Distributor / authorized representative that deals with supply & delivery of compressors to industrial enterprises of Russia
Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level.Contents:
We are interested in cooperation with the manufacturers of compressors (compressor lines), who are looking for an official and reliable distributor to supply their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your compressors. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative for compressor lines in Russia, our marketing staff will carry out a market research in order to check the demand for compressor lines, will submit a market overview for compressors that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your compressor lines and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods or for various types of compressors (compressor lines) in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for compressors as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your compressor lines into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of compressors. They will also provide necessary training and guidance for the customer’s personnel.
Compressors. Brief overview
Compressors, like other complex technical devices, have a great amount of different characteristics varying within wide limits. However, we can identify a number of values that are fundamental for this device. They define the compressor application field and form the basis for the designing and selection of the compressor equipment for a particular task. Other characteristics are of secondary importance and in most cases depend on the value of the main parameters. Secondary characteristics also affect the design, operation and overall efficiency of the compressor, but to a much lesser extent.
The value of the main characteristics defines the conditions of the compressor operation as well as the parameters of the compressed gas flow that can be achieved by the compressor. It is convenient that with a small number of parameters you can define the application of the compressor, or vice versa outline devices suitable for the task. The selection may be performed both based on one main characteristic and on several characteristics, depending on the requirements for the compressor.
The following characteristics have major influence on the compressor applicability:
- Operating pressure
Certainly, other characteristics such as: overall dimensions, weight, gas outlet temperature, noise, etc. can also have a significant impact on the designing and the final choice of the compressor, however, the main choice of a suitable device type is based on the capacity and operating pressure. For example, if a certain task requires to supply air under high pressure, but with a relatively low flow rate, this correlation of the required main characteristics will immediately eliminate a group of low-pressure compressors such as centrifugal or liquid-ring compressors. Attempts to achieve the required operating pressure on these types of units will be either impossible or economically impractical. At the same time, high-pressure compressors, by definition, are more suitable for the conditions. The device type can be further defined based on various secondary characteristics and results of the technical and economic analysis. Reciprocating compressors are less expensive in terms of capital expenditures, and screw compressors produce cleaner air, but all of them meet the requirements according to the main characteristics.
Typically, a buyer does not have, and often simply cannot have the full information on the parameters of the necessary compressor. There are only the basic requirements, which the compressor shall provide: amount and pressure of the supplied gas, limitations of the power to be supplied to the device. In other words, the operating pressure, capacity and consumed power. Certainly, this basic set of requirements can be supplemented and updated with such parameters as corrosion and chemical resistance of parts, noise level, feed consistency, etc. Based on these data you can select and design some compressors, and each of them would be able to complete the task. They will differ in details, based on which the buyer will be able to choose the best option. The optimality criterion in this case can be any of the secondary characteristics, for example, the amount of the consumed power (in case of the compressor unit with an electric motor) or the unit maintenance costs.
Despite the fact that the above characteristics are the main ones, there are a number of parameters, which often have a commensurate impact on the compressor choice. For example, the chemical and physical composition of the gas can be crucial, since the compressor's ability to pump such medium will define not only its efficiency, but also mainly its ability to operate at all. In addition, the replacement of the parts material with a chemically resistant and durable material can raise the cost of the entire device by several times. In other cases, the requirements for the compressed gas at the outlet of the compressor, for its purity, feed consistency and temperature, not only for the values of the flow rate and pressure, can be of importance. For example, there are increased requirements for the purity of media and materials in the food industry. Therefore, it is fundamentally unacceptable to use the oil lubrication of screws in the screw compressor, if it is possible for the lubricant to get into the gas flow, whereby the values of other characteristics will not have any impact on the final decision on the applicability. The difference of such significant yet secondary, characteristics from the main ones lies in the fact that the degree of their impact varies from case to case, while the operating pressure, capacity and power are always important.
Compressors can be classified by the following features
By the principle of operation
The most common classification of compressors is based on the gas discharge principle that they use, and therefore, they are divided into two types:
- Positive displacement compressors
- Dynamic compressors.
