An Overview of Positive Displacement Scroll Technology for Oil and Gas Applications 39 th Gas-Lift Workshop Houston, Texas, USA May 16 – 20, 2016
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An Overview of Positive Displacement Scroll Technology for Oil and Gas Applications
39th Gas-Lift WorkshopHouston, Texas, USAMay 16 – 20, 2016
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
Air Squared Company Introduction
o Air Squared was founded in 1991 to service the needs OEMs with oil-free
scroll solutions for positive displacement applications.
o Only make scroll type devices (95% of products are oil free):
-Compressors -Vacuum pumps -Expanders
o Specialize in custom design, every product start with a custom design.
o Range of Experience:
o 3 LPM up to 3000 LPM
o From low vacuums to pressures over 3600 PSI
o Air, Helium, Hydrogen, Nitrogen, Oxygen, Refrigerants and Tritium
Key OEM Customers
Fuel cell solutions for the material handling market. Thousands of Air Squared in use across the entire GenDriveproduct line.
Simulation healthcare products. Thousands of Air Squared units
in use throughout the METI Learning product line.
Innovated artificial heart solutions. Using Air Squared units in
the only FDA approved driver for the Total Artificial Heart.
Leading aircraft manufacturer. Using Air Squared units on the
world’s largest passenger aircraft, the Airbus A380.
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
Scroll History
Scroll History
Invented, 1903 by Leon
Creox as a “Rotary Engine” Implemented as Scroll
Compressor, 1970s
Air Squared Receives First
Scroll Expander Inquiry, 2005
2015
• Scroll technology has been around for over 100 years
• Little activity on the use of scroll technology as a positive
displacement expander
① L. Creux
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
Types of Compressor and Expander Technology
Expander/Compressor Types
Positive Displacement
Reciprocating
Piston Diaphragm
Rotary/Orbiting
ScrewRotary Vane
Scroll
Dynamic
TurbineCentrifugal
or Axial
Where do Scrolls Fit?
Reciprocating
Rotary
Scroll
Fractional
Fractional
10 W 70 kW
10 kW
200 kW
Screw
150 kW 1500 kW
Centrifugal
350 kW and up
② E. Groll
Limitation of Scroll Compressor and Expander Technology
3 to 4 W 100 kW
Air Squared Limits
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
Scroll Technology: Geometry
Fixed Volume Device
Larger Volume:
Inlet for a compressor
Outlet for a expander
Smaller Volume:
Outlet for a
compression
Inlet for a expander
Displacement:
Inlet Volume
Volume Ratio:
Ratio of the larger
volume to the
smaller volume
Scroll Technology: Operation
Orbiting Spinning
No Valves: Geometry gives natural valving
Few moving parts: complexity of the device is
in the geometry, not the part count.
Higher efficiency than other PD devices
Compact size
Rotary motion: gives low vibration and noise
Can easily be designed for oil-free or oil
lubricated with few design changes.
Can be easily converted between an
expander and compressor
Advantages of Scroll Technology
Semi-Hermetic Configurations
Integrated Generator/Motor
Magnetic Coupling
Bellows Design Canned Motor
Scroll Technology: Configurations
Scroll Technology: Configurations
Integrated Generator/Motor
o All components integrated into one semi-hermetic shell.
o Generator/Motor housing is integrated into the scroll housing
o For an expander, the flow enters on the left, expands out radially, cools the
generator and discharges on the right.
7kW R245fa ExpanderSemi-Hermetic Configurations
Integrated Generator/Motor
Magnetic Coupling
Bellows Design Canned Motor
Scroll Technology: Configurations
Magnetic Coupling Design
o Allows external isolation of the generator or motor
o Popular in semi-hermetic applications where the motor or generator can’t be in contact with the process fluid
E15 Refrigerant Expander
Semi-Hermetic Configurations
Integrated Generator/Motor
Magnetic Coupling
Bellows Design Canned Motor
Scroll Technology: Configurations
Canned Motor
o Integration of a magnetic
coupling and motor/generator.
o Can be a cheaper alternative to
magnetic coupling assembly.
o Used when axial space is
limited.
o Canned motor pumps are used
frequently in chemical
processing.
