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In 2007, US Anrun Long made a notable appearance at the Asia PTC exhibition by launching new compressor oils designed to reduce downtime and enhance return on investment. These innovative lubricants have become a key focus in the industry's push toward energy efficiency and cost reduction. Industry experts are now exploring ways to further improve the reliability of compressors, which play a critical role in the petrochemical sector.
Compressors are essential in many industrial applications, especially in gas processing plants. The two most common types are centrifugal and reciprocating compressors, each with its own set of advantages and development trends.
Centrifugal compressors are evolving toward larger sizes, higher energy efficiency, and greater reliability. Recent technological advancements focus on improving operational efficiency, lowering energy consumption, and optimizing production processes. The application of ternary flow theory in the design of impellers and diffusers has significantly boosted unit efficiency, reaching up to 88%. Advanced control systems now offer better detection, alarm, and interlock shutdown capabilities, ensuring stable operation for 3 to 4 years between maintenance cycles.
Leading manufacturers like Shenyang Blower (Group) Co., Ltd. are developing high-capacity compressors for major petrochemical projects. For instance, they are working on a cracking gas compressor for a 1 million-ton ethylene plant with an inlet flow rate of 341,494 standard cubic meters per hour and a shaft power of 51,106 kW. Meanwhile, Shaanxi Blower (Group) Co., Ltd. has integrated axial compressor technology from Swiss manufacturer Sulzer, producing large-scale fans for catalytic cracking units, with one main fan reaching 300,000 standard cubic meters per hour and 40,000 kW of power.
On the other hand, reciprocating compressors are also undergoing significant improvements. With the growth of refining, ethylene, and fertilizer industries, demand for high-capacity, high-pressure, and energy-efficient models has surged. Modern reciprocating compressors can handle piston loads over 1,250 kN and shaft power exceeding 10,000 kW.
The current development direction includes compact designs, lower noise levels, improved efficiency, and enhanced reliability. Advanced software tools are used for thermodynamic and dynamic calculations, allowing for more accurate performance predictions. Companies are also focusing on electromechanical integration, enabling automated control and real-time monitoring for optimized energy use.
Shenyang Gas Compressor Co., Ltd. has adopted German Borzig technology to develop large and medium-sized reciprocating compressors. In 1990, they launched the 4M50 series hydrogen compressor, and in 1998, the 4M80 series followed, featuring a flow rate of 34,000 standard cubic meters per hour, a piston force of 800 kN, and a shaft power of 4,000 kW. These compressors were successfully applied in Maoming Petrochemical’s residue hydrodesulfurization unit. More recently, Tianhua Machinery Research Institute and Wuxi Compressor Co., Ltd. developed a three-row labyrinth seal reciprocating compressor for Qilu Petrochemical’s polyethylene plant, demonstrating ongoing innovation in this field.