Positive displacement compressors operate by means of the sequential filling of the working chamber with gas and its further compression by the forced reduction of the available volume of the working chamber. To prevent the reverse gas flow, they use a system of valves, which alternately open and close in the phases of filling and emptying of the chamber. In their turn, dynamic compressors increase the gas pressure by transferring the kinetic energy to its flow, which is then partially converted into the potential pressure energy. The same principle of compression may be implemented in various ways different from each other in characteristics of the produced compressed gas, compression conditions, etc. This allows you to adjust the device for a specific task to the greatest possible extent.
Positive displacement compressors
Positive displacement compressors are divided into the following groups:
Reciprocating compressors were one of the first compressors to appear. They perfectly reflect the principle of operation of positive displacement compressors. The crank mechanism driven by a shaft ensures the reciprocating motion of the piston in the cylinder. Thus, the working chamber bounded by the piston and cylinder sequentially changes its volume depending on the piston position. The system of non-return valves prevents the leakage of gas in the reverse direction.
The design features also allow dividing these devices into subgroups. By the working chamber, design compressors can be of single or double action. In the second case, the piston has a lesser thickness and divides the working chamber into two parts. When it moves in one part of the chamber, the gas compresses and its flow enters the outlet nozzle, whereby the second part is filled with the gas coming from the inlet nozzle. Thus, one revolution of the shaft covers two compression cycles. By the number of cylinders, the reciprocating compressor can be single-cylinder, two-cylinder, etc. If the gas sequentially undergoes compression within multiple cylinders of the compressor, then it is called a multistage compressor, and the number of stages determines the number of cylinders the gas goes through. Depending on the position of cylinders, reciprocating compressors are divided into horizontal, vertical, angular, V-type, and opposed.
Furthermore, reciprocating compressors are classified according to their application into 4 groups:
- Residential compressors
This type of equipment is characterized by small overall dimensions, mobility, need for a small amount of the compressed substance, short-term operation, low noise, and virtually requires no maintenance. Residential compressors usually produce pressure up to 8 bar. Long and intense operation of such compressors can result in significant damage, repair costs of which will be commensurate with the purchase of a new unit. This class of compressors is commonly used in repair shops, at motor transport service stations, and in construction.
- Semi-professional compressors
Pressure up to 16bar, capable of pumping up to 2m3/min. Reliable in operation. Disadvantages include noisy operation and need for periodic maintenance. The compressed air produced by this type of compressors contains a lot of oil, so they are not characterized by economical operation. Consumers: individuals and small businesses.
- Industrial compressors
This type of equipment is used in different parts of the technological cycle in technical industries. Light and heavy industry enterprises, car repair shops, major manufacturers.
Medical compressors are equipped with adsorption dryers and soundproof housing. Receiver with treatment against corrosion. High-pressure compressors. The maximum operating pressure at the outlet up to 60bar is provided by means of a powerful electric motor.
- Compressors without cylinder lubrication
Machines of this type compress various gases and are necessary in industries requiring clean oil-free compressed medium at the outlet.
Piston sealing rings of composite material are used as a seal. The labyrinth seal has not proven itself in practical use.
Compressors without cylinder lubrication operate without repair for a longer time.
Reciprocating compressor layout
Screw compressors consist of one, two or more engaged screws enclosed in the housing. Therefore, screw compressors can be single-screw, double-screw, etc. When screws move, they create moving working volumes of space bounded by screws and housing walls. These compressors have smaller size than that of reciprocating compressors. They are much more stable and able to provide better performance. During operation, substantial friction forces can be generated between the screws, so lubricants (usually lubricating oil) are used to reduce wear of the parts. However, anti-friction materials make it possible to get along without additional lubrication, and therefore, there are oil-filled and oil-free compressors. The latter are used in cases when the contact of the compressed gas and lubricant is unacceptable.
Screw compressor layout
Gear compressors use a pair of engaged counter-rotating gears as an actuating element. The gears can vary significantly from model to model; in some cases, they have a shape of toothed gear wheels. The working chamber in such compressors is formed through cutting off the space by the gear teeth and compressor housing. When teeth of different gears engage, the working chamber volume decreases, and the gas is displaced under pressure to the outlet nozzle. These compressors are successfully used in cases requiring the gas supply under slight pressure.
