Compressor design, application andproduction are fascinating subjects atany level, but when the design reachesthe “Hyper” level, imaginations tend torun wild and design innovation is at itsmost creative. A recent news item fromBurckhardt Compression AG, Winter-thur, Switzerland, trumpeted the“World’s most powerful single-framecompressor delivered.” When a num-ber of dimensional and performancestatistics are revealed, the claim asWorld’s Most Powerful is certainly be-lievable. For example, its 350 ton totalweight includes a 180 ton motionwork. This, in turn, includes a crank-case of approximately 86 tons and a 25ton crankshaft. The compressor is de-signed as a two-stage unit with sixcylinders in each of the two stagesmaking a 12-cylinder machine.

The unit, recently delivered by

Burckhardt Compression, is driven bya directly coupled 200 rpm, 60 Hz,36,900 hp (27,500 kW), 11,000 V, spe-cially designed synchronous electricmotor. The compressor is expected tocompress some 160 tons of ethyl-ene/hour to a discharge pressure upto 38,400 psi (2650 bar). Hyper com-pressors are high-pressure reciprocat-ing compressors for low-density poly-ethylene plants up to 50,000 psi (3500bar). These compressors are charac-terized by long life and high safety re-quirements because of their many de-sign features.

The order was received in Octoberof 2005 from National PetrochemicalIndustrialization NPIC (Tasnee) for thelow-density polyethylene (LDPE)plant that is part of the integrated eth-ylene and polyethylene (PE) complexat Al Jubail, Saudi Arabia. The respon-

sible contractor for this project isTecnimont. The compressor is to beinstalled in Al Jubail by mid-July ofthis year.

The new petrochemical complex in-cludes a gas cracker and two 400,000tons/year PE plants. One of theseplants will produce LDPE, based onBasell’s Lupotech T technology. Thejoint venture project was set up byBasell Polyolefins GmbH and Tasnee &Sahara Olefins Company. The projectis scheduled to be completed in 2008.

A number of features contribute tolong life, ease of maintenance and themeeting of safety requirements forBurckhardt Compression’s Hyper com-pressor. For example, to reach and sus-tain ultra-high pressures, special designconsiderations and material composi-tion must be met. The plungers (thepistons in the Hyper compressors) con-

GIANT HYPER COMPRESSOR DELIVERED FOR SAUDI ARABIAN POLYETHYLENE COMPLEX

Termed by Burckhardt Compression as the Most Powerful Single-FrameCompressor, its 350 ton (344 tonnes) Weight and 38,400 psi (2650 bar)

Discharge Pressure Lends Support to This ClaimBy Joe Kane

JULY 2007 XX COMPRESSORTechTwo

■ This Burckhardt Compression Hyper compressor is for installation in a low-density polyethylene (LDPE) plant that is part of the integrated ethyl-ene and polyethylene (PE) complex at Al Jubail, Saudi Arabia. . It is expected to compress some 160 tons of ethylene/hour to a discharge pressureup to 38,400 psi (2650 bar).

sist of solid tungsten carbide bars. Thecylinders are special and are assembledof several high-pressure cups made outof special alloy steel and containingbronze sealing elements. The centralvalves (cylinder valves) also are madeout of special alloy steel. Each cylinderis equipped with one central valvebody in which both suction and dis-charge valves are combined.

Long life and ease of maintenanceare enhanced by the 200 rpm drivermotor speed, which accounts for lowfriction and consequently low wear.Also, the massive crankshaft construc-tion without webs lends greater rigid-

ity and stiffness to this moving part.The compressor is equipped withlarge diameter bearings, providing ex-ceptionally low specific loads. Themassive design of the Hyper compres-sor enables Burckhardt Compressionto manufacture machines using fewercylinders than other basic designs.This feature enables BurckhardtCompression to design its machineswith fewer moving wear parts, result-ing in low operating costs.

Contributing to ease of mainte-nance is the construction of thecrankcase. It is produced from a com-pound welded design with main walls

of cast steel along with steel plates tocomplete the construction. Large steelcovers on top of the crankcase alloweasy access to all internal componentsand contribute to easy inspection anddismantling for maintenance. Aunique cartridge system enables rapidchange-out of cylinders.

As a safety feature, the compressor isequipped with an additional distancepiece so that ethylene gas will not en-ter the crankcase. Burckhardt Com-pression compressors are equippedwith an auxiliary crosshead betweenthe main crosshead and the plunger.This arrangement eliminates all unde-sired movements and lateral stress tothe plunger. All cylinder materials andmoving parts are made out of specialalloy steel, contributing to long life.

According to a company spokesman,Burckhardt Compression is the onlymanufacturer that offers a completerange of Laby (labyrinth piston), proc-ess gas and Hyper compressors. Thesecompressors are used in a wide rangeof applications in the chemical andpetrochemical industry, in refineries, airseparation systems and for gas trans-port and storage. They also are used tocompress, cool or liquefy gas, for ex-ample hydrocarbon or industrial gases.

Burckhardt Compression says itsglobal service network gives compres-sor operators, especially in remote lo-cations, peace of mind. It enablesBurckhardt Compression to offer com-prehensive customer support services,such as delivery of top-quality com-ponents, servicing of compressorvalves, complete system overhauls,engineering services and establishingand fulfillment of comprehensivemaintenance contracts. ■

SEE DIRECTLINK ATWWW.COMPRESSORTECH2.COM

JULY 2007 XX COMPRESSORTechTwo

■ The massive crankshaft for the Hyper compressor is shown resting on its bearings in thelower half of the crankcase.

■ Computer-generated instal-lation of the Al Jubail Hypercompressor from BurckhardtCompression. View shows theoperating components plusthe foundation and auxiliaryskid.