The impact of fouling on process compressors

The function of a process compressor is to increase the pressure of a gas or vapour. Anything that stops the equipment from doing this job efficiently costs you money and jeopardises production. However, many engineers are unaware of the costly impact that fouling is having on their equipment at this very moment.

Through normal use, process compressors accumulate foulants, and removing them is key to regaining efficiency and maximising profit. Here’s how…

How do process compressors become fouled?

The foulants that build up in a process compressor originate within the process itself, e.g.:

Inorganic solids

• Introduced via the process gas
• Corrosive products
• Oxides
• Carbonates
• Sulphates
• Silica

Organic solids

• Light hydrocarbons
• Polymeric compounds
• Coke
• Lubricants/grease

Production chemicals

• Corrosion inhibitor
• Hydrate inhibitor
• Defoamer

Once process compressor fouling begins, more and more deposits build up and the performance of the equipment plummets.

Signs of process compressor fouling

Without opening up the equipment itself, it can be hard to comprehend how serious the foulant build-up is. However, there are some telltale signs that you have a problem, including:

• Reduced head/pressure
• Reduced capacity/flow
• Reduced efficiency
• Reduced pressure ratio
• Increased speed
• Increased vibrations
• Higher temperature
• Greater power consumption
• Drop in intercooler pressure

A boroscope inspection can also be used to confirm your suspicions if desired.

Why is fouling a problem?

Process compressor fouling impacts performance and can ultimately cause costly damage to your equipment.

Fouling increases friction and internal recirculation while also reducing capacity. Compromised in these ways, the compressor does not work as intended and more fuel or energy will be needed to obtain the same results, increasing costs by potentially $100s of thousands per year.

Another issue is vibration which, as it increases with greater fouling, can cause a loss up to 10% efficiency per year.

In a nutshell: fouling = reduced efficiency, increased costs and greater potential for damage.

Fouling prevention

In an ideal world, we would prevent fouling from happening in the first place. Unfortunately, due to the nature of contaminant introduction, it is simply impossible to stop them from getting in! However, there are steps we can take to minimise the build-up of contaminants and remove any last residue when necessary.

Specialised surface coatings can be used to limit fouling, but they are not enough alone to eliminate the problem.

Process compressor cleaning

In order to maintain efficiency, maximise productivity, and minimise fuel costs, process processor cleaning is essential. A combination of regular on-line cleaning using specialised cleaning nozzles, and occasional off-line cleaning is the best combination to maintain your equipment and ensure the highest level of performance and lifespan. Washing should be a core part of your process compressor maintenance.

Get in touch

At Rochem, we specialise in process compressor washing products and equipment. Our team are here to help with a performance analysis, feasibility study, custom equipment design, wash nozzles, skids, compressor cleaning chemicals, installation and all the support you need to regain lost efficiency at your site.

If you’re interested in how we can help, please get in touch to discuss your specific requirements.