Gear compressor layout
Rotary-vane compressors have a distinctive feature in the form, as the name implies, of a rotor having special grooves with inserted movable vanes. The rotor is mounted in the cylindrical housing (stator), whereby the rotor axis does not coincide with the axis of the housing. During the rotation, the centrifugal force pushes the vanes from the rotor center and presses them against the housing, forming in the compressor moving working chambers bounded by the adjacent vanes, housing and rotor. The change in the working chamber volume is caused by the axes misalignment. Compression springs can be installed in the rotor grooves to create additional force to press the vanes against the housing. Like reciprocating compressors, rotary-vane compressors are able to develop significant gas pressure at the outlet, but they have the advantage of the compact size and lower noise.
Rotary-vane compressor layout
Diaphragm compressors are characterized by a flexible polymer diaphragm integrated into their design. This type is similar to reciprocating compressors, but the diaphragm performs the role of the piston here. Bulging in opposite directions, the diaphragm changes the volume of the working chamber and of the valve systems in the same manner. The diaphragm itself can have a mechanical, pneumatic, electric or diaphragm-piston drive. All these types of drives are united by the fact that during operation the pumped gas comes into contact with nothing but the diaphragm and the working chamber housing. This makes diaphragm compressors popular in cases when it is necessary to ensure high purity of the discharge gas.
Diaphragm compressor layout
Liquid-ring compressors use an auxiliary liquid for their operation. The rotor with the vanes mounted on it is fixed in the cylindrical housing (stator), whereby the rotor axis is misaligned relative to the stator axis. The compressor is filled with a liquid, which during the rotation of the rotor is pushed to the housing walls taking the shape of a ring. The rotor vanes, housing and surface of the liquid, limit the working volume. Like with rotary-vane compressors, the misalignment of the rotor and stator axes ensures the change in the volume of the working chambers. The pumped gas in these compressors inevitably contacts the liquid, which is partially carried away with the gas flow; therefore, they have an outgoing flow separation unit and the system feeding the compressor with the actuating fluid. Such devices work particularly well in cases, when the pumped gas already has the actuating fluid droplets in its composition.
Liquid-ring compressor layout
Dynamic compressors are divided into the following main groups:
- Radial (centrifugal)
Radial compressors have received their name from the direction of the gas motion in the device. The simplest compressor of this type consists of housing with the impeller inside mounted on the shaft. Rotating, the impeller blades move the gas from the axis in radial directions, transferring the kinetic energy to its flow, which is then partially converted into the potential pressure energy. The gas enters the impeller through the axial inlet, then contacts the blades, gets pushed in radial directions, enters the spiral gas collector, and then discharges through the outlet diffuser. The impellers of such compressors may vary in form of the blades, and in the overall design, for example, they can be open or closed. Centrifugal compressors can also be multi-stage. In this case, multiple impellers are placed on one shaft, and the gas sequentially passes through them. Devices of this type are compact, have a low noise level and are not subject to severe vibration during operation. They are well suited for applications that require the supply of uncontaminated gas in large amounts.
Radial compressor layout
Axial compressors are characterized by the fact that the gas therein moves in the axial direction. The main design elements of these devices include the rotor mounted on the shaft and the stator (housing). The rows of vanes are arranged on the rotor. Passing through these rows the gas flow receives additional kinetic energy and undergoes a swirl. The rows of guide stator vanes are arranged between the rows of rotor vanes in order to level the direction of its movement. The inlet guide vanes and the outlet rectifying vanes limit the area, where the characteristics of the gas flow change. Such devices are significantly more complex in manufacturing and operation in comparison with simpler radial compressors, however, the have a higher efficiency while having a similar head value.
Axial compressor layout
Jet compressors represent ejectors that use the energy of one (active) gas or vapor to increase the pressure of another (passive) gas or vapor. It means that two gas flows with high and low pressure enter this device, and at the outlet you get one flow with a pressure higher than that of the passive gas flow, but smaller than that of the active one. Jet compressors are characterized by simple design and, as a result, high reliability. They are particularly preferred in those cases, when you already have a high-pressure gas, the energy of which should be used. For example, such devices are used in gas production, when the gas field has wells with both high and low pressure, and the application of the jet compressor allows receiving a single flow with acceptable characteristics.
Jet compressor layout
Regarding application field
Compressors, depending on the application and the industry, can be divided into general-purpose, energy, chemical, petrochemical units, etc.
