GAS COMPRESSOR CASE STUDIES
Gas: Heliox breathing gas (He & O2)
Suction Pressure: 220 psig
Discharge Pressure: 798 psig
Flow: 197 scfm
Offshore energy industries often require subsea dive work at depths of up to 300 meters (985 feet). Due to the critical safety requirements and the very real life-threatening nature of this kind of work, LexMar Engineering was required to have third party safety and quality certification of their saturation diving systems. LexMar Contracted with DNV to meet their clients requirements for the safety and quality certification.
Working with LexMar, Hycomp engineers developed a Heliox gas compressor that LexMar incorporated into several of their diver gas reclaim systems. The compressor is uniquely designed to provide gas compression for service at the full 300 meters or any fraction thereof. To our knowledge, this is the first DNV approved compressor for this application, worldwide.
Continuous duty and reliability were very important factors in LexMar choosing Hycomp for the job. LexMar Dive Engineer Graham Winters was very pleased with the five compressors Hycomp provided. “After a long and arduous road, LexMar Engineering has proved to DNV, the outstanding capabilities of the LESGAZ Divers Gas Reclaim with the strong and reliable Hycomp Oil Free Compressors, chosen for their impressive track record in helium compression and transfer.”
Suction Pressure: 35 psig
Discharge Pressure: 125 psig
Flow: 10 scfm
To prevent moisture pickup and reduce ignition potential during installation of an explosive media, an automotive airbag manufacturer required high purity, dry nitrogen. The customer had already installed a local nitrogen generation system to provide the gas but required a compressor to increase the pressure from 35 psig to a storage pressure of 125 psig. The compressor had to maintain the 99.99% nitrogen purity without risk of introducing oil or oxygen into the process.
Hycomp provided a turnkey nitrogen compressor system including the gas compressor, control panel, motor, belt guard, after-cooler and receiver. The small AN6A-B nitrogen high pressure compressor was mounted onto an 80 gallon receiver to save space. Because nitrogen supply was critical to ensure uninterrupted production, the nitrogen compressor was made capable of continuous duty operation.
Since 2000 the Hycomp oil free nitrogen compressor has provided trouble free service requiring only standard preventative maintenance. The nitrogen gas supply has remained successfully dry and pure keeping the production of airbags within industry quality standards.
Gas: Nitrogen, 99.9% Purity
Suction Pressure: 300 psig
Discharge Pressure: 450 psig
Flow: 71 scfm each
One of the largest family owned laser-cutting facilities in the United States runs 29 lasers. Part of their current nitrogen supply was at 300 psig coming off a cryogenic bulk nitrogen tank. To increase their cutting capabilities for the machines fed by the cryogenic system they needed to increase the pressure to 450 psig. As they already had a Hycomp nitrogen compressor installed with their on-site nitrogen generation system, it was a natural fit to install two additional high pressure compressors to assist the cryogenic system.
A Hycomp high suction pressure oil free nitrogen compressor was installed. Standard Hycomp packings were arranged in a way to accept and contain the 300-psig suction pressure. Hycomp gas compressors are oil free and designed to prevent the introduction of oil into the gas stream, enabling the customer to maintain the nitrogen at high purity.
With this increased pressure, the customer can cut up to one inch carbon steel, 5/8 inch stainless steel and 1⁄2 inch aluminum on each machine. The plant is now able to run all 29 lasers concurrently at the high-pressure nitrogen demand.
Suction Pressure: 45 psi
Discharge Pressure: 435 psig
Flow: 91 scfm
A steel mill in China required a high pressure nitrogen compressor to optimize plant uptime. Complete turnkey installation was desired in order to minimize the technical requirements of local installation and start-up.
Because nitrogen is used in multiple areas during the manufacturing of steel, and many times the nitrogen is required at an elevated pressure, Hycomp oil free nitrogen gas compressors were a great choice for this application.
Through Eumex Enterprises we supplied this water-cooled, two stage nitrogen booster compressor. Two redundant 30 horsepower systems were installed and the units were each packaged with an 80-gallon low-pressure suction receiver, a 240 gallon 500 psig discharge receiver, aftercooler, gas filter, control valves and a control panel. The receivers were both Chinese Safety Quality License (SQL) certified.
Since the initial installation, three additional sets of nitrogen compressors have been installed in the same facility.
Gas: Wet carbon dioxide
Suction Pressure: 19 psig
Discharge Pressure: 95 psig
Flow: 130 scfm
Carbon sequestration is a process that involves drilling up to 7,000 ft. into the earth and compressing industrial byproduct CO2 into the geological substrata. The result is permanent containment of this harmful waste gas. A clean energy technologies leader in North America is testing the effects of wet carbon dioxide sequestration at an approved site in Ohio.
Their carbon sequestration process demands a compressor that can handle the corrosive nature of wet carbon dioxide, a combination of CO2 (91%), H2O (8%) and NH3 (1%). The customer’s existing available wet CO2 pressure is 19 psig; however their higher pressure sequestration process requires 95 psig.
Hycomp manufactured the 2WN137F1-G221 gas compressor system to meet their requirements. This industrial duty compressor system handles the corrosive wet carbon dioxide at the desired pressure and provides a truly continuous flow of 130 scfm. The compressor is packaged with a stainless steel inlet scrubber, stainless steel intercooler & separator, a VFD and PLC controls.