Process-gas screw compressors

(dry type) compared with

reciprocating-, oil flooded screw-
and centrifugal compressors
 Process-gas screw compressors (dry type) compared with reciprocating-,
oil flooded screw- and centrifugal compressors
Dipl.-Ing. Klaus Lelgemann

1. Functional principle of a
process gas screw compressor
Process gas screw compressors are
twin-shafted rotating displacement
machines. From the point of view of
their operating characteristics, they
are comparable with reciprocating
compressors. (Fig. 1)

2. Comparison with reciprocat-

ing (piston type) compressors
The characteristic of the screw com-
pressor confirms that its rotors with
their innovative and sophisticated
Figure 1: PV-diagram of a screw compressor with an inbuilt ratio of 3
profile comprising lobes (teeth) and
flutes, perform similar positive
displacement compression strokes
as those encountered in the recipro-
cating compressor.

In the meshing profile of the rotor

pair, as the male rotor lobe exits
from a flute in the female rotor at the
intake side, a chamber is formed
into which the gas flows. As rotation
continues, the filled flute leaves the
intake port and migrates to the
discharge end.

At this, the opposite side of the rotor

pair, the male rotor lobe enters the
flute of the female rotor, so reducing
the size of the previously formed
chamber in which the gas is located.
(Fig. 2)
The gas is thus continuously com-
pressed.
Before the male rotor lobe completely
fills the flute of the female rotor, thus
eliminating the previously formed
chamber, a port is reached through
which the gas is discharged. The
Figure 2: Mode of operation
size of this aperture determines the
length of time during which the gas
remains in the flute, and the pres-
sure at which the gas is discharged.
Nevertheless, the compression prin-
ciple described is based on a purely
rotational action. There are no os-
cillating masses which have to be
balanced or compensated for by the
foundation, and which can excite
vibrations and oscillations in the
plant components installed in the
vicinity of the compressor.
This mechanically neutral operating
action means that the foundation
is simple and ideal also for critical
installations on vessels or oil plat-
forms. Moreover, the screw com-
pressor does not give rise to any
low-frequency gas pulsations. These
have to be modified at great expense

2
Compressor Type Availability Reliability
% %
Recip., lubricated 97.3
Recip., conv. non lube 91.3
Recip., labyrinth piston 97.6
Screw, oil free 99.0
Notes:
IMR&O: Inspection, Maintenance, Repair & Overhaul, MTBF: Mean Time Between
Failure, DT: Down Time
by pulsation dampers to produce a
smooth gas flow so that the down-
stream systems is not adversely
affected.
In fact, the screw compressor does
indeed produce gas pulsations, but
these have such a high frequency
that they are only acoustically per-
ceptible, i.e. they are manifested
solely as noise. The gas flow is uni-
form. The noise must be attenuated
by means of silencers.
The screw compressor is fitted with
2 rotors. These rotor pair are the
only moving parts in the machine.
The bearing system in the case of
Figure 3: Rotor pair with
synchronizing gear
IMR&O Forced DT MTBF that the availability of such machines
hr/year hr/year year falls well short of that of a process
97.8 237.2 189.2 0.5 gas screw compressor.
92.3 766.1 670.1 0.3
The machine elements in a recipro-
98.3 207.2 147.2 2.0
cating compressor which are exposed
99.7 90.0 30.0 5.0
to the most danger are, however,
the inlet and outlet valves, which
open and close with each compres-
sion stroke. It is these which actually
determine the machine availability
the process gas screw compressor and reliability. There have been innu-
is provided exclusively in the form merable investigations, reports and
of hydrodynamic plain bearings for dissertations regarding this subject.
both the radial (journal) and axial In processes, two reciprocating
(thrust) directions, and these are compressors have to be provided
generally regarded as technically in many cases to ensure adequate
wear-free. redundancy because of the asso-
ciated problems.
A reciprocating compressor has a
crankshaft with a connection rod, See the availability and reliability
a crosshead with guideway, plus a rating of process gas screw com-
piston rod moving back and forth, pressors compared to reciprocating
not to mention the pistons them- compressors.
selves with their piston rings. These
mechanical components are, in The above tabulation shows the
some cases, exposed to mixed average values, based on a statistic
friction, so it is hardly surprising presented in Hydrocarbon
Processing, January 1999.
3