Compressor operating pressure
We can call this feature fundamental, since it reflects the basic function of the compressor, to compress gas, which leads to an increase in its pressure. The pressure generated by the compressor is usually measured in Pascals (Pa), bars (bar) or atmospheres (atm), but can also be measured in millimeters of mercury (mm Hg), kilogram-force per square centimeter (kgf/cm2) or pound per square inch (PSI). The most common units of measurement are Pa and bar which correspond as follows:1bar = 0.1MPa. The operating pressure is also divided into excessive (Pg) and absolute (Pa). Their values differ by a value of the atmospheric pressure (Patm) and are connected by the relation Рg = Рa - Рatm.
When choosing a compressor, you need to keep in mind that the pressure generated by the device gradually decreases towards the operating tool or machine. The pressure drop can occur throughout the gas pipeline and in the so-called local resistances: valves, bends of the gas pipeline, flaps, etc. The operating pressure of the compressor should cover all the losses on the way to the consumer, and fulfill the specified requirements at the outlet.
In some cases, conditions of the compressed gas supply can be of importance. Therefore, reciprocating compressors due to their design produce a pulsating flow of the compressed gas, whereas screw compressors compress the medium consistently without fluctuations in time. In such cases as spraying of paints and lacquers, the consistent feed is an important condition for proper operation. The compressor pressure pulsations can be reduced by various ways. For example, reciprocating compressors may have multiple working chambers. The operation cycles of chambers shift in time relative to each other, thus causing partial smoothing of the total flow. However, most compressors use a device called receiver - a vessel accumulating the compressed gas coming from the compressor - which makes it possible to almost entirely eliminate the pulsation of the outgoing gas flow.
Depending on the developed pressure, compressors are divided into:
- Vacuum (negative pressure more than 0.05MPa)
- Low-pressure (from 0.15 to 1.2 MPa)
- Medium-pressure (from 1.2 to 10 MPa)
- High-pressure (from 10 to 100 MPa)
- Ultrahigh-pressure (more than 100MPa).
The capacity of the compressor means the amount of gas discharged per time unit. Generally, it is measured in m3/min, L/min m3/h, etc. The compressor capacity value can be specified for the suction side and the discharge side, which are not equal to each other, because in the process of compressing the gas changes its volume. Standard conditions, i.e. atmospheric pressure and temperature of 20°C, are typically taken to calculate the capacity at the inlet. The choice of the way to indicate the compressor capacity may depend on the convenience of perception depending on the application of the device. The recalculation of the conditions at the inlet into the outlet conditions can be performed using special formulas. The recalculation of the capacity may also be required, if the gas has a different temperature.
Depending on the capacity, value compressors can be divided into:
- High-capacity devices (more than 100m3/min)
- Medium-capacity devices (from 10 to 100 m3/min)
- Low-capacity devices (up to 10m3/min).
In general, the power - following the standard definition - is a value of work performed per a period in relation to the duration of this period. With regard to the compressor, it is the product of the capacity (amount of gas) by the work performed to compress it. This power is referred to as theoretical and calculated using the formula:
Nт = (Q∙ρ∙A)/1000
Nт – theoretical power, kW
Q – capacity, m3/min
ρ – gas density, kg/m3
A – theoretical work of gas compression, J/kg.
However, it should be noted that the theoretical power is not the same as the power that should be supplied to the compressor for its operation, and the power that must be generated by the motor connected to the compressor. This is caused by the power loss phenomenon that is numerically described by a set of efficiency coefficients. The compression process carried out in the compressor has its own efficiency coefficient (depending on the process type). In addition, a part of the power supplied to the compressor is lost when using mechanical transmission. Therefore, the power that needs to be supplied to the inlet shaft of the compressor is called the shaft power or the actual power, which is associated with the theoretical power through the following formula:
Na = Nт/(ηm∙ηpr)
Na – actual power, kW
ηm – mechanical efficiency of the compressor
ηpr – efficiency of the gas compression process.
If we consider the compressor unit also equipped with the motor and transmission, we will see additional power losses reflected by two efficiency coefficients ηm and ηtr, respectively. Then the power Nm that needs to be supplied to the compressor unit motor for its operation will be equal to:
Nm = Na/(ηm∙ηtr)
Nm – power of the compressor unit motor, kW
ηm – motor efficiency
ηtr – mechanical transmission efficiency.
