Turbocompressor STC-GV Your compressor of choice since 1948. Integrally geared. siemens.com /compressors
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A success story since 1948 The integrally geared type compressor operates both as the Main Air Compressor (MAC) and Booster Air Compressor (BAC) for Air Separation Units (ASU) as well as for applications like CO 2, O 2, etc. Implemented and patented in 1948 by DEMAG, the STC-GV compressor is now part of Siemens AG and is a preferred compressor for ASU applications with more than 2200 machines sold worldwide. The first MACs were delivered in 1975 to the USA and India and in 1977 to China. Based on the flexible design to combine multi-shaft arrangements with different speeds around a centre bull gear and inter-stage cooling, the STC-GV compressor ensures robust, reliable operation with the highest efficiency. Because of its tailor-made design, the STC-GV compressor can be used in a wide range of operation points e.g. in high turndown and max operating points. Since its inception nearly 70 years ago, the STC-GV compressor series has been meeting demands for compression solutions with high efficiencies and pressures up to 200 bar. STC-GV compressors, designed according to customer specifications and in accordance with both API 617 and API 672, guarantee the highest quality and technical standards for a broad range of industrial applications. Highlights The perfect match for all air separation and process industry requirements High efficiency and outstanding operating range Powerful and robust design, with integrated turbine or expander options Four-shaft gear for cost sensitive motor driven train Optimal combination with Siemens steam turbine drive Flexible design concepts combining customtailored design with standardized components for maximum reliability Siemens is the only compressor manufacturer who also develops and supplies proprietary gear technology Powerful, robust and reliable The STC-GV integrally geared centrifugal compressors feature a multi-shaft arrangement with different speeds. All shafts are mounted in maintenance-free, oil-lubricated hydrodynamic bearings. With up to eight compressor stages around a central bull gear, the STC-GV compressor series forms a compact unit for the multi-stage compression of a wide range of gases. Optimized shaft speeds, state-of-theart 3D impellers, tailored aerodynamics and mechanics, along with optimized auxiliaries guarantee the highest efficiency. Adjustable inlet guide vane units at the first and/or any other compression stage optimize the operating range. External cooler arrangements allow for project specific optimized customer operation. Package and driver options For small- to medium-size STC-GV compressor sizes, Siemens offers a package design. The package includes the compressor, driver, process gas coolers, lube oil console, process piping, and all tubing and wiring. The package design leads to significantly reduced on-site installation time. For large-size STC-GV units all main train components are delivered separately on site and installation is on a concrete foundation. These compressor types are also suitable for direct turbine-drive or integrated turbine design (STC-GVT). Driver: depending on process and energy resources: electric motor, steam turbine or gas turbine. Siemens also offers variants of the STC-GV STC-GV (H): this compressor is designed for high-pressure applications with suction pressures higher than 5 bar, especially booster air in air separation. STC-GT: single- or multi-stage expanders enable power recovery from process gases. STC-GVT: with its single or multiple expander stages, STC-GVT is the ideal solution for simultaneous gas compression and expansion of process gas. 3
Customized integrally geared turbocompressors STC-GV / STC-GVT The robust multitalent. The STC-GV integrally geared centrifugal compressors feature a multi-shaft arrangement with different speeds and up to eight compressor stages around a central bull gear, forming a compact unit for the multi-stage compression of a wide range of gases. These trains are typically supplied as complete packages, including all rotating equipment, intercoolers and oil console.the STC-GVT compressor is an integrally geared multi-stage compressor comprising expander stages, designed in accordance with both API 617 and API 672. STC-GT Proven concept for direct power recovery. The STC-GT is an integrally geared process gas radial turbine that enhances power supply in processes with off-gas or process gas as byproducts. Medium- or hightemperature gas can be used directly to drive a compressor or electric generator without additional heat exchange or steam generation equip ment. The STC-GT turbine design is in accordance with both API 617 and API 672. For economic part-load operation, the STC-GT turbine can be fitted with an adjustable nozzle vane unit. This unit is normally