3. Comparison of the process
gas screw compressor with
the oil flooded screw compressor
There are two types of screw com-
pressor offering the same compres-
sion principle and the smoothness
of operation, but which are never-
theless quite different.
Outside the compression chamber,
the process gas screw compressor
has a synchronizing gear. This
means that there is a pair of toothed
wheels which are mounted on the
male and female rotor and which
synchronize the rotation of these
two components, so that they
remain properly in mesh. (Fig. 3)
The profiles of the rotors intermesh
to produce the suction and com-
pression stroking without any
mechanical contact. The compres-
sion chamber is not lubricated
and the gas remains completely
uncontaminated.
4
Figure 4: Oil flooded
Screw Compressor
It is worth mentioning that the male
rotor requires more than 90% of the
compressor power input, with less
than 10% of the energy being trans-
mitted via the synchronizing gear
to the female rotor.
In the case of oil flooded screw
compressors, there is no synchro-
nizing gear unit. The male rotor
drives the female rotor via the profile
lobes, which simultaneously perform
the gas suction and compression
operations. Needless to say, this
mechanism cannot function without
lubrication. (Fig. 4)
The same lubricant must be injected
into the compression chamber
which is also used for lubricating the
bearings, because there are no semi-
hermetic seals between the com-
pression space and the bearings.
Compressor Type Availability Reliability
% %
Screw, oil flooded 97.7
Screw, oil free 99.0
Notes:
IMR&O: Inspection, Maintenance, Repair & Overhaul, MTBF: Mean Time Between
Failure, DT: Down Time
The oil flooded screw compressor
have the following advantages:
A. Owing to its high viscosity,
the lubricant is able to seal off the
clearances between the rotors in the
compression space. This means that
oil flooded screw compressors are
able to offer a better volumetric
efficiency than that of an equivalent
process gas screw compressor in
which no liquids are injected. This is
particularly so at low circumferential
velocities. In the case of the process
gas screw compressor, a portion of
the gas escapes unhindered at its
sonic figure through the rotary clea-
rances in the compression space
from those flutes with the higher
pressure into those flutes in which
the prevailing pressure is lower.
The portion of the gas which flows
in the reverse direction has to be
compensated for by raising the
speed of the process gas screw
compressor, and this costs addi-
tional power.
B. The injected lubricant cools
the gas and the compressor.
Compression is performed under
polytropic conditions with the tem-
perature of compression depending
on the isentropic exponent and the
pressure ratio.
The oil flooded screw compressor
can, for example, compress air in a
single stage with an isentropic expo-
nent of 1.4, from atmospheric pres-
sure to e.g. 10 or 12 bar.
IMR&O Forced DT MTBF
hr/year hr/year year
98.8 199.9 99.9 1.5
99.7 90.0 30.0 5.0
This is not possible with a process
gas screw compressor as there is
no lubricant to provide the cooling
effect. The process gas screw com-
pressor must, in such cases, be of
two-stage design and be provided
with additional intercooling.
C. The injected lubricant muffles the
compression noise. Owing to the
partial sealing of the rotary clearances
in the compression space, the gas is
unable to flow back with the sonic
figure from the flute with the higher
pressure to the flute with the lower
pressure. This means that the gas
flows back more slowly. Consequently,
the oil flooded compressor is quieter
overall.
Depending on the design of the
compressor installation, the respec-
tive sound pressure levels of com-
pressors with no sound insulation
are likely to be in the region of
approx. 103 dB (A) at 1 m for the
process gas screw compressor,
compared with approx. 93 dB (A) for
the oil flooded compressor.
If, however, a maximum of 85 dB (A)
sound pressure level is allowed for
manned compressors, both com-
pressor systems must be encapsu-
lated in acoustic enclosures.
D. The oil flooded compressor was
originally developed as an air com-
pressor for diesel-engine-operated
portable compressors. In this sector,
the oil flooded screw compressor
dominates the market. The advanta-
ges of this compressor are so great
that it is virtually the only compres-
sion system used for such applica-
tions.
The experience gained with this
design led companies to develop
their refrigeration compressors also
with lubricant injection. These com-
pressors have also conquered their
respective market and nowadays
they are virtually the only compres-
sors found in small and medium size
refrigeration units.
The associated refrigeration capacity