It is very important to take into account the efficiency of all the elements. The same motor may not be suitable for the same task of gas compression, if compressors of different types perform it, since their efficiency coefficients may be very different. The power coming directly to the gas compression may simply not be enough due to large losses. For example, the average efficiency coefficient of screw compressors amounts to 95%, whereas in reciprocating compressors, this value is closer to 80%, i.e. the difference in the efficiency of the supplied power use can be 10-15% in favor of the screw device.
Application of screw compressors
The application of oil-free machines includes all the processes that are sensitive to impurities in the actuating medium, or where the lubricating oil may be contaminated with the actuating medium. They are used in many unique applications for butadiene; recycle gas of styrene monomer, soda ash, linear alkylbenzene, etc. In many cases, water injection is used to cool the compression process.
Oil-flooded screw compressors can reach a little more efficiency than "dry" compressors, and can use oil for cooling.
With the increased use of separators for synthetic oils, the last 20 years have seen a significant shift in favor of the use of oil-flooded screw compressors in many applications. Most screw machines used today to compress gases inject the oil into the operation area for lubrication, sealing and cooling in the amount approximately from 10 to 20 gal/min per 100 hp. The use of such large amounts of oil allows transferring the heat generated in the compression process to the oil, and makes it possible to maintain low temperatures at the discharge even at high compression ratios.
Application of centrifugal compressors
Centrifugal compressors, also referred to as radial compressors, are crucial for many applications in various industries.
These machines provide reliable compression in very compact configurations. Centrifugal compressors are distinguished by the type (horizontal or vertical), by the profile of the blades in the impeller, by the thickness of the walls of parts for certain operating pressure.
Their direct purpose is the compression of liquid, gas or mixture of gas and liquid into a small volume with simultaneous increase in pressure and temperature of the compressed medium.
Centrifugal compressors are classified as dynamic machines or turbocompressors. Progress in production methods was a key factor in the development of modern high-tech turbomachinery. The main components of the centrifugal dynamic compressor include the guide blades, impeller, diffuser, scroll, and side outlet. Impellers are responsible for all the work done with the medium flow, and, therefore, it is impossible to achieve efficiency in the entire compressor or a compressor stage without the properly designed impeller.
Centrifugal compressors are used in a large number of different applications requiring compression:
- Oil and gas industry
- Air separation plant
- Mining industry
Centrifugal compressors are used:
- In the chemical and petrochemical industry for the production of ethylene and propylene, and aromatic hydrocarbons, in the liquefaction of gas, for the compression of hydrogen, CO, methanol, ammonia and so on.
- In the oil refining in catalyst crackers, reforming furnaces, in desulphurization.
- In the processing of natural gas in gas liquefaction plants and gas processing plants.
- For mechanical vapor compression (to condense the vapor produced by the mother liquid, raising both the pressure and the temperature) in desalination of seawater, and in the pulp and paper industry.
- For the recovery and storage of carbon dioxide. CO2 is recovered directly at the source, preventing its release into the atmosphere, and then transported to a specified location.
- In the electric-power industry for pumping fuel gases, in desulfurization of flue gases, for supplying air during soot blowing, for supplying process air, as compressed-air atomizers for gas turbines.
Centrifugal compressors are used for applications requiring the compression of oil-associated gas. At the wells there is a mixture of hydrocarbons, and the problem is to separate the oil from the volatile components. The oil field facilities also have a number of areas that require the use of compressors. The most typical is the recompression of the produced gas and its supply to the gas pipeline. The gas compression may also be required to compress the reservoir as a temporary measure before selling, or to maintain the gas pressure in the reservoir.
Centrifugal compressors are also used in gas recovery plants, where the gas from gas fields is either compressed or supplied to gas plants or pipelines. The gas usually comes from several wells with different levels of pressure. The gas compresses to approximately 70-100 bar. Usually small compressors are installed near the well, which supply gas to the gasworks. At some gas fields, the level of the inlet gas pressure is reduced to separate the gas and liquid.
In the gasworks producing dry gas and products of liquefied petroleum gas (propane, ethane, butane) centrifugal compressors are involved in the following processes of compression:
- Auxiliary compression (at the inlet), to adjust the pressure of the supplied gas to the pressure of the gasworks.
