Maximize MTBR in Challenging Conditions
In the processing and production of ethylene, propylene, polyethylene, polypropylene, ammonia, chlorine and other chemicals, a wide range of reciprocating compressors may be employed.
While operating conditions may vary greatly, these applications do share some things in common, including the likelihood of dirty service and the need for specialized engineering of components to extend service life. In addition, high pressures may combine with toxic and/or corrosive gases, leading to rapid ring wear and increased leakage.
With its advanced designs and proprietary materials, Cook Compression can increase mean time between repair (MTBR) for chemical and petrochemical facilities. We can also assess your full compressor system to identify opportunities to improve performance.
TruTech Engineered Materials
High-performance TruTech™ 3330 is a proprietary polymer alloy that delivers extended service life for sealing components in non-lubricated compressors. Components made from TruTech 3330 have delivered longer, more reliable service in a wide range of dry gases, including hydrocarbon mixtures, ammonia and ethylene.
|Service||Lubricated?||Product Type||Discharge (psi)||Avg Speed (ft/min)||Performance|
|Isobutane||No||Piston rings, rider rings||225||750||3x improvement over filled PTFE|
|Ethylene||No||Piston rings, rider rings||195||814||3x improvement over filled PTFE|
|Carbon Dioxide||No||Piston rings, rider rings, packing rings||240||430||6x improvement over filled PTFE|
|Ethylene||No||Piston rings||200||788||4x improvement|
Low-Emissions Rod Packing
Cook’s patented gapless rod packing improves sealing effectiveness, decreases leakage and reduces frictional loading against the rod. Ultimately, the ring technology extends packing life by lowering the rod temperature.
Valves for Sticky Gas
The Manley radiused-disc compressor valve boasts proven performance in the high pressures and sticky gas associated with ethylene and propylene service, and in hydrogen and hydrogen-rich compressors.
The valve body, springs and bolts are constructed from alloys carefully selected for their high resistance to corrosion; plastic internals are available for chlorine compressors. In addition, flow area, spring force, clearance volume and lift area are all engineered to your specific application in order to generate improvements in both flow and reliability.
The MOPPET valve also provides excellent service in high-pressure applications, delivering long life by combining advantages of the Manley valve with key benefits of poppet valves.
Materials are selected to resist corrosion, hydrogen embrittlement, and damage from debris, while the customized flow path maximizes gas volume.
Related Case Studies
Upgrade Boosts Unit Productivity Up to 30% at Polymers Plant
At a polymers plant in Thailand, the run time of a two-stage compressor used to recycle polypropylene gas was only three to six months and part of a significant production bottleneck. Preliminary inspection found the compressor was running overloaded and experiencing excessive vibration. Cook proposed a comprehensive upgrade for the valves and packing.
Redesign Extends Run Time for Non-Lubricated Hydrogen Chloride Compressor
A plant in France was struggling with rapid ring and packing wear on a hydrogen chloride compressor, causing leakage and a reduction in throughput. Based on a thorough design review, Cook recommended modifications to the piston and rider ring styles on all three stages of the tandem piston, as well as a redesign of the pressure packing.
New Technology Aids Non-Lube Conversion in Russia
A petrochemical company was experiencing severe problems and high costs in maintaining the filtration/separator phase of their process after compression. The trouble revolved around a hydrogen compressor that had originally been installed with lubricated cylinders and packing cases. Cook Compression was asked to assess the possibility of converting the compressor to non-lubricated service.
Packing Upgrade Extends Service Life, Reduces Vent Leakage at Aromatics Plant
Operators at an aromatics plant were searching for ways to increase the service life of rod packing and reduce seal leakage in a lubricated compressor in hydrogen service. The Cook Compression team conducted a field inspection and proposed a comprehensive packing upgrade that has achieved more than 18 months of continuous run time and gas vent leakage near zero scfm.