Siemens has manufactured and tested what it says is the world’s largest geared compressor rotor for use in the air separation unit of the 4 GW Jazan integrated gasification combined cycle power project. The IGCC, built on behalf of Saudi Aramco, will form part of its refinery and terminal complex on the Red Sea coast.
“The first-stage impeller with a diameter of 1.8 meters is the largest installed on an integrally geared compressor rotor,” Siemens stated. Produced and tested in Duisburg, Germany, the compressors are now on route to the site in Jazan.
In total, 19 STC-GV integrally geared compressors were manufactured for the air separation unit of the Jazan IGCC as part of an order placed last year by UK-based Air Products. All units were scrutinized in Duisburg at Siemens Mega Test Center, with all test successfully completed.
Commissioning and putting up the parts onsite is due to start in mid-2018. The air separation plant will ultimately be operated by Jazan Gas Projects Company, a joint venture between ACWA Holding and Air Products.
Making use of refinery residues
Once operational at Jazan IGCC in two years’ time, the air separation facility will supply 75,000 metric tons per day – 20,000 oxygen and 55,000 nitrogen. The integrated combined-cycle power plant will fuelled with gasified refinery residues and will supply electricity to the industrial area of Jazan city as well as process steam for the gas complex.
Each of the rotors that will be assembled inside the STC-GV compressors weighs more than seven tons, Siemens said, adding that the impeller was balanced in Duisburg at a speed of 3970 revolutions per minute. At its average operating speed, the outside diameter of the first-stage impeller rotates at a speed of 1350 km/h.
"This project proves that we have the necessary capabilities to provide large air separation plants with the appropriate compression equipment," said Thomas Moenk, head of product development for Siemens PG’s Dresser-Rand business. He singled out the customized design of the integrally geared main air compressors, calling it “a tremendous demonstration of our technical expertise.”