located in front of the first stage and offers very good turn-down and part-load efficiencies. Integrally geared centrifugal turbocompressor Integrally geared process gas radial turbine Technical data Flow rates from 10,000 to 1,0 mio m³/h (471 to 588,578 cfm) Discharge pressure up to 200 bar (2,901 psi) Driver: e-motor, steam turbine, gas turbine (fixed speed) Fields of application Air separation Carbon capture and storage CAES Refineries Ammonia Synthetic fibers Petrochemicals Metal making Features STC-GV High efficiency due to tailored aerodynamics Wide operating range due to adjustable guide vane units Combined MAC/BAC unit allows lowest footprint Coupling power up to 65 MW Features STC-GVT Inlet guide vane unit in front of each stage Interheating between each stage Technical data Discharge volume from 3,000 to 600,000 m³/h (1,766 to 353,160 cfm) Expansion ratio 4 Power recovery up to 45,000 kw Gas inlet temperature up to 550 C ( 1,022 F) Fields of application Synthetic fibers, especially Pure Terephthalic Acid (PTA) Dimethyl Terephthalate (DMT) Nitric acid Features Adjustable inlet guide vane for economic part-load operation Uses many of the proven components from the integrally geared centrifugal compressor concept Radial inlet to each stage Long life due to process-optimized materials 4
Standardized integrally geared turbocompressors STC-GC (10 100) The compact solution for air separation. The STC-GC is an integrally geared compact turbocompressor available in nine frame sizes and offers a wide range of options packaged as a compact single-lift unit. The STC-GC product line is the compact and standardized version of the customized integrally geared STC-GV compressor series, the trusty workhorse of the air separation and process industries. This range of compact integrally geared compressors is also available as a high-pressure version STC-GC (H). STC-GC (165 400) Highest efficiencies and highly pre-engineered. The existing STC-GC compressor range has been extended by the introduction of a new preengineered series covering the 120,000 400,000m 3 /h capacities with five casing sizes. Eighty percent of the machine is pre-engineered for consistency and repeatability; 20 percent of the machine can be customized for specific customer process needs. This design means lean processes, minimal lead time and reduced costs of the compression system with highest efficiency levels, guarantees the use of well proven components, enhancing plant reliability and availability. Compact integrally geared centrifugal turbocompressor Pre-engineered compact integrally geared turbocompressor Technical data Flow rates from 3,600 to 120,000 m³/h (2,120 to 70,680 cfm) Pressure ratio up to 20 Electric motor drive (fixed speed) Fields of application Air separation Compression of plant air Compression of nitrogen Features Compact, single-lift unit Maximum performance due to pre-designed gears, highest efficiency impellers, tailored aerodynamics, and pre-defined auxiliaries Up to four compressor stages Technical data Flow rates from 120,000 to 400,000 m³/h (70,680 to 235,600 cfm) Pressure ratio up to 6.5 Electric motor drive (fixed speed) Fields of application Air separation (main air compressor) Features Highest efficiency through use of well proven flow components Efficiency as high as with customized compressor series STC-GV Highest flexibility derived from large number of fixed options 5
Core components all from a single source Siemens high-end 3D impellers are right on the top of aerodynamic efficiency levels and easily scalable to a wide range of suction flow. Based on nearly 70 years of experience, every impeller family is heavily investigated by state-of-the-art computational fluid design (CFD) codes followed by intense testing procedures in the in-house test bed. Only those impellers that meet expectations are incorporated in the design tools of the STC-GV family. In order to adapt the compressor to the operational requirements, guide vane units can be installed. An adjustable inlet guide vane unit is fitted as a standard feature at the inlet to the first impeller on all STC-GV compressors because as fixed-speed units no expensive speed control is necessary. When required, inlet guide vane units can be installed in front of each impeller, further expanding the operating range. Siemens is still the only compressor manufacturer worldwide, that produces the integrated gears by themselves. The gear is part of the rotating equipment and, therefore, a core component in the compressor train. Customers benefit from the One Hand Competence which is not only obvious during the concept, proposal and manufacturing phase (knowledge of the interactions of mechanical forces, resulting from aerodynamic and thermodynamic influences), but also especially during maintenance and emergency. Siemens has extensive experience with integrated gears with one bull gear and up to four pinion shafts. 6