is, however, limited by the maximum
possible flow capacity of these com-
pressors.
E. The fact is, that these compressor
types are manufactured in large
numbers and are thus less expensive.
The oil flooded screw compressor
have the following disadvantages:
F. The lubricant contaminates the
gas being compressed, something
which cannot be permitted in many
processes.
G. The lubricant must be recovered
by means of sophisticated separat-
ing and filtration systems, in order
to ensure that the oil tank does not
need constant replenishment.
5
 H. The lubricant may be deteriorated
by the process gas itself or by gas
constituents located within it. The
lubricant is used in a extremely manner:
1. When the lubricant is injected into
the compression space to the rotors
which are moving with up to 50 m/s
tip speed, a part of the lubricant is
distributed into million of particles
(droplets and aerosols) which forms
a large surface and in the same time
happens a close contact between
the gas and the lubricant.
2. The lubricant is shock-heated
from an injection temperature of
about 50 C to the discharge tem-
perature of about 90 C in some
milliseconds, because by the theore-
tically existing temperature of may
be 300 C in a polytropic compres-
sion (without cooling), this tempera-
ture rise will heat up the lubricant.
3. To keep the compressor cool, a
large lubricant quantity is necessary
to inject. The reservoir is situated in
the lower part of the oil separator
and therefore the lubricant quantity
in the reservoir is restricted. That
means, short retention time are used
and not the 8 minutes which are
determined in the API 619 specifi-
cation.
If the lubricant is deteriorated the
compressor integrity is endangered!
I. Liquids in the gas stream are
absorbed by the lubricant. The
lubricant is diluted or emulsified
(depending on the liquid), and again
the compressor is likely to be en-
dangered!
6
J. Dusts in the gas flow are absorb-
ed by the lubricant so that the oil
filter currently in operation is quickly
clogged; the filtration system then
has to be switched over to the
stand-by oil filter. If the switch over
intervals are very short, the custo-
mer cannot except this service. The
dust therefore has to be efficiently
removed from the gas stream by
filters at the suction end.
K. Owing to its high viscosity, the
lubricant tends to become adhered
to the flanks of the rotors. The
circumferential speed therefore has
to be limited to approx. 50 m/s. If
operations were faster, having to
overcome this adhesion effect would
require more and more power input,
so reducing the efficiency of the
compressor. The compressor stage
therefore has to be larger than
would otherwise be the case with a
process gas screw compressor. In
the case of the process gas screw
compressor, the circumferential
speed is determined solely by the
sonic figure of the gas concerned.
L. The oil tank can only be emptied
following a lengthy period of degas-
sing under atmospheric pressure. All
the gases or gas constituents which
have an affinity with the lubricant
are dissolved in the lubricant. When
depressurizing the oil to atmospheric
pressure, the lubricant tends to foam
as a consequence. The escaping
gas may be combustible and thus
explosive.
When draining off the lubricant,
therefore, the utmost care must be
taken.
The lubricant used has to be care-
fully disposed off, if the oil flooded
screw compressor has been
employed to compress gases which
contain constituents hazardous to
health!
The drained lubricant must then be
declared and treated as toxic waste,
thus rendering its disposal extremely
costly.
M. A lubricant refill, during service,
is only possible with a pressure
pump as the oil tank is exposed to
the discharge pressure of the gas.
Rsum:
The oil flooded screw compressor
is an ideal solution for clean gases
and in processes in which the gas
contamination by the lubricant is
acceptable. In the case of all other
gases, compromises in relation to
service interval, availability, reliability,
maintenance costs and repairs have
to be made.
The problem is predicting whether
functional integrity can be guaran-
teed in relation to specific gas mixtur-
es, because lubricant manufacturers
are rarely in a position to test in their
laboratories the particular gas mix-
ture of a specific customer.
Consequently, the question as to
whether the oil flooded compressor
will function properly when employed
for this or that gas mixture is very
difficult to answer.
Not any supplier of the lubricant will
perform a guarantee for the suitability!
Conventional mineral oil can normally
not be used in oil flooded screw
compressors for gas service.
Currently polyalphaolefin and lubri-
cants on diester, polyester and
glycol basis are required.

