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Process Debottlenecking Problem

A major magnesium plant was prevented from raising production due to a bottleneck in the compression and liquefaction of the chlorine gas produced as a byproduct. With a robust market for magnesium metal, the plant wanted to remove the bottleneck, yet the amount of investment necessary to solve the problem was limited. Process solutions that would have required extensive downtime or a major rebuild of the chlorine handling system were out of the question. The customer needed an analysis of the situation and a plan of action which would both solve the problem, but be easy to install without losing production.

Solution

Universal Dynamics engineers analyzed the plant's production needs and the performance of the existing equipment. It was determined that the second stage of a large nine-stage centrifugal compressor was not performing up to the desired capacity. This limitation was affecting the amount of chlorine which could be processed by the system. Repairing and reconfiguring the compressor's impellers would have resulted in a time consuming and expensive rebuild. Universal Dynamics engineers suggested, instead, that the customer install a high capacity blower ahead of the compressor to raise its suction pressure, more or less acting like an automobile supercharger.

Results

Raising the suction pressure increased the gas density and lessened the volume passing through the compressor at the same mass flow rate. The volume capacity of the compressor was no longer limiting the plant production. The production restriction was removed and the desired increase in plant capacity was achieved. Moreover, eventually rebuilding the compressor when needed will allow still another increase in capacity for future production requirements.