Research Article | | Peer-Reviewed

Application of Oil-free Screw Compressor in Hydrogen Chloride Mixed Gas Compression

Received: 15 July 2026     Accepted: 31 August 2026     Published: 14 September 2026
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Abstract

Aiming at the difficult to recover hydrogen chloride mixed tail gas generated during the production of lithium bis(fluorosulfonyl)imide (LiFSI), the PRO II process simulation software was adopted to optimize the parameters of the compression condensation recovery process in this paper. Considering equipment investment, operating energy consumption and anti corrosion risks comprehensively, the optimal process parameters were determined, with the final compressor pressure of 2.0MPaG and condensation recovery temperature of 0°C. By comparing the advantages and disadvantages of reciprocating compressors and oil injected screw compressors, a two stage series oil free screw compressor was selected as the pressurization equipment. High temperature corrosion caused by acidic gas was inhibited by upgrading the compressor casing and rotor to 2205 duplex steel material and using thionyl chloride as the special internal liquid spraying medium. A three stage composite sealing structure consisting of front labyrinth, double end dry gas and isolation comb tooth seals was designed to achieve zero leakage of process gas. The industrial operation results of the LG58/0.0 2.0 unit show that under working conditions with wide fluctuations of inlet pressure (0–0.01MPaG) and inlet temperature (−10–10°C), the discharge pressure of the unit remains stable, the outlet temperature can be steadily controlled within 70–75°C, no medium leakage or oil contamination occurs, and the purity of recovered hydrogen chloride products meets process requirements. This complete oil free screw compression solution can provide engineering references for pressurization recovery and equipment selection of strongly corrosive mixed gas in the lithium battery and fluorine chemical industries.

Published in Science Research (Volume 14, Issue 5)
DOI 10.11648/j.sr.20261405.22
Page(s) 350-355
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2026. Published by Science Publishing Group

Keywords

Oil-free Screw Compressor, Hydrogen Chloride Mixed Gas, Gas Compression, Condensation Recovery

1.引言
氯化氢混合气体广泛应用于氟化工、精细化工、多晶硅制备、锂电锂盐合成等工业领域。该混合气体具有强腐蚀性、易水解、忌油污、组分复杂的特性,其压缩技术是化工生产中的核心难点。传统活塞式、喷油螺杆式压缩机存在油品污染介质、密封易失效、设备腐蚀快、故障率高等问题,难以适配氯化氢混合气体的严苛压缩工况。无油工艺螺杆压缩机同时具备容积式和速度式压缩机的特点,具备气流脉动小、运行可靠、耐脏、适应性强、易损件少和维修操作简单等特点,适合中等压力、中大流量、带液、带尘、介质气易聚合的复杂工艺流程。无油螺杆压缩机在炼油和化工领域工艺气工况下得到了广泛的应用。本文以双氟磺酰亚胺锂(LiFSI)合成工艺副产氯化氢尾气为研究对象,借助 PRO II 流程模拟开展压缩 - 冷凝工艺参数优化,选用两级无油螺杆压缩机将尾气增压至 2.0 MPaG,完成工业长周期运行验证,为同类腐蚀性特种气体压缩工程提供设计依据。
2.工艺流程模拟
目前六氟磷酸锂(LiPF6)是商用最成功的电解质锂盐,但其热稳定性和化学稳定性较差,阻碍了其在高动力和高储能电池上的应用。双氟磺酰亚胺锂(LiFSI)具有远好于六氟磷酸锂的物化性能,更好的热稳定性、更好的电导率以及更优的热稳定性,使其成为改善六氟磷酸锂的最佳替代品。双氟磺酰亚胺锂作为充电电池的电解液时,能有效降低在电极板表面上的SEI层在低温下的电阻,降低锂电池在放置过程中的容量损失,从而提高电池容量和电池的化学性能 。双氯磺酰亚胺(HCLSI)作为合成LiFSI的核心中间体,最为成熟的工艺是利用磺酰胺与二氯亚砜、氯磺酸反应得到,该路线操作简单、收率高、纯度好,是目前国内主流的工艺路线。该工艺路线会产生氯化氢、二氧化硫、氯化亚砜等尾气需要进行回收处理,本文选用工业尾气体工艺参数如下表1所示:
表1 尾气组成及参数。