This lubricants are expensive and

sometimes not available in some
countries. Also it is necessary to
clarify the disposal of the used lubri-
cant. The process gas screw com-
pressor is lubricated with normal
turbine oil. Also, it is only possible
to purchase the compressor stage
models which are commercially
available on the market. Often com-
promises in regard to the materials,
bearings, sealing and on a lack of
comprehensive test documentation
has to be made.
Consequently, the oil flooded screw
compressor therefore is often not
accepted by process operators in
the oil field, chemical-, refinery- or
petro-chemical sector. With these
customers, it is primarily the availa-
bility rating which counts rather
than the initial investment outlay.
See the availability and reliability
rating of process gas screw com-
pressors compared to oil flooded
screw compressors.
The tabulation shows the average
values, based on a statistic presented
in Hydrocarbon Processing, January
1999.
Figure 5: Performance curves centrifugal compressor compared to screw
compressor
4. Comparison of the
process gas screw compressor
with the centrifugal compressor
As already indicated, the screw
compressor is a displacement
machine; the centrifugal compressor
on the other hand, is a dynamic
machine. (Fig. 5)
Here we can see the characteristic
of a centrifugal compressor com-
pared with a screw compressor.
The screw compressor has a rigid
performance characteristic meaning
that neither the discharge pressure
nor the molecular weight of the gas
have a great effect to the volume
flow.
In the case of the centrifugal com-
pressor the discharge pressure and
gas molecular weight play an impor-
tant role. If the discharge pressure in
a centrifugal compressor is higher
than the pressure for which the com-
pressor is designed, the centrifugal
compressor surges. If the molecular
weight falls below the value for
which the compressor is designed,
the centrifugal compressor again
surges. The occurrence of surging
is, however, reliably prevented by
special fast-response controls an
important safeguard as the occur-
rence of surging is highly damaging
for the centrifugal compressor.

7
 Compressor Type Availability Reliability IMR&O Forced DT MTBF

% % hr/year hr/year year

Centrifugal, clean service 99.7 99.8 24.8 18.8 8.0

Centrifugal, fouling service 99.0 99.5 90.6 40.6 3.7

Screw, oil free 99.0 99.7 90.0 30.0 5.0

Notes:
IMR&O: Inspection, Maintenance, Repair & Overhaul, MTBF: Mean Time Between
Failure, DT: Down Time

Screw compressors cannot surge
because they are displacement
machines.
Due to this different compression
principles the process gas screw
compressor needs less stages in
case of light gases. The screw com-
pressor can often produce the
necessary pressure with just one
compression stage, while the centri-
fugal compressor requires several
impellers (stages).
The process gas screw compressor
thus constitutes a more cost-effi-
cient solution than the centrifugal
compressor in the case of light
gases.
In addition, the process gas screw
compressor is also suitable for
gases in which the molecular weight
constantly changes. The centrifugal
compressor gives rise to consider-
able problems in relation to these
gases. This is very important in flare
gas service, where the molecular
weights changes very often.
There is a further advantage.
The centrifugal compressor generally
runs at a tip speed which is three
times than that of a process gas
screw compressor. This explains
why the process gas screw com-
pressor is not as sensitive to the
presence of dust and liquid droplets
in the gas as the centrifugal com-
pressor.
In principle, dust entrained in the
gas causes abrasion also in a screw
compressor. But here the progress
of wear with 1/3 of tip speed takes
approx. 9 times longer as with a
centrifugal compressor.
For liquid droplets entrained in the
gas there is nearly no limitation for
the process gas screw compressor.
The quantity is allowed up to 0,5
percent of the volume of the gas
under inlet conditions. It is self-evi-
dent that the liquid has to be distri-
buted into droplets.
If a big quantity of liquid enters into
the process gas screw compressor
in one portion, it will of course cause
a liquid hammer.
Due to the right material selection
for the process gas screw com-
pressor erosion will not occur.
This is complete different for a cen-
trifugal compressor. The liquid drop-
lets therefore has to be efficiently
removed from the gas stream by a
separator at the suction.
See the availability and reliability
rating of process gas screw com-
pressors compared to centrifugal
compressor, where is nearly no
difference.
The above tabulation shows the
average values, based on a
statistic presented in Hydrocarbon
Processing, January 1999.

