Flowserve Compression Systems GmbH ikompressor CNG & Biogas Refueling Systems Driven by LINDE Compression Technology Experience In Motion
A Powerful Team The Linde Group and Flowserve Corporation have formed a joint venture to commercialize and deploy Linde s revolutionary ionic compressor technology for natural gas and biogas refueling stations. By replacing metal pistons in conventional piston compressors with ionic liquids, the ikompressor delivers safer, more reliable and more cost-efficient fuel-gas compression. With the cost-saving advantages of ikompressor, profitability is now within the grasp of refueling station operators. Flowserve Compression Systems GmbH manufactures the ikompressor at its headquarters in Brunn am Gebirge, Austria. It markets and supports these systems through its extensive European network of sales offices and quick response service centers. About Linde The Linde Group is a world-leading gases and engineering company which operates in approximately 100 countries and has more than 50 000 employees. The Gases Division offers a wide range of compressed and liquefied gases to make myriad products in virtually every industrial sector. The Engineering Division provides process engineering, project development and construction of turnkey industrial plants such as refineries and chemical process plants. The Linde Group is headquartered in Munich, Germany. About Flowserve Dallas, Texas (USA) based Flowserve Corporation is the recognized global leader in supplying pumps, valves, seals, automation and services to the oil and gas, power, chemical and other industries. Its products move and control even the most volatile liquids and gases safely and securely. With more than 14 000 employees working in more than 56 countries, Flowserve provides its customers a global reach with a truly local presence. 2
flowserve.com Innovative liquid piston gas compression delivers life cycle cost benefits A New Innovation in Compressor Technology Fluctuating petroleum prices, reduced oil field production, environmental concerns and government mandates are driving the quest for alternative fuels. The race is on to develop clean, renewable technologies that will reduce greenhouse gas emissions and reliance on oil as the primary source for transportation fuels. One of these technologies is gas compression, specifically, natural gas and biogas. In Europe, natural gas is less expensive than traditional petroleum fuels. Although a carbon-based fuel, compressed natural gas (CNG) burns much cleaner than petrol or diesel and, therefore, is more environmentally friendly. Natural gas vehicles (NGVs) reduce NO x emissions and eliminate particulate emissions. Introducing ikompressor An innovation in compressor technology, the ikompressor is based on the use of a patented ionic liquid as a piston that delivers the suction and discharge cycles similar to that of a conventional reciprocating compressor. Virtually inert and with negligible vapor pressure, the ionic liquid does not chemically react with natural gas and remains stable at high-pressure compression conditions. Compression occurs at nearly constant temperature which is the most efficient thermodynamic cycle for gas compression. For the refueling station operator, this means reduced life cycle costs. The breakthrough design of the ikompressor is based on two key elements: Use of innovative and proprietary ionic liquids as pistons replacing solid pistons Near-isothermal compression Operator Benefits ikompressor benefits include significant reduction in wear-and-tear parts, extended maintenance intervals and life cycle cost savings. Isothermal compression reduces energy required for compression as compared to other thermodynamic cycles. Extended maintenance intervals Pre-compression step designed for a fluctuating and wide range of inlet pressures Few moving parts for low maintenance costs and reliable operation Compact footprint (20 ft standard container) with a total weight of less than 10 tonnes Modular configuration for installation flexibility and scalability Optional smart technology for local or remote on-line monitoring Life cycle support through technical services group and quick response service centers Competitive price for leading-edge technology Reduced total life cycle cost 3
Efficient thermodynamic conversion of electrical energy into compression energy at constant temperature The ikompressor Natural Gas Refueling Station The ikompressor refueling station is designed for fast-paced and reliable commercial operation. At the heart of the system is the ionic liquid compressor, an all-new gas technology with near-isothermal compression. Every measure has been taken to ensure safe operation. The ikompressor system design complies with global standards for CNG refueling stations. The entire assembly is CE stamped and ATEX compliant. The ikompressor station is designed to work with popular EU dispensers preferred by retail operators. (Please see page 6.) Operation Sequence Inlet gas is conditioned to remove impurities. Pre-compression is accomplished with an ionic liquid cooled and lubricated screw compressor when inlet pressure is less than 15 bar. The main compression step uses a radial piston pump with five liquid pistons. There are two storage bundles with a maximum filling pressure of 300 bar and storage capacity of 1200 liters. The bundles are connected to a threebank system- the low pressure/ medium pressure/ high pressure bank. Booster Line Storage Bundles 4 Gas Distribution System Inlet Block Precompressor Dryer Intermediate Circuit Main Compressor 3 Bank Block Dispenser Vehicle Tank Cooling Loop
