Interstage Condensation

First-stage compression heats ammonia vapor. Intercooler drops temperature causing partial condensation. Oil carryover from lubricated cylinders mixes with condensate. Second-stage suction separator removes these liquids preventing mechanical damage and maintaining compression efficiency.

Separator Design

Vertical vessel between intercooler and second-stage suction. Gas inlet from cooling, liquid collection zone, mist eliminator, gas outlet to compressor, drain to recovery or disposal, and high-level shutdown. Compact design mounts near compressor suction.

Operating Pressure

Interstage pressure typically 3-8 bar for ammonia refrigeration, higher for synthesis gas compression. Design accommodates pressure between stages. Materials rated for ammonia service at operating temperature and pressure.

Liquid Removal

Condensed ammonia drains for recovery or recycling. Oil separates for disposal or reclamation. Level control manages mixed liquid inventory. High-level protection prevents carryover to second-stage cylinders avoiding catastrophic damage.

Material Selection

Carbon steel or stainless steel construction resists ammonia corrosion. Materials meet refrigeration or industrial ammonia codes. Design handles ammonia phase changes and thermal cycling.

Safety Systems

High and high-high level switches provide alarm and compressor shutdown. Fast-acting valves isolate separator preventing liquid ingestion. Redundant instruments ensure protection. Safety interlocks meet ammonia refrigeration standards.

Applications

Industrial ammonia refrigeration multi-stage compression, ammonia synthesis gas compression, cold storage facility compressors, ice plant refrigeration, and any multi-stage ammonia compression system.

Oil Handling

Lubricated compressors carry oil into discharge gas. Oil accumulates in separators requiring periodic removal. Some systems include oil coalescers. Proper oil management maintains compressor lubrication and prevents contamination.

Performance Benefits

Protects second-stage cylinders from liquid damage. Maintains volumetric efficiency by removing incompressible liquids. Recovers ammonia condensate reducing system losses. Simple proven protection for multi-stage compression.

Maintenance Requirements

Periodic inspection during turnarounds. Oil drainage as needed. Mist eliminator replacement if fouling occurs. Simple maintenance supports continuous refrigeration or synthesis operation.

Construction Standards

Design per ASME Section VIII and IIAR standards for ammonia service. Materials suitable for liquid and vapor ammonia. Relief protection per ammonia codes. Complete documentation with shutdown logic.

ERGIL second-stage suction separators protect ammonia compressors through reliable interstage liquid removal in refrigeration and synthesis applications.