Methanol synthesis gas compression issue! Solve?
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May I ask why the quality of gas at our factory is not very good? Current turbines simply cannot reach the rated speed! So, what would be the consequences if a turbine is not operated at its rated speed for an extended period of time?
It is sufficient to operate at an adjustable speed; it doesn’t matter if it’s below the rated speed.
It has little impact on the turbine; it’s mainly your company’s profitability that is greatly affected. If the rated speed isn’t achieved, full-load production cannot take place, and thus the desired profits won’t be obtained. It’s better to find out the cause – that’s the right approach. There’s no doubt that the gas is dirty; try to find a way to purify it in the upstream system
If the turbine does not reach its rated speed, it indicates that it is not operating at full load; the inlet air volume is low, and this has no impact on the stable operation of the turbine. However, due to the low load, the anti-surge valve remains open, resulting in unnecessary work and low efficiency.
Reducing the CO2 content by an appropriate amount will make things better. Check whether the vacuum level is slightly insufficient, and see if the steam pressure can reach the design value; it may be appropriate to increase it up to the upper limit of the parameters. Generally speaking, adjusting the components is the right approach. Check the gas composition and molecular weight specified in the compressor design, and then consider the actual conditions. Is it a design flaw in the compressor? Is the rated air intake volume of the turbine normal? Is it possible that the control valve of the turbine has fallen off? Are there any signs of bending in the feedback lever? Is the quality of the steam inadequate? Are there deposits on the nozzles and impellers? After ruling out a problem with the machine, it’s time to check the gas composition. It’s not a problem to operate at a speed other than the rated speed; generally, the rated speed of turbines is not reached in practice. Unit operation is viewed in terms of the compressor. Turbines generally have a higher rated speed than compressors, haha
The impact is not significant; it’s possible that the temperature of the circulating water is high, the exhaust temperature of the turbine is high, the vacuum level is low, and as a result the speed cannot be increased!
The impact is not very significant; it merely prevents the factory from handling additional load, which affects its efficiency. An opportunity should be found to resolve this issue.
Reply to 8#: The 60th anniversary of the founding of the country has little impact. There is a certain relationship between the volume of gas used in the methanol synthesis process (i.e., the load) and the speed setting of the turbine; in other words, a certain load corresponds to a certain system pressure. Of course, there is no simple direct proportionality between load and pressure, as when the catalyst is under the same load during the SOR and EOR stages, the required adjustment to the system pressure will definitely differ. This is related to the synthesis reaction itself. When full load is reached, the turbine must have its speed adjusted to the rated speed.