- Recompression, when the pressure of the natural gas from the gasworks is adjusted to the pipeline pressure.
Centrifugal gas compressors are used to inject gas from pipelines into underground gas storages and vice versa. Natural gas containing H2S and CO2 (acid gas) in some cases is compressed untreated.
Centrifugal compressors are replacing reciprocating compressors for the supply of CO2 in the production of fertilizers (especially urea).
Compressors of this type are also used in small gas turbine engines of auxiliary power sources, and small aircraft gas turbines.
Centrifugal air compressors
Many chemical processes require compressed gas. Ammonia plants and air separation plants are typical examples here. Compressed air is used for mechanical equipment operation. It is also used for mine ventilation.
Centrifugal compressors increase the air pressure by means of impellers - rotating disks - as well as a diffuser in order to convert the speed energy into the pressure energy. The compression stages are intended to produce excessive air pressure up to the desired level, driven by a motor, a gas or steam turbine. Since in the centrifugal compressor the compression takes place in stages, the air remains cooler, and the air compressor is more efficient both mechanically and in terms of energy consumption.
Some integrated gasified combined-cycle plants require large compressors. Often electrically driven multi-stage compressors find application here.
Centrifugal compressors are also used in air separation plants. Air consists of many components. All processes of the air separation begin with the air compression.
Among other advantages of centrifugal air compressors is the ability to produce oil-free air for the food industry, as well as their ability to produce large volumes of air.
In recent years, the efforts of many manufacturers aim to reduce capital expenditures and operating costs. So, in recent years many manufacturers offer centrifugal compressor systems consisting of a series of standard, pre-assembled modules. The use of these modular components reduces the overall number of components, costs, and accordingly speeds up the subsequent assembly of the unit. It is more convenient for users in terms of maintenance.
Application of reciprocating compressors
The use of reciprocating compressors in the industry started already in the beginning of the last century. This was one of the first types of compressors to be invented. It contributed to the progress and development of production capacities, with which we are dealing today. Applications that use the force of the piston motion while compressing the actuating media are quite diverse.
In reciprocating compressors, the compression of the medium is carried out due to the motion of the piston. When the compressor runs, the piston moves up and down in the cylinder. The valve system is used to let the medium into the machine and then release the compressed medium.
The application is determined primarily by indisputable advantages of this type of compressors.
Advantages of reciprocating compressors:
- Generation of high compression ratio (the lower capacity limit is open)
- High efficiency
- Relatively moderate price
- Convenient maintenance (simple internal structure)
- Can be used as booster equipment
Due to these advantages, one can assume that the reciprocating compressor for air or gas will be used for a long time in many different processes in various industries.
Industrial reciprocating compressors are used in processes requiring high reliability and efficiency at long continuous operation.
Below you can see the main applications of industrial reciprocating compressors:
- Air separation plants
- Chemical industry
- Cryogenic equipment
- Enhanced recovery of oil from reservoirs
- Environmental protection and reclamation
- Ethylene oxide / glycol
- Fertilizer production
- Production of food and drinks
- Filling of balloons for compressed gas
- Gas injection
- Hydraulic cleaning
- Industrial-purpose gas processing
- Storage for natural gas
- Oil and gas industry
- Petrochemical industry
- Oil treatment
- Polyethylene production plants
- Production of low-density polyethylene
- Polymer production
- Polypropylene production
- Polysilicon production
- Main pipelines
- Synthetic fuel production
- Underground gas storage
- Oxidation processes
- Reciprocating compressors have found their application in catalytic reforming unit
Industrial reciprocating compressors are used to compress the following actuating media:
- Air and various non-corrosive gases and gas mixtures
- Dry gas
- Benzene, toluene, xylene
- Carbon dioxide
- Carbon monoxide
- Cryogenic gas
- Dust-laden gas
- Ethylene vinyl acetate
- High pressure gases
- Highly corrosive gases
- Gaseous hydrocarbons
- Hydrogen chloride
- Hydrogen sulfide
- Liquefied natural gas
- Liquefied hydrocarbon gas
- Mixed gases
- Natural gas
- Process air
- Toxic gases
- Volatile flammable substances
The invention of non-cylinder lubrication has opened up new prospects for the use of reciprocating compressors. The piston seals and glands were replaced by the self-lubricating type, with the use of composite materials, which prevents the wear of cylinders and rods, and consequently ensures the properly functioning process in the production.