flowserve.com Designed Global Service for fastpaced, and Technical reliable and safe Support commercial operation Technical Features High Booster ( HB ) This special operational mode increases the normal delivery rate from 140 Nm 3 /h to the highest booster or HB rate of 1500 Nm 3 /h during peak loads. This mode reduces the fueling time of vehicle tanks and delivers more natural gas in less time. Redundant System Plus An optional second main compressor including radial piston pump and piping for booster mode is part of the standard station design. Both main compressors are able to compress from 15 to 25 bar to 300 bar (bundle fill mode). This makes it possible to switch between the operating and redundant main compressor at regular intervals to permit high system reliability. Switching between booster and main compressor mode is also possible. The optional Redundant System Plus second main compressor is installed within the standard container footprint. Safety Global standards compliance External insulation for outside fire protection including F90 doors per EU standard Overpressure relief panel on roof Electronics and arcing components housed separately from natural gas and pressure components Storage bundles housed within the 20 ft container Energy Consumption Capacity Technical Data Low- and high-pressure stage driven with ionic liquid at near-isothermal compression Variable inlet pressure from 20 mbar 10 bar* Rated 140 Nm 3 /h at one bar inlet pressure Booster rating to 1500 Nm 3 /h during peak loads or to customer specification Liquid pistons or piston-less high-pressure stage Constant compression stream with five highpressure cylinders per main compressor rack Compression heat dissipated in water and air-cooled systems Two storage bundles with high booster for improved, simultaneous refueling capacity CNG stored at 300 bar maximum Housed in a 20 ft standard container with controlled ventilation system; total weight of less than 10 tonnes Low noise (less than 65 db) * For high inlet pressure application exceeding 20 bar contact your Flowserve representative. Delivery Rate vs. Energy Consumption Capacity [Nm 3 /h] 150 140 130 120 110 100 0 1 2 3 4 5 Inlet Pressure [barg] 0,40 0,30 0,20 0,10 0,00 Energy Consumption [kwh/m 3 ] 5
Completing the ikompressor Refueling System Dispensers Flowserve offers a wide selection of dispensing units to match the convenience and service retail operators wish to provide their customers. All units are unlocked either with clerk authorization or credit card reader device. They feature modern design cabinets built in a variety of materials including stainless steel and thermoformed plastic with two simultaneous delivery hoses, highly visible electronic display and communication interface for remote system monitoring. Dispensers are equipped with redundant safety interlocks for the security of customers and station personnel and for environmental protection. The dispensers are always separated from the buffer bundles with quick-acting switching valves. All dispensing units comply with local market/country standards and regulations. The ikompressor station is compatible with many standard dispenser models allowing a maximum of four filling units. Smart, Online Monitoring Assurance The Flowserve IPS APEX is pre-engineered specifically for ikompressor station systems. It makes the benefits of data acquisition, diagnostics and automated smart controls more accessible. Embedded with intelligence derived from Flowserve s extensive process system expertise, IPS APEX enables station operators to lower total life cycle costs through greater operational control. Data acquisition for sensor signal monitoring and logging Mechanical and hydraulic anomaly detection and diagnostics Seamless integration into the Flowserve TEAM/OS Management Portal Visualization Performance history Exception notification Reporting Communication interfaced for local and/or remote monitoring include: Wired or wireless Ethernet Serial Multiple communication process 6
flowserve.com Expert local service and technical support Service Where And When You Need It Authorized Flowserve technicians are readily available for local, responsive service. In almost every respect, the ikompressor CNG refueling system design makes routine service both infrequent and simple. Spacious container. Equipment design and open layout makes access by maintenance personnel safe and easy even with the optional second main compressor. Off-the-shelf parts. Generally speaking, ikompressor parts are few and they are frequently available as modularized components from local supply houses. The only proprietary equipment is the pre-compression screw compressor and the main compression ikompressor. Both have proven to deliver reliable performance with recommended inspection and maintenance. Local field service technicians supported by Flowserve factory and quick response center experts offer timely assistance in the event of system outage. 7
Bulletin PS-90-10a (E) December 2008. Flowserve Corporation Flowserve Compression Systems GmbH Industriestrasse B / 6 Brunn am Gebirge Austria, A 2345 Telephone: +43 2236 31530 Email: FCS-Brunn@Flowserve.com flowserve.com