser passage 140 , as indicated by the arrow F.
  • the centrifugal impeller 160 embodiments shown in all of the figures are open or “unshrouded”, because they do not incorporate a rotating shroud that defines a boundary of the process fluid path between the inlet 122 and the outlet 130 upstream of the centrifugal impeller.
  • Unshrouded impellers are capable of achieving higher rotational speeds of the blade tips than shrouded designs, enabling higher compression ratios for any given process fluid molecular weight range.
  • multi-stage compressor embodiments such as the compressor 102 A of FIG. 3
  • each of the impellers is unshrouded.
  • the boundary of the process fluid path between the inlet 122 and the outlet 130 upstream of the centrifugal impeller i.e.
  • the wall of the housing 120 is defined by the wall of the housing 120 , and is referred to as the “shroud side” of the housing.
  • the boundary of the process fluid path between the inlet 122 and the outlet 130 downstream of the centrifugal impeller (i.e. on the right side of the figure) is defined by the wall of the housing 120 , and is referred to as the “hub side” of the housing.
  • the centrifugal impeller is semi-open or shrouded.
  • the process fluid is discharged from the trailing edges 168 of respective blades 162 of the impeller 160 at the flow angle ⁇ into the annular diffuser passage 140 .
  • the annular diffuser passage 140 has a shroud wall 142 and a hub wall 144 , which define the diffuser-passage height b 3 there between.
  • there is a diffuser pinch in the diffuser passage 140 so that the diffuser-passage height b 3 is less than the tip width b 2 of the impeller trailing edge 168 .
  • a plurality of diffuser vanes 146 is oriented in the annular diffuser passage 140 .
  • the respective diffuser vanes 146 convert kinetic energy imparted in the process fluid by the impeller 160 into static pressure increase, which increases the process fluid's potential energy.
  • the diffuser vanes 146 extend axially from the shroud wall 142 towards the hub wall 144 of the diffuser passage 140 .
  • the diffuser vanes 146 have a vane height b 3R , and are circumferentially disposed about the periphery of the centrifugal impeller 160 . In FIGS. 4, 5 and 7B , the vane height b 3R of the vanes 146 spans the entire passage height b 3 of the diffuser, such that the ratio b 3R /b 3 equals unity.
  • each diffuser vane 146 regardless of its vane height b 3R , respectively defines curved, opposing vane pressure 148 and vane suction sides 150 , a vane leading edge 152 proximate the periphery of the centrifugal impeller at a radial distance R 3 relative to the shaft axis 108 A and conjoining the suction side 150 , a vane trailing edge 154 facing the outlet 130 and conjoining the suction side 150 .
  • a vane radial extent, between the vane leading 152 and trailing 154 edges, has a radial length RE measured relative to the shaft rotational axis 108 A.
  • the vane height b 3R does not extend all the way across the diffuser passage height b 3 , such that the ratio b 3R /b 3 is less than unity.
  • the vane 146 spans the entire diffuser passage height.
  • the embodiment of FIG. 7A incorporates a second vane 146 A downstream of the vane 146 .
  • the second vane 146 A has the same construction features as the vane 146 in FIGS. 7A and 7B .
  • FIG. 7B when the vane 146 spans the entire diffuser passage height b 3 , the second vane 146 A is optional, as shown in phantom lines.
  • FIG. 5 illustrates a front, radial view taken along line 5 - 5 of a portion of the centrifugal impeller 160 and the annular diffuser passage 140 of FIG. 4 .
  • the annular diffuser passage 140 incorporates a static diffuser, constructed as a modular, annular vane ring 155 , which is inserted or into or interposed within the housing 120 , between the impeller 160 and the outlet 130 .
  • vane 146 profiles within the annular diffuser passage 140 are easily varied by substitution of different annular vane rings 155 for different compressor applications.
  • the annular diffuser 140 is configured to convert kinetic energy of the process fluid from the centrifugal impeller 160 into increased static pressure.
  • An annular-vane, static diffuser 140 is shown in the exemplary embodiments of FIGS. 4, 5, 7A, and 7B .
  • the plurality of diffuser vanes 146 controls the rate of change of, and thus the diffusion or area increase there between.
