Dresser-Rand says new centrifugal compressor represents major advance in technology
In what it claims is a major advance in centrifugal compressor technology, Dresser-Rand said on Thursday that it successfully engineered, manufactured and tested the world's highest-density centrifugal compressor for re-injection service.
While the units will be used in the oil and has upstream market, the technology is applicable to other market segments requiring the compression of carbon dioxide and heavy gases such as urea production and carbon capture and sequestration.
The unit, which compresses a mixture of natural gas and carbon dioxide, is one of two trains that will be installed on a floating production, storage and offloading (FPSO) vessel destined for the "pre-salt" fields of offshore Brazil. Dresser-Rand booked the order in the first quarter of 2010, it said.
"We are extremely proud of this ground-breaking achievement," said CEO Vince Volpe. "The move reinforces Dresser-Rand's commitment to innovation and technological leadership. This advancement offers clients significant value, and complements our existing technologies in the global oil and gas industries. It represents a cost-effective solution that adds real value to our clients' capital projects and operations throughout the life of the equipment."
Chris Rossi, Dresser-Rand's vice president of technology and business development, said, "the design of this class of compressor presented many challenges such as reaching discharge pressures that exceed 550 bar (7975 psi) while compressing gases that are heavier than typical offshore natural gas blends, including a CO2-rich gas blend that is nearly 65% heavier than these natural gas blends.
“At these conditions, the unit handles a gas in a super-critical state; or stated differently, a "gas" that is between its gaseous and liquid phases, which requires very accurate prediction tools."
The compressor was tested at full load and actual field conditions exceeding 550 bar discharge pressure and the range of specified gas compositions at the Company's facility in Olean, NY.
"The unit achieved a discharge pressure in excess of 560 bar (8120 psi) compressing the CO2-rich gas while exhibiting a very robust and stable rotor dynamic behavior, generally considered the greatest challenge in this class of machinery. When the unit operated at this condition," added Rossi, "it reached what we believe to be the highest gas density any multi-stage centrifugal compressor has handled.
“This density level is equivalent to what a natural gas compressor would achieve at a discharge pressure of approximately 900 bar (13000 psi). Gas density is one of the most critical parameters affecting a compressor's stability and its ability to operate reliably,” he said.
Overall, the footprint required by a conventional compression and pumping module can be reduced by approximately 50% while its weight can be reduced by approximately 35% or more depending on the exact configuration, the company said.
Officials noted that FPSOs, enhanced oil recovery and floating LNG operations were likely target markets for the compressors.
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