Boosting performance Siemens compressor automation You need optimal solutions to economically and flexibly automate your machines and plants. To optimize a compressor train s performance and lifetime, a system that controls the rotating equipment automatically is essential. In combination with new compression solutions, or in addition to existing ones, Siemens offers a complete automation system from a single source. Siemens Compressor Automation Solution (SCAUT) is based on the world s leading automation system family, Siemens SIMATIC S7. SCAUT is a standardized system designed to meet your needs regarding operation, monitoring, control, and protection of complete compressor trains. This means that your compressors, drives and all auxiliaries run at the highest efficiency adjusted to your process requirements. SCAUT is designed in accordance with the international standards of IEC (International Electrotechnical Commission). A large variety of configurations allows for the implementation of flexible machine concepts. Benefits: Optimum performance and reliability due to powerful algorithms and proven program modules Fast and effective commissioning for the entire compressor train, including unit control panel ensured by standard tools Reduced maintenance costs due to standard SIMATIC components Compressor Control SCAUT comprises complete compressor control functions, based on Siemens-approved algorithms, that are integrated into the SIMATIC S7 PLC for all types of compressor trains. Driver: depending on process and energy resourcescan be a steam turbine, gas turbine or electric motor. Anti-surge control designed to cover even the most complex tasks, such as variable molecular weight, fastclosing discharge valves or increasing suction temperature during recycling. Performance control acting on mass flow, suction or discharge pressure, including limiting functions such as discharge pressure or motor current. Simultaneous control of sets of variable inlet guide vanes. Load-sharing controller for parallel trains. Fully or semi-automatic start-up and shutdown sequences matched exactly to your process demands. Integrated Steam Turbine Control Steam turbine speed-control algorithms established through the proven operation of many generator sets and compressor trains over the years have been integrated into the SIMATIC S7 PLC in the SCAUT system. Once again, the redundancy concept for the PLC is adapted to the control system, thus reducing the number of required subsystems. Speed governors are available for: Back-pressure turbines Condensing turbines Extraction / induction condensing turbines SCAUT system turbine control includes: Safeguarding functions, such as overheating or minimum flow protection Additional extraction pressure control, inlet pressure or induction pressure covering all interactions with the speed governor Automatic ramp-up to minimum governor speed according to predefined start-up curves, including the avoidance of maximum two critical speed bands 7
Key partner for innovative solutions in air separation Air separation Siemens integrally geared turbocompressors STC-GV are the perfect match for air separation and air compression. In these processes, the integrally geared turbocompressor serves as the main or booster air compressor, combined main and booster air compressor and oxygen compressor. While functioning as a main air compressor (MAC), discharge pressures between 5 and 30 bar are critical; the booster air compressor (BAC) STC-GV (H) realizes up to 100 bar, depending on process specifications. In combination with the Siemens SST-600 Enhanced Platform steam turbine, Siemens is the market leader for large ASU trains for gasification with more than 35 trains delivered in the last several years. The company has been engaged in the continuous development of gear-type compression technology for nearly 70 years. Siemens integrally geared compressors cover volume flows up to 1.0 mio m 3 /h. Flexible, reliable and proven, the STC-GV series ensures optimum performance as a main air, booster air or combined main and booster air compression solution. Furthermore, these integrally geared compressors are used as oxygen compressors in air separation. Generally all compressor frame sizes are manufactured in Duisburg or in Huludao/China with equal quality levels. Whether the air separation plant is a standardized or customized unit, the key factors are efficiency, availability and lifecycle costs. Siemens meets all the industry s requirements with regard to optimized CAPEX and OPEX and is the technological partner of choice with its unique range of air compressors. 8
