Objective
The use of a flue gas expander in a Fluid Catalytic Cracker (FCC)Unit for vacuum gasoil, to achieve maximum electric power conservation of 7.1 MW,coresponding to 13,OOO MT/y of low sulphur fuel oil.
Gas expanders are used for the recovery of energy from waste flue gases, and from combined process cycles. They can be used to drive other turbomachinery or for direct power generation. Process gas temperature at the expander inlet can be up to 750 deg.C. in the event of expected temperatures in excess of 650 deg.C. rotor or blade root cooling is normally provided. Operating pressures normally lie within the 2-25 Bar range, although in some cases they are in the order of 60 Bar. Gas mass flows of 220,000 kg/h can be handled, with machine speeds ranging from 3,000 to 15,000 rpm and power outputs of up to 25 MW.
For this particular project there is a requirement that the expander be capable of 26,000 hours of continuous operation at full speed with no load (windmilling). Additional cooling steam, if required for windmilling, will be manually actuated. Expander speed will be regulated by electric motor generator. An overspeed controller will regulate expander overspeed by throttlingthe inlet valve when the generator breaker is open or during loss of generator load. Regenerator pressure will also be controlled by an expander inlet valve plus split range bypass valves. A slide type inlet valve will throttle flow to the expander when there is a significant reduction in flue gas rates (turndown operation) or to compensate for expander blade wear. The valve will also serve to shut-off flow to the expander during emergencies.
The expander's characteristics are :
Speed 5400 rpm
Trip speed 5727 rpm
1st critical speed 2067 rpm
2nd critical speed 7569 rpm
The design inlet and outlet characteristics are :
Inlet pressure (abs) 2.873 bar
Inlet temperature 692 deg. C
Outlet pressure (abs) 1.128 bar
Outlet temperature 531 deg. C
Gas flowrate 131,300 kg/h.
The project is scheduled to begin in March 1985, with commercial operation at the end of August 1990.
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Coordinator
10558 Athens
Greece
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