8
5. Summary of the special
features of process gas screw
compressors
Process-gas screw compressors can
be employed for all normal operating
conditions where a compressor offe-
ring high availability, reliability and
tailored performance is required.
In addition, these compressors are
particularly suitable for applications
where difficult conditions occur and
other compressor systems are less
reliable or impractical.
This predestinates the process
gas screw compressor special for
unmanned service in oil field service.
As you remember, the compressor
has no wear parts and the 24,000
operating hours required in API 619
between two major sevice activities
can be achieved without any pro-
blems.
The mechanically neutral operation
action means that the foundation is
simple and forms no problem in oil
fields, on platforms or vessels.
The comressor can handle, due to the
positive displacement characteristic,
gases with changing molecular
weights like flare gas without sur-
ging. The compressor can handle,
due to low tip speed liquid droplets
entrained in the gas stream like
associated gas in gas processsing
or tank vapor applications.
The compressor can compress
gases with varying inlet pressures
and discharge pressures without
surging. All compressor stages are
available conform to NACE MR 0175
alloy steels to handle gases with a
high content of H2S.
Compressor stages can be supplied
for recompresssion of boil-off gas
even at LNG for -160C inlet tem-
perature.
Compressor stages as a module
system are available in casing exe- Figure 6
cutions with nominal pressure 16 bar
(230 psi) in a flow range from 3,500
- 90,000 m3/h actual inlet volume
(2,000 - 53,000 acfm) and with a
casing execution nominal pressure
50 bar (725psi) discharge pressure,
in a flow range from 150 - 19,000 m3/h
actual inlet volume (90 - 11,000 acfm).
For details in regard to process-gas
screw compressors please send
your inquiry to Fax No.:
0049/208/692-9787.
Figure 7
9
 Figure 8 Figure 9

6. Main applications of process In chemical plants: 7. Examples of application and

gas screw compressors Acetylene, Ammonia, Carbon mono- design
Oilfield (onshore, off-shore and on xide, Carbon dioxide, Lime kiln gas, Flare-gas compressors with acces-
FPSOs): calcination gas, Chlorine (dry), HCI sible noise enclosure.
Gas processing (last stage up- (dry), Frigene, Hydrogen, Hydrogen- Two two-stage process-gas screw
stream of the flare) (Gas gathering rich gas, Nitric acid gas (dry), compressors are mounted on a single
of associated gas) Phosgene (TDI, MDI process) Vinyl table-top foundation. Each unit com-
Refineries: chloride presses 11,000 m3/h of flare gas
Air compressors to API 619 Power plant: from 1.01 bar to 7.0 bar. (Fig. 6)
standard Gas turbine feeding Process gas screw compressor
Boil-off gas from liquefied gas Mining/Coking plant: completely assembled at the manu-
tanks (down to -160C) Pit gas facturers works as a packaged unit
Delayed coker gas Coke oven gas for installation directly at a well-head
Fuel gas Steel works: (gas gathering) without needing a
Flare gas Blast furnace top gas, converter foundation. It compresses 3,950 m3/h
Crude gas gas, reduction gas, cooling gas of associated gas from 1.03 bar to
Recycle gas Brewing, Alcohol distillation: 3.44 bar. (Fig. 7)
Flue gas Wort boiling, Steam compression, Process gas screw compressor
Flush gas vacuum distillation, concentration completely assembled at the manu-
Offgas facturers works as a single-lift
Tail gas package for direct mounting on the
Strip gas deck of an offshore oil production
Vent gas platform. The machine compresses
Wet gas 5,650 m3/h of associated gas from
In Petrochemical installations: 1.37 bar to 6.85 bar. (Fig. 8)
Air compressors to API 619 Tank vapor compressor used in a
standard desert area. Process gas screw
Butadiene extraction, Caprolactam compressor with speed regulating
plant, Hydrogen-rich gas (catalytic motor driver in a degassing station.
reforming, LAB cycle gas, MBE 3,200 - 7,000 m3/h of tank vapor
Process), Olefin facilities, Styrene gas is compressed from 1,018 bar
off gas, VCM gas. to 2,1 bar. (Fig. 9)
PSA, charge and offgas compressors

10
Figure 10 Figure 11

Process-gas screw compressor

with noise enclosure in a refinery.
Semi packaged unit compresses
2,200 m3/h recycle gas from 16 bar
to 22 bar. (Fig. 10)

Process-gas screw compressor in

foundation block design with separate
oil unit.
Flare gas in an amount of 11,500 m3/h
is compressed from 1,07 bar a to
4,5 bar a. (Fig. 11)

Figure 12 Process-gas screw compressor

completely assembled at manufac-
turers works as a packaged unit.
Single lifting unit during string test.
It compresses 20,000 m3/h associat-
ed gas from 1,0 bar a to 4,0 bar a.
(Fig. 12)

11
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In the interests of technical progress,
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