Key partner for environmentally friendly CO 2 and process gas compression CO 2 compression The compressors in the STC-GV series are ideal for CO 2 compression where high-pressure capacities of about 200 bar are essential, paired with the highest efficiencies and most reliable technologies. Based on building blade systems, Siemens has developed a tailor-made, optimized solution for carbon capture and storage. The STC-GV integrally geared compressor series covers a suction volume of CO 2 between 25,000 and 250,000 m 3 /h. With multistage design and possible intercooling after each stage, the STC-GV realizes up to 200 bar in one machine. Up to eight stages enable four different rotational speeds, leading to optimized aerodynamic efficiencies. Impeller outlet diameter deadline to 110 mm and pinion shaft speed reaches up to 35,000 rpm. Two pinion shafts located in the upper split line allow easy maintenance and service. Process gas compression The STC-GV compressor family fulfills the complex requirements of the global refinery and petrochemical businesses. Related to API, the integrally geared compressor can be equipped with carbon ring or dry gas seals, including the relevant seal gas modules. Depending on customer process requirements, the number of intercoolers can be optimized just as well as the number of extractions. Package arrangements are available as a complete one or as a combined one where compressor unit, lube oil unit and driver a delivered as separate packages. To satisfy market demand, Siemens is able to offer PTC 10 Class 1 Full-Load / Full-Pressure testing at the Duisburg test facility. More than 60 references within the last 25 years show the competitiveness of the Siemens process gas GVs. 9
Train solutions covering all PTA plant sizes PTA Pure Terephthalic Acid (PTA) is an organic compound. This white solid is a commodity chemical, used principally as a precursor to the polyester PET, used to make clothing and plastic bottles. To ensure a stable and reliable process, large turbomachinery trains from Siemens are well established and ahead of the competition. Basically, a large Siemens PTA trains consists of an SST600 steam turbine, an STC-GV process air compressor, a motor / generator, and an STC-GT radial expander. Based on the exothermal PTA process itself, the SST converts the generated steam into mechanical energy to drive the PAC, which itself is necessary to support the PTA reactor with compressed air. Waste off-gas out of the reactor is converted again into the radial expander to Typical Siemens PTA train, 1.2 MTPA plant output mechanical energy and the surplus energy is used by the generator to generate electricity. Overall, the PTA train is one of the most economical turbomachinery trains. 10
High efficient production of ammonia Ammonia Ammonia is a compound of hydrogen and nitrogen (NH 3 ) used mainly as fertilizer and is also a building block for the synthesis of many pharmaceuticals. To produce the desired end-product ammonia, the hydrogen (obtained from gasification of natural gas or coal) is then catalytically reacted with nitrogen (obtained from air separation plant) at very high pressure to form anhydrous liquid ammonia. This step is known as the ammonia synthesis. Siemens portfolio covers all required compressor trains, mainly single-shaft solutions for refrigerant, syngas, etc. and the STC-GV for the ASU portion. All compressor trains can be driven by an electric motor, steam turbine or gas turbine. Recommend omitting this sentence as we have photo/caption below. Thanks to innovative solutions from Siemens, the fertilizer plant in Bahia Blanca, Argentina can now increase its production while using the same amount of energy. A highly efficient compressor, an industrial gas turbine, a generator, and a heat recovery steam generator, all from Siemens, make it possible. The addition of the Siemens components to this plant enabled increased urea production (by 11 percent) and ammonia by 21 percent using the same amount of energy. Siemens scope of supply includes a model STC-SV (80-6) geared turbo compressor, an SGT-600 industrial gas turbine, a 13-megawatt (MW) generator, and an NEM heat recovery steam generator. The gas turbine drives the compressor and generator, while the heat recovery steam generator uses exhaust heat from the gas turbine to generate process steam. The highly efficient geared turbocompressor from Siemens convinced the customer to choose the innovative end-to-end solution as an alternative to the existing, conventional single-shaft compressor solution. This increased the profitability of the plant enormously. Water consumption is also simultaneously reduced by six percent. Ammonia plant in Argentina, oprating with Siemens compressor technology. 11
Published by Siemens AG 2016 Power and Gas Division Freyeslebenstrasse 1 91058 Erlangen, Germany For more information, please contact our Customer Support Center. Phone: +49 180 524 70 00 Fax: +49 180 524 24 71 (Charges depending on provider) E-mail: support.energy@siemens.com Article-No. PGCP-B10007-00-7600 Printed in Germany Dispo 21614 K12 160026, WS 1609 Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract.