Performance analysis of a hyper-compressor for vinyl acetate and ethylene mixture using real-fluid properties

The ethylene and vinyl acetate (VA) mixture must be compressed to a high pressure of over 100 MPa in a hyper-compressor system to initiate the polymerization. This paper presents a numerical and experimental investigation into the effects of VA concentration on the performance of a hyper-compressor. To this end, an equation of state in the form of Helmholtz free energy was developed to calculate the real thermodynamic properties of VA–ethylene mixture. The average absolute deviations of density and compressibility factor for VA-ethylene compared with experimental values were 1.82% and 1.46%, respectively. Additionally, a three-dimensional (3D) computational fluid dynamics (CFD) model was constructed considering real-fluid thermodynamics, incorporating the motion of the central valve and upstream and downstream pressure pulsations. The predicted [Formula: see text] diagram and pressure pulsation were compared with experimental data to validate the accuracy of the 3D-CFD model. The results demonstrated that a higher VA weight fraction results in a shorter expansion and compression phase; higher indicated power, suction, and discharge losses; and greater pressure fluctuation. The increment of power loss during the discharge process accounted for 73.27% of the indicated power growth 35.96 kW as the VA weight fraction increased from 0% to 40%. The increment of pressure pulsation in the suction and discharge pipe were mainly attributed to high-frequency pulsations above 10 orders and low-frequency pulsations below 10 orders, respectively.