序号

名称

单位

数据

1

温度

°C

0

2

压力

MPaG

0

3

组分

Mol%

HCl (60%), SO2 (35%), SOCL2 (5%)

备注:现场大气压101KPaA。
混合气体压缩冷凝回收的收率与压缩压力、冷凝温度相关,压力越高,饱和蒸气压对应的液化难度越低,越容易冷凝。冷凝温度越低,饱和蒸气压越低,冷凝回收率越高。高压回收压缩机会增加压缩功耗、增加设备投资,降低设备的稳定性。低温回收需要低温冷冻机组或液氮会增加低温制冷功耗及设备投资,同时低温还会造成结霜及冻堵风险。实际应用通常采用中压+冷水冷凝方式,因此需要通过模拟确定压缩压力及冷凝温度。通过PRO II 物流模拟分别考察压缩压力和冷凝温度对回收率的影响,如下表2所示:
表2 冷凝压力与功耗对照表。

序号

冷凝压力/MPaG

冷凝温度/°C

压缩电耗/kWh

循环水/t/h

制冷电耗/kWh

回收率/%

1

0.5

-40

300

32

594

100

2

1.0

-20

400

51

356

100

3

1.5

-10

470

75

206

100

4

2.0

0

521

95

109

100

5

2.5

5

563

112

66

100

由上表2可以看出,压缩压力较低时压缩电耗较小,但是由于尾气液化回收所需冷凝温度较低,制冷剂低温制冷的制冷系数较低,因此制冷耗电量较高,综合运行成本偏高。随着压缩压力提供,压缩机功耗上升,但由于尾气液化所需温度提高,制冷机所需制冷功耗明显降低,整体综合能耗持续降低。当机组的压缩压力升高到2.0 MPaG后,继续升压至2.5MPaG,压缩机增量功耗与制冷电耗减量功耗差值大幅缩小,但高压下设备投资和腐蚀风险同步上升。设备投资、运行能耗、机组防腐难度,采用压缩排气压缩2.0MPaG作为工艺终压。
3.压缩机系统设计
3.1.压缩机结构
无油工艺螺杆压缩机属于容积式压缩机,通过转子与转子之间、转子与壳体之间啮合的过程中容积变化实现气体压缩。压缩机阴、阳转子之间不接触,存在微小间隙,其传动靠后端的同步齿轮实现。无油螺杆压缩机在同步齿轮的带动下,相互啮合做高速转动,连续地“吸入-压缩-排出”气体。无油螺杆压缩机通常采用滚动轴承或滑动轴承,轴承采用润滑油强制润滑,压缩机的工作腔与轴承座由密封装置隔开,用于隔离介质气与润滑油系统,一方面防止介质气漏入润滑油系统破坏润滑油品质,另一方面防止润滑油漏入介质气污染介质气。针对HCl、SO₂混合强腐蚀工况,压缩机壳体及转子材质升级至2205双相钢,大幅降低高温酸性气体的均匀腐蚀与点蚀速率。无油螺杆压缩机结构如下图1所示:
Figure 1. 图1 无油螺杆压缩机结构图。
3.2.压缩工艺流程
无油螺杆压缩机单级压比一般在4~8之间,由于本项目要压缩到2.0MPaG,因此采用两级串联无油螺杆压缩机。两级串联无油螺杆压缩机由一台主电机通过五轴齿轮箱分别拖动一级压缩机和二级压缩机。需要压缩的介质气首先进入一级压缩机压缩,压缩机后的气体经冷却器冷却,再经过分离器分液后进入二级压缩机压缩,二级压缩机出口同样设置冷却器和分离器,用来冷气体却和分离气体中凝液。螺杆压缩机内部喷入液态氯化亚砜完成近似等温压缩,严格控制压缩机出口温度≤85°C,抑制氯化氢高温腐蚀,机组设计参数如下表3所示:
表3 无油螺杆压缩机选型参数。

序号

级数

1级

2级

1

压缩机入口压力(MPaG)

0

-

2

压缩机入口温度(°C)

0

40

3

压缩机出口压力(MPaG)

0.93

2.03

4

压缩机出口温度(°C)

85

85

5

冷却器后压力(MPaG)

0.9

2.0

6

冷却器后温度(°C)