  • Each of the diffuser passageways 156 is bounded radially by the respective pressure 148 and suction sides 150 of opposing diffuser vanes 146 ; and bounded axially by the respective shroud 142 and hub 144 walls of the annular diffuser passage 140 .
  • the diffuser passageway 156 defines a subsonic diffusion zone 157 .
  • one or more of the plurality of diffuser vanes 146 includes supersonic compression-inducing surface at its leading edge 152 , between its pressure side 148 and its suction side 150 , such as the ramp 158
  • each of the diffuser vanes 146 includes a supersonic, compression-inducing ramp 158 disposed at its leading edge 152 .
  • the supersonic, compression-inducing ramp 158 is integral with the respective diffuser vane 146 ; however, in some embodiments, one or more of the supersonic compression-inducing ramps 158 are formed as a separate component.
  • the radial process fluid flow F exiting the blades 162 at the trailing edges 168 enters each of the diffuser passageways 156 and exits the diffuser passageway via the respective diffuser passageway outlet 140 .
  • the supersonic compressor 102 provided herein is said to be “supersonic” because the centrifugal impeller 160 designed to rotate about the shaft axis of rotation 108 A at high speeds such that a moving process fluid encountering the supersonic compression-inducing surface 158 disposed within the diffuser passageway 156 is said to have a fluid velocity which is supersonic.
  • the moving process fluid encountering the supersonic compression-inducing surface 158 may have a velocity in excess of Mach 1.
  • the moving process fluid encountering the supersonic compression-inducing surface 158 may have a velocity in excess of Mach 1.2.
  • the exemplary compression inducing surface 158 shown in FIG. 5 has a ramp shape.
  • FIG. 9 shows the physical challenge facing compressor designers who want to maximize single-stage pressure ratio r for different mole weight (MW) process fluids.
  • Impeller tip speed needed to add energy to any given process fluid to a desired pressure ratio is directly proportional to mole weight. Achievement of supersonic velocities in the working fluid by impeller and/or annular vane structure enhances compression capabilities, as is done in embodiments of the invention disclosed herein. Despite achievement of greater than Mach 1, velocities in working fluid by embodiments of compressors disclosed herein, impeller tip speed is limited by mechanical stress limits of the impeller geometry and its material. Exemplary centrifugal impellers described herein are capable of achieving impeller tip speed rotational velocities at their blade trailing edges greater than or equal to 1400 feet/second.
  • the horizontal stress limit line shown in FIG. 9 is in a typical range for titanium alloys.
  • Lower mole weight fluids e.g., in the 10 MW range, are not compressible in a single stage greater than about 2:1 with current impeller stress limits.
  • higher mole-weight process fluids are compressible to 9:1 or greater pressure ratios.
  • conventional compressors that limit impeller tip speed and pressure ratio r to the lower left quadrant can achieve pressure ratios of approximately 1.05:1 to about 5:1 for a broad variety of process fluids, so long as the compressor user is willing to add more stages in the compressor to achieve desired pressure ratio throughput.
  • Embodiments of the present invention achieve higher-pressure ratios r for a broad range of disparate process fluids having widely varying mole weight ranges (MW).
  • MW mole weight ranges
  • compressor housings 120 centrifugal impellers 160 driven at blade tip speeds of greater than or equal to 1400 feet/second, annular diffusers 140 , and annular vane rings 155 , having specified differing dimensional ranges in accordance with embodiments of the invention
  • higher pressure ratios r and stage head are achieved by tailoring the compressor 102 structure to the MW properties of specific process fluids. Construction of the invention's housings, impellers, and discharge vane embodiments allows precise configuration and assembly of a specific compressor to meet needs of a narrow bandwidth of MW.
  • dimension ranges of the annular diffuser passage 140 , the centrifugal impeller 160 , and the diffuser vanes 146 , 146 A, and housings 120 needed to support those components vary as a function of pressure ratio r, regardless of the process fluid MW.
  • the impeller 160 dimensional ratio of hub length 164 to diameter A x /D 2 varies between 0.1-0.4, as shown in FIG. 10 .
  • Higher-pressure ratios require axially longer impellers for a given impeller diameter.
  • One way to reduce the impeller inventory is to standardize hub diameter D 2 and select a limited number of axial lengths A x . Concomitantly, the number of types of housing 120 modules only needs to match the limited number of impeller lengths.
