Effectively eliminate emissions from reciprocating compressors in stand-by mode

HOERBIGER supports the energy industry with innovative solutions to maximize reliability, save energy and reduce emissions – for a better tomorrow. Reciprocating compressors are potential sources of emissions, including fugitive emissions from seal leaks that occur during operation and when a pressurized compressor is on stand-by. This is precisely where the new EmissionShield Static Rod Sealing System, the latest emissions product from HOERBIGER, comes in. EmissionShield eliminates packing case-related emissions from compressors during stand-by.

Conventional rod seals and packing cases are designed to seal gas inside the compressor during operation, but in standby mode, conventional packing will allow pressurized gas to escape from the compressor. According to the Environmental Protection Agency, the average internal compressor volume is approximetly 15 Mcf – the same amount of gas that can potentially leak into the atmosphere during each compressor stop. As a result, these pressurized stand-by occurrances are a serious environmental problem, and also result in a loss of potential revenue for the customer.

Effectively eliminate emissions
With EmissionShield, these emissions are effectively eliminated because this new solution has been specifically developed to seal the compression chamber along the piston rod from the outside environment when the compressor is not in operation (when it is in stand-by mode). The gas-tight packing case design eliminates cup-to-cup leakage, allowing the compressor cylinders to remain pressurized indefinitely. As a result, emissions are significantly reduced as the compressor can be utilized intermittently or kept on hot stand-by when needed, with virtually zero gas loss.

"After activation, the EmissionShield system completely eliminates rod packing leakages," says Hervé Ferraris, Global Product Manager for Rings and Packing at HOERBIGER. "Our extensive field tests have shown that vent flows from the packing, continuously monitored, remained at a consistent zero throughout the compressors' standstill periods. The longest stand-by period recorded was 37 days."

Rugged and reliable, with minimal required maintenance
Overall, the system is much more reliable than conventional stand-by seals as it has no moving parts or mechanical components inside the packing case or in contact with the piston rod. Its rugged design is not impacted by dirt entering the packing housing, and it will not wear out while the compressor is running. Extensive laboratory tests have shown that the Stand-by Seal Packing Ring (SBS) installed in  this system can easily withstand frequent start-stop cycles without any problems – maximizing both reliability and efficiency.

Quick and cost-effective installation, operation and maintenance
EmissionShield is easy to install, easy to operate, and easy to maintain – the system's simple plug-and-play design reduces installation costs and time compared to other solutions available today. Its rugged design also makes it ideal for a wide range of compressor types and environments, without compromising safety.

“The EmissionShield was developed in response to our customers' need to run their compressors without producing fugitive emissions while idle. This reliable and efficient solution is a major step forward in our goal to make reciprocating compressors almost free of fugitive emissions,” says Alejandro Barrios, Head of Emissions Business Center NAM.

About HOERBIGER
Locally close to our customers – globally successful: HOERBIGER is active worldwide in 43 countries on all continents. 6,174 employees at 133 locations – including 30 production plants – deliver reliable solutions for better performance, increased safety, and fewer emissions. In 2023, they generated sales of 1.416 billion euros. For renowned customers from the energy sector, the process industry, the automotive industry, the mechanical engineering industry, safety technology, and the electronics industry, performance-determining products, and services from HOERBIGER make the difference. With innovations for decarbonization and energy transition, HOERBIGER is already enabling change today for a better tomorrow. As majority shareholder, the HOERBIGER Foundation preserves the 129-year-old entrepreneurial heritage and guarantees stability, independence, and a future-oriented strategy.