40

40

备注:压缩机内部喷氯化亚砜液体。
无油螺杆压缩机压缩工艺流程如下图2所示:
Figure 2. 图2 压缩系统工艺流程。
3.3.压缩机密封设计
针对腐蚀性气体,单一密封结构容易出现酸洗介质渗透、密封端面容易腐蚀失效的难题。本项目采用前置迷宫密封+双端面干气密封+隔离梳齿密封的三级复合密封结构,前置密封气采用氯化氢气体,可以阻挡机壳内脏的气体窜到干气密封区域,避免污染密封,主密封气采用氮气可以阻挡机壳内脏的气体窜到干气密封区域,隔离气采用氮气主要作用是防止润滑油污染密封端面。干气密封是将开槽密封技术用于气体密封的一种新型轴端密,适用于工艺气不能被污染的场合,可确保压缩过程中工艺气体的绝对纯净。封密封结构示如下图3所示。
Figure 3. 图3 密封系统示意图。
4.现场应用分析
本研究选用LG58/0.0-2.0型两级无油螺杆压缩机,先后完成了空气空载试车、工艺气负荷试车,2023年投入工业化连续运行,目前已累计运行2年。压缩机实际运行参数和设计参数如下表4所示。
表4 设计工况与运行工况对比。

序号

项目

设计工况

运行工况

1

一级入口压力(MPaG)

0

0~0.01

2

一级入口温度(°C)

0

-10~10

3

一级出口压力(MPaG)

0.93

0.92

4

一级出口温度(°C)

85

70~75

5

一级冷却器后压力(MPaG)

0.93

0.9

6

一级冷却器后温度(°C)

40

40

7

一级喷液量(t/h)

3.3

4.5~5.6

8

二级出口压力(MPaG)

2.03

2.03

9

二级出口温度(°C)

85

70~75

10

二级冷却器压力(MPaG)

2.0

2.0

11

冷却器后温度(°C)

40

40

12

二级喷液量(t/h)

1.7

2.2~3.0

由上表4可以看出,压缩机实际入口压力和温度存在大幅波动,但由于无油螺杆压缩属于旋转式容积压缩对工况扰动适应性强适,现场排气压力稳定、运行平稳,无机组振动。现场通过提高氯化亚砜喷液流量,将排气温度由设计 85°C降至 70~75°C,显著降低高温酸性气体对转子、壳体的腐蚀速率,延长设备检修周期。复合密封无介质外漏及润滑油污染,氯化氢回收产品纯度稳定达标,设计完全满足使用需求。
5.结论与展望
本文对氯化氢混合气体压缩回收流程进行了探究、通过 PRO II 流程模拟,设备投资、运行能耗、机组防腐难度,采用压缩排气压缩2.0MPaG作为工艺终压。通过升级压缩机材质,优化复合干气密封系统,匹配氯化亚砜专用喷液介质,解决传统压缩设备腐蚀、故障率高等难点。工业长周期运行验证表明机组工况适应性强,温度、压力波动下运行稳定,低温喷液工艺可有效缓解高温酸性介质腐蚀。随着,国内新能源行业快速发展,锂电池、多晶硅、氟化工、半导体等新型行业对强腐蚀特种气体压缩需求日益增加。本研究无油螺杆压缩成套方案可为同类腐蚀性尾气增压回收工艺改造、新装置设备选型提供成熟工程参考。
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Cite This Article
  • APA Style

    You-cai, W., Chun-cheng, X., Zhou-bo, C., Yi-shi, Z., Lin-rui, W., et al. (2026). Application of Oil-free Screw Compressor in Hydrogen Chloride Mixed Gas Compression. Science Research, 14(5), 350-355. https://doi.org/10.11648/j.sr.20261405.22

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    ACS Style

    You-cai, W.; Chun-cheng, X.; Zhou-bo, C.; Yi-shi, Z.; Lin-rui, W., et al. Application of Oil-free Screw Compressor in Hydrogen Chloride Mixed Gas Compression. Sci. Res. 2026, 14(5), 350-355. doi: 10.11648/j.sr.20261405.22

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    AMA Style

    You-cai W, Chun-cheng X, Zhou-bo C, Yi-shi Z, Lin-rui W, et al. Application of Oil-free Screw Compressor in Hydrogen Chloride Mixed Gas Compression. Sci Res. 2026;14(5):350-355. doi: 10.11648/j.sr.20261405.22