  • Curvature 1/R C of the blade tip 170 of the impeller blades 162 varies between 0.5-0.15 for pressure ratios r between 2:1 and 10:1, regardless of the process fluid MW.
  • the radius R C becomes steeper closer to the trailing edge 168 of the impeller blades 162 .
  • Impeller exit flow angle ⁇ is influenced by the impeller back sweep angle ⁇ , the impeller 160 tip speed at its trailing edge 168 and the mole weight of the process fluid. Impeller tip speed and the back sweep angle are selected to achieve a desired pressure ratio. Referring to FIG. 14 , the ratio of the radius R 3 of the vane leading edge 152 to the outer hub radius R 2 (R 3 /R 2 ) is 1.07-1.15, between a range of impeller exit flow angle ⁇ , of 68 to approximately 80 degrees. As shown in FIG.
  • the ratio of the diffuser vane 146 radial extent RE to the impeller hub radius R 2 (RE/R 2 ) varies approximately linearly from 0.1-0.5 between same range of impeller exit flow angles ⁇ , between 70 degrees and the maximum critical angle of 80 degrees.
  • Dimension ranges of the respective heights b 3R of the diffuser vanes 146 and b 3 of the annular diffuser passage 140 vary as a function of flow coefficient ( ⁇ ) of the process fluid flowing between the inlet 122 and the outlet 130 of the compressor 102 .
  • ⁇ flow coefficient
  • the ratio of b 3R /b 3 is 1.0; the vane 146 spans the entire height of the annular diffuser passage 140 .
  • the ratio of b 3R /b 3 is 0.5-1.0, and the vane 146 spans between half and the full height of the annular diffuser passage.
  • Use of a second vane 146 A is optional when ⁇ is in the range of 0.030-0.050.
  • the ratio of b 3R /b 3 is 0.3.
  • Single-stage, centrifugal compressors constructed in accordance with embodiments described herein are capable of driving their respective, single, unshrouded impellers at rotational velocities of greater than or equal to 1400 feet/second.
  • the high kinetic energy imparted by these impellers on the process fluid achieves the following pressure ratios (r):
  • the first process fluid has a molecular weight of 24-27.99;
  • the first process fluid has a molecular weight of 20-24;
  • the first process fluid has a molecular weight of 16-20;
  • the first process fluid has a molecular weight of 10-16;
  • the first process fluid has a molecular weight less than 10.
  • commonly available natural gas compositions have molecular weight ranges of 12-20.
  • Single-stage compressor embodiments disclosed herein, with tip speed velocities of greater than or equal to 1400 feet/second, are capable of achieving pressure ratios (r) greater than or equal to 2.5: 1 on such commonly available natural gas compositions in the 12-20 MW range.
  • two of the aforementioned single-stage, centrifugal compressors are combined in series, with the outlet of the first stage coupled to the inlet of the second stage.
  • the two stages in combination receive the process fluid in the inlet of the first stage, and discharge the process fluid out of the outlet of the second stage at a throughput pressure ratio (r) of:
  • the first process fluid has a molecular weight of 24-27.99;
  • the first process fluid has a molecular weight of 20-24;
  • the first process fluid has a molecular weight of 16-20;
  • the first process fluid has a molecular weight of 10-16;
  • the first process fluid has a molecular weight less than 10.
  • Two-stage, centrifugal compressor embodiments disclosed herein, with unshrouded impeller, tip speed velocities of greater than or equal to 1400 feet/second, are capable of achieving pressure ratios (r) greater than or equal to 5:1 on commonly available natural gas compositions in the 12-20 MW range.
  • multi-stage compressors having 3 or more of the aforementioned single-stage, centrifugal compressors in series, are configured to impart sequentially with the assembled multi-stage compressor a throughput pressure ratio (r) of greater than or equal to 10:1 on process fluids having a molecular weight of 2.0-27.99.
  • Process fluids in the aforementioned molecular weight range include compositions of natural gas.
  • multi-stage compressors, having 3 or more of the disclosed, single-stage, centrifugal compressors in series are configured to impart sequentially compressor a throughput pressure ratio (r) of greater than or equal to 10:1 on commonly available natural gas compositions in the 12-20 MW range.
  • ACFM Average cubic feet per minute
  • ⁇ the stage head coefficient (relationship of head increase, impeller rotational speed and impeller hub diameter)

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