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ATLAS COPCO Catalog

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Atlas Copco Gas and Process Solutions Driving Expander Technology
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Page 1: ATLAS COPCO Catalog

Atlas Copco Gas and Process Solutions

Driving Expander Technology

Page 2: ATLAS COPCO Catalog

2

To achieve this goal, we foster innovation and engage

in a close dialog with our customers early in the

design process. With thousands of our machines in

operation worldwide, we are your ideal partner to drive

turboexpander technology further.

Building Productive Partnerships

When you choose Atlas Copco turboexpanders for

your process, you initiate a continuing partnership that

extends well beyond design, delivery, and installation.

From project initiation through design, delivery, and

commissioning, total quality management is fundamental

to every Atlas Copco project.

Atlas Copco Gas and Process is continuously working to improve and extend

the capabilities and performance of radial in-flow turbines, or turboexpanders.

As a market leader for this technology, we see it as our responsibility to help

our customers achieve superior productivity in their processes.

Overview

Utilizing our worldwide manufacturing and packaging

facilities, we provide the highest quality in the custom-

engineered turbomachinery world.

Even after our machine is operating in the field, we

maintain our commitment to this partnership: through the

support provided by Atlas Copco’s global sales engineers,

and the facilities and personnel of Atlas Copco service

centers. These centers offer timely support for scheduled

and emergency services, 24 hours a day.

Driving Expander Technology

Page 3: ATLAS COPCO Catalog

3

Exponential Expander Power

Even years after the acquisition of Mafi-Trench Corporation (MTC), Atlas Copco Gas and Process is proving time

and again that it is one of the world’s premier turboexpander technology companies.

Here’s a look at the two companies’ histories and pedigree:

Here’s an overview of our

turboexpander technology:• Custom-engineered solutions

designed to fit your application

• High efficiency

• Robust construction

• Wide operational range

• Highest quality

• Reliable performance

• Thousands of references worldwide

”We foster innovation and engage in a close dialog with our customers to achieve sustainable productivity.”

Atlas Copo Energas

• LocatedinCologne(Germany)

• Beganin1936astheKTDivisionofLindeAG

• Hasdesigned,manufactured,andcommissioned

thousands of turboexpanders

• Marketleaderinturboexpandertechnology,

especially in air separation and integrally-geared

applications

Atlas Copco Mafi-Trench Company LLC

• LocatedinSantaMaria(USA)

• Hasproducedmorethan700hydrocarbon

turboexpanderssince1975

• Knownasthepreferredsupplierofhydrocarbon

turboexpanderstotheworldformorethan35years

• Globalleaderinlargesingle-stage

high-horsepower applications

Page 4: ATLAS COPCO Catalog

4

Industrial Gases

Your Application

Our solutions for the industrial-gas market are designed

with increased customer value in mind. Compact

and highly efficient designs provide our customers with

advantages in their process operations.

Our expander design is simple and provides even and

efficient air inlet and outlet. Furthermore, innovative

insulation is employed at the expander casing and various

other locations within the machine, achieving optimal

results.

We were, after all, the first expander manufacturer that

successfully employed dry-gas seals in cryogenic

applications. In the bigger picture, our solutions help

generate superior cooling capacity in cryogenic

processes and subsequently a greater product yield

in your industrial-gas process.

Atlas Copco turboexpanders maximize cold power

for your plant and are simple to install, operate,

and maintain. We also provide compressors for

air-separation plants, giving customers a complete

turboexpander solution.

Single-stage ETB 190 NS

“The highly efficient Atlas Copco turboexpanders minimize energy consumption.”

In the industrial-gas industry, efficiency is key. Our expanders boost

productivity and maximize cold power for your plant.

Page 5: ATLAS COPCO Catalog

5

Your Application

Page 6: ATLAS COPCO Catalog

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Oil and Gas

Your Application

Expander compressor with magnetic bearings for a gas-processing plant in Saudi Arabia

Hydrocarbon applications:• LiquefiedPetroleumGas(LPG)

• NaturalGasLiquids(NGL)

• Dew-pointControl(DPC)

• LiquefiedNaturalGas(LNG)

-Baseload/peakshaving

-FPSO–FLNG

- Regasification

• Nitrogen rejection

In the oil and gas business, performance and reliability

are the name of the game. That’s why all of our solutions

are created to ensure the highest reliability and satisfy

your requirements. Incorporating the latest technology, our

aerodynamic designs maximize machinery performance

without sacrificing dependability.

Custom-engineered solutions for the oil and gas

industry are designed to meet a wide variety of customer

requirements and provide many years of reliable service.

”When you choose Atlas Copco Gas and Process, you choose technology solutions that satisfy

your process requirements.”

Our expanders offer a host of reliable solutions

that support every link in the hydrocarbon value chain.

Page 7: ATLAS COPCO Catalog

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Your Application

(Photo: Kjetil Alsvik – Statoil)

Page 8: ATLAS COPCO Catalog

8

Chemical / Petrochemical

Your Application

“We supply turboexpanders for many applications within the highly complex and demanding chemical / petrochemical market.”

Fewmarketsareascomplexaschemical/petrochemical.

The industry’s broad range of applications is covered by

Atlas Copco Gas and Process turboexpanders.

Our key areas of expertise include ethylene-olefin

recovery, ammonia purification, carbon-monoxide

purification, propane dehydrogenation, and hydrogen

recovery.

Expander compressor for an olefin petrochemical plant in Qatar

Within the realm of oxidation processes and hot gas

applications, Atlas Copco Gas and Process machinery

covers numerous areas, including terephtalic acid (PTA),

phenol, hydrogen peroxide, ammonia, nitric acid, and

caprolactam.

In this complex sector, reliability and safety are more crucial than ever.

Our expanders help you meet every challenge.

Page 9: ATLAS COPCO Catalog

9

Your Application

(Photo: The Linde Group)

Page 10: ATLAS COPCO Catalog

10

Energy Recovery

Your Application

For many years, Atlas Copco Gas and Process has

helped customers around the world in unlocking the

vast potential of renewable-energy sources. Whether

you want to produce electricity from a geothermal

resource or recover power in a pressure-letdown

application, Atlas