Water Technologies & Solutions
technical bulletin
SUEZ’s ethylene compressor efficiency solution
more reliable charge gas compressor operation with SUEZ’s combined resources
challenge
Compared to just a few years ago, today’s ethylene
industry requires more feedstock flexibility, as well
as improved upstream and downstream integration.
These factors have increased the complexity of
cracker design and management, exacerbating
longstanding process challenges such as equipment
corrosion and fouling. The cracked gas compressor is
one of the most critical pieces of equipment in an
ethylene plant and may be the limiting factor in
ethylene plant performance optimization.
Compressor fouling can have a dramatic deleterious
impact on overall plant performance, along with
significant associated economic penalties in energy
and productivity losses.
Ethylene producers are now looking for longer
intervals between turnarounds. Six to nine year runs
are being targeted in several cases. To achieve those
challenging targets, compressor efficiency decline
must be kept below 1% per year. To illustrate the
magnitude of this economic driver; a machine
processing 100 t/h of gas, with a total efficiency loss
of 5%, will increase energy costs by approximately
$500,000 per year.
Fouling phenomena also have a strong impact on the
operation of the anti-surge system. As the speed is
increased to compensate for the reduced efficiency,
the machine ends up operating much closer to the
surge control line. Apart from the risks related to
machine integrity, additional gas recycle and higher
energy costs may result if the anti-surge system is
not tuned appropriately.
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©2017 SUEZ. All rights reserved.
TB1165EN.docx Jun-12
Ethylene producers have many choices when
selecting fouling control technology. Through the
years, various approaches to minimize equipment
fouling have been employed. They include injecting
water to control discharge temperature, injecting
wash oil to solubilize polymeric deposits, and
specialty antifouling programs to prevent
polymerization phenomena, among others. Also,
multiple methods have been used to monitor and
evaluate machine performance. This has led to mixed
results and difficulties in the correct assessment of
compressor efficiency.
SUEZ’s integrated efficiency solution
SUEZ has decades of experience and unsurpassed
expertise in all the segments of the ethylene market
providing machines, asset monitoring systems, and
comprehensive chemical treatment programs.
SUEZ offers an integrated solution that includes:
• Design and manufacture of the machine
according to the latest technologies, also
including the anti-surge and the asset monitoring
systems
• Optimization of the water/oil injection systems
• Tailored antifouling programs
• Full monitoring programs
With regard to the monitoring of compressor
performance, a common problem is the lack of
necessary data. Intermediate flows and pressures
are often missing, as well as information about gas
characteristics.
Through the integrated actions of SUEZ, new tools
have been, and continue to be, developed. Advanced
fiber optic technology is currently being used to
capture and evaluate all necessary parameters. Its
benefits include, but are not limited to, reduced cost,
and no addition of pressure drops to the system.
The IT (Information Technology) platform of SUEZ,
along with the process knowledge SUEZ provides
accurate and timely on-line monitoring of the process
data and performance.
SUEZ also contributes to the reliability and smooth
operation of charge gas compressors with proven
fouling control programs, drawing upon decades of
global experience.
New COMP-RATE* software by SUEZ provides a
powerful tool to evaluate compression costs.

cost of fouling evaluation

As a result of the precise efficiency calculation
available, when compressor design curves are
known, SUEZ’s COMP-RATE evaluation program can
accurately simulate the compressor operation under
clean conditions and therefore provide a method of
quantifying the true cost of efficiency loss (sample
report shown below).
The COMP-RATE software provides full monitoring
and simulation in the case of variable speed
machines with four and five stages.
At the same time, the simulation of the operation
allows for better understanding of the impact of the
pressure drops that occurs in inter-stage equipment.
Finally, being able to accurately calculate and track
the economic impact of fouling, helps in optimizing
the fouling control treatment program, i.e. wash oil
and specialty chemicals injection.

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TB1165EN.docx Page 3
COMP-METER* - SUEZ’s compressor “thermometer”
The status of the compressor is summarized through the evaluation of several different parameters. By
assigning a scale of colors to the relative positive or negative results for each parameter, a visual “snapshot” of
the overall status of the operation is provided.

benefits
SUEZ’s integrated approach offers ethylene producers
the unique opportunity to work with one company
covering all aspects of the compressor design,
manufacturing, operation, and on-going performance
reliability.
Better understanding of the operation through the
integrated approach provides the necessary
knowledge to evaluate in the most appropriate and
efficient way to address any problem that might occur
while the machine is in operation, regardless if the
problem is related to mechanical, process control, or
fouling issues.
In addition, the availability of expertise from other
SUEZ businesses offers the valuable benefit of
evaluating and troubleshooting any anomalous
conditions that can influence the operation of the
compressor.
The net result of this integrated approach is increased
efficiency, smoother operation, and decreased
operating costs.

Page 4 TB1165EN.docx