Everllence Centrifugal Compressor Efficiency Improvement

This case study details the collaboration between Everllence and Greene Tweed to enhance the efficiency of centrifugal compressors through the implementation of Arlon® 4020 labyrinth seals. The initial challenge identified by Everllence was the need to reduce internal leakage within the compressors to achieve energy and cost savings. The investigation revealed that traditional metallic seals had design constraints that contributed to efficiency losses. Greene Tweed introduced a novel tooth design using advanced thermoplastic material, which provided improved performance and durability. Rigorous testing confirmed that the new seals could achieve efficiency gains of approximately 1 to 1.5%. After nine years of operation, a comprehensive overhaul demonstrated that the seals showed no significant wear or corrosion, validating the long-term effectiveness of the design. The estimated lifecycle cost savings for a typical new booster air compressor were projected to be around $300,000, highlighting the financial benefits of the implemented solution.