Many refineries are practicing the use of compressors without cylinder lubrication and glands. The use of dry reciprocating compressors in the production of propylene makes sense, since there is no adsorption of oil on alumina gel during the drying of propylene.
Reciprocating compressors have proven themselves when working with compressed air, the most important resource for the majority of industrial enterprises. Uninterrupted production of compressed air is the main condition for the normal functioning of the enterprise as a whole.
When there is a need for small amounts of compressed air, semi-professional reciprocating units and residential reciprocating compressors become relevant to use. Residential reciprocating compressors are usually used in repair shops, at motor transport service stations, and in construction.
They are characterized by compact design, reasonable price, and operation in conditions of low and high loads. Single-stage compressors are intended mainly for pressures up to about 8bar, while versions with multiple stages can produce up to 16 bar. Whereby their operation is intermittent. The load level of the compressor with air cooling should not exceed 60-70%. The maximum operation time of these units recommended by some manufacturers is 4 hours. After 2 minutes of operation, it is advisable to take a break for 1.5 minutes.
- Water spray
- Nail drawing
- High pressure washers
- Driving nails and staples
- Professional blowing
- Professional screw driving
- Professional powder coating
- Pneumatic impact wrenches and ratchet wrenches
- Inflation of truck tires
Some noiseless models of reciprocating compressors are installed in areas close to workplaces.
Possible typical applications:
- Liquid atomization for industrial purposes
- Pneumatic hammers and impact wrenches
- Professional ratchet wrenches and high pressure washers
Reciprocating compressors as a part of compressed air systems are used in the food and beverage industry, for example, for cleaning the containers (before filling them with the product), automatic sorting of products and product packaging systems. Compressed air is also used here in production processes such as bottling.
For some applications, the presence of oil in the compressed air presents no problem. However, some situations require the air without oil content.
Oil-free reciprocating compressors have many advantages such as environmental friendliness - no leaks and oil spills. Their safety is sustained, among other things, by the lack of a fire risk associated with oil spills near electrical wires. The oil does not accumulate in the air collector. Such compressors have fewer components, which means that they require less spare parts and less maintenance in this regard. The associated equipment will have a longer service life. Less energy is required to drive the oil-free reciprocating compressor, and this makes the application of such compressors more cost-efficient for the enterprise. All these advantages make the users choose this type of compressors.
Typical applications range from the food and beverage industry, digital printing and sorting of rice to medicine and the railway industry.
Some companies require compressed air free of oil to use it later to clean sensitive circuit boards. Compressed air can also be used for cleaning machines involved in production processes directly connected with electric circuits.
Pharmaceutical companies also pay much attention to clean air in the production process of their pharmaceutical products. Oil-free reciprocating compressors are used in these cases.
In the textile industry, compressed air is used for textile machines with air nozzles.
Such oil-free reciprocating compressors can be found in the medical industry. Typically, such compressors have a compact size and light weight, which makes it possible to move them to any distances and in any position.
Oil-free compressors are also required in the production of upholstery and carcass furniture as well as minor painting work, and in power supply to dental equipment.
Compressors and blowers
- Air and gas blowers
- Axial vane compressors
- Basic steps to compressor unit calculation and selection
- Booster compressor stations
- Diaphragm compressors
- Example problems for the calculation and selection of compressors
- Examples of Pipeline Calculation and Selection Problems with Solutions
- Filters calculation and selection
- Main characteristics of a compressor. Throughput and power
- Pipeline Design and Selection. Optimum Pipeline Diameter
- Positive displacement compressors
- Reciprocating compressors
- Rotor compressor (Rotor compressor lines)
- Screw compressors
- Основные характеристики компрессора. Производительность компрессора. Мощность компрессора
- Классификация компрессоров
- Винтовой компрессор. Многообразие областей применения
- Применение центробежных компрессоров
- Применение поршневых компрессоров на современных предприятиях
- Booster Kompressoren
Upon becoming the official distributer of compressors (compressor lines), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (compressors) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!