Canned Motor Compressor
Semi-Hermetic Configurations
Integrated Generator/Motor
Magnetic Coupling
Bellows Design Canned Motor
Separation barrier or “Can” installed in
airgap between rotor and stator.
Scroll Technology: Configurations
Bellows Design
For applications
that require
complete isolation
of all running
components from
the working fluid.
All Metal Tritium Vacuum Pump for Tritium
Processing
Bellows installed
between fixed and
orbiting scroll
Semi-Hermetic Configurations
Integrated Generator/Motor
Magnetic Coupling
Bellows Design Canned Motor
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
High Pressure Scroll Compressor Development
Design Goals:
o Hermetically sealed to Helium Leak Tightness.
o Option to removal of all electrical hardware.
o Flow of 4 CFM at the discharge.
o Maximum pressure differential up to 200 PSID.
o Maximum inlet pressure of 3600 PSI.
o Minimized Vibration during operation.
o Minimum time before maintenance: 10,000 hrs.
2012: Air Squared was contracted to develop a high pressure natural gas
booster which could boost natural gas from 1500 PSI to over 1600 PSI.
High Pressure Scroll Compressor
Integrated Motor
High Pressure Scroll Compressor
Magnetic Coupling
Motor
Magnetic
Coupling
Inlet
Outlet
Pressure Plate for high
pressure operation
Technical Risks
Deflection of the fixed scroll at high pressures
Internal
Pressure
Pressure Plate
Pressure across scroll goes from
3400 PSI to 200 PSI.
Discharge pressure
boundary
Fixed Scroll contains the internal
pressure. Applied strain on fixed scroll
Technical Risks
High pressure differential
Scroll sizing for a low pressure ratio with a high differential
Going from 3000 PSI to 3100 PSI
requires a volume ratio of 1.05:
Pre
ss
ure
Volume
A volume ratio of 1.2 results in
significant over compression:
Pre
ss
ure
Volume
Low wrap count puts design at risk of not sealing
High Pressure Scroll Compressor Results
Differential Pressure [PSID]
Vo
lum
etr
ic E
ffic
ien
cy
1500 PSI Inlet
High Pressure Scroll Compressor Results
Differential Pressure [PSID]
Vo
lum
etr
ic E
ffic
ien
cy
1000 PSI Inlet
Conclusion on High Pressure Scroll Prototype
o High pressure differentials can be achieved with a low scroll wrap
count.
o Pressure differentials above 300 PSID can be achieved when
operating as low as 1000 PSI on the inlet.
o Deflection and thermal issues can be prevented with use of a
pressure plate.
The performance opens the door for use of scroll compressors
and expanders in high pressure oil and gas applications.
I. Company Introduction
II. Scroll History
III. Types of Compressor and Expander Technology
IV. Scroll TechnologyI. Overview
II. Advantages
III. Semi-Hermetic Configurations
V. High Pressure Capability of Scroll Units
VI. Other Applications
VII.Final Discussion
Presentation Outline
Other Applications
Scroll Expanders
• Reliable power generation
in remote locations
• Low Noise: Quiet power
generation in residential
locations
• Scalable: Small sizes for
mobile equipment and
larger sizes for industrial
equipment (5 Watts to 80
kW)
References
①Creux, L., Rotary engine. US Patent No. 801182.
1905.
②R. Cohen, and E.A. Groll, "Update on Refrigerant
Compressors in Light of CFC Substitutes," Bulletin
IIF/IIR, Tome LXXVI, No. 5, August 1996, pp. 2-19.
③USA Tolerance Rings:
http://www.usatolerancerings.com/
May 16 – 20, 20162016 Gas-Lift Workshop 33
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May 16 – 20, 20162016 Gas-Lift Workshop 34
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