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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