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  • @article{10.11648/j.sr.20261405.22,
      author = {Wang You-cai and Xu Chun-cheng and Cui Zhou-bo and Zhu Yi-shi and Wu Lin-rui and Wang Yao-de and Wang Yan and Gao Wei-kang},
      title = {Application of Oil-free Screw Compressor in Hydrogen Chloride Mixed Gas Compression},
      journal = {Science Research},
      volume = {14},
      number = {5},
      pages = {350-355},
      doi = {10.11648/j.sr.20261405.22},
      url = {https://doi.org/10.11648/j.sr.20261405.22},
      eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.sr.20261405.22},
      abstract = {Aiming at the difficult to recover hydrogen chloride mixed tail gas generated during the production of lithium bis(fluorosulfonyl)imide (LiFSI), the PRO II process simulation software was adopted to optimize the parameters of the compression condensation recovery process in this paper. Considering equipment investment, operating energy consumption and anti corrosion risks comprehensively, the optimal process parameters were determined, with the final compressor pressure of 2.0MPaG and condensation recovery temperature of 0°C. By comparing the advantages and disadvantages of reciprocating compressors and oil injected screw compressors, a two stage series oil free screw compressor was selected as the pressurization equipment. High temperature corrosion caused by acidic gas was inhibited by upgrading the compressor casing and rotor to 2205 duplex steel material and using thionyl chloride as the special internal liquid spraying medium. A three stage composite sealing structure consisting of front labyrinth, double end dry gas and isolation comb tooth seals was designed to achieve zero leakage of process gas. The industrial operation results of the LG58/0.0 2.0 unit show that under working conditions with wide fluctuations of inlet pressure (0–0.01MPaG) and inlet temperature (−10–10°C), the discharge pressure of the unit remains stable, the outlet temperature can be steadily controlled within 70–75°C, no medium leakage or oil contamination occurs, and the purity of recovered hydrogen chloride products meets process requirements. This complete oil free screw compression solution can provide engineering references for pressurization recovery and equipment selection of strongly corrosive mixed gas in the lithium battery and fluorine chemical industries.},
     year = {2026}
    }
    

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  • TY  - JOUR
    T1  - Application of Oil-free Screw Compressor in Hydrogen Chloride Mixed Gas Compression
    AU  - Wang You-cai
    AU  - Xu Chun-cheng
    AU  - Cui Zhou-bo
    AU  - Zhu Yi-shi
    AU  - Wu Lin-rui
    AU  - Wang Yao-de
    AU  - Wang Yan
    AU  - Gao Wei-kang
    Y1  - 2026/09/14
    PY  - 2026
    N1  - https://doi.org/10.11648/j.sr.20261405.22
    DO  - 10.11648/j.sr.20261405.22
    T2  - Science Research
    JF  - Science Research
    JO  - Science Research
    SP  - 350
    EP  - 355
    PB  - Science Publishing Group
    SN  - 2329-0927
    UR  - https://doi.org/10.11648/j.sr.20261405.22
    AB  - Aiming at the difficult to recover hydrogen chloride mixed tail gas generated during the production of lithium bis(fluorosulfonyl)imide (LiFSI), the PRO II process simulation software was adopted to optimize the parameters of the compression condensation recovery process in this paper. Considering equipment investment, operating energy consumption and anti corrosion risks comprehensively, the optimal process parameters were determined, with the final compressor pressure of 2.0MPaG and condensation recovery temperature of 0°C. By comparing the advantages and disadvantages of reciprocating compressors and oil injected screw compressors, a two stage series oil free screw compressor was selected as the pressurization equipment. High temperature corrosion caused by acidic gas was inhibited by upgrading the compressor casing and rotor to 2205 duplex steel material and using thionyl chloride as the special internal liquid spraying medium. A three stage composite sealing structure consisting of front labyrinth, double end dry gas and isolation comb tooth seals was designed to achieve zero leakage of process gas. The industrial operation results of the LG58/0.0 2.0 unit show that under working conditions with wide fluctuations of inlet pressure (0–0.01MPaG) and inlet temperature (−10–10°C), the discharge pressure of the unit remains stable, the outlet temperature can be steadily controlled within 70–75°C, no medium leakage or oil contamination occurs, and the purity of recovered hydrogen chloride products meets process requirements. This complete oil free screw compression solution can provide engineering references for pressurization recovery and equipment selection of strongly corrosive mixed gas in the lithium battery and fluorine chemical industries.
    VL  - 14
    IS  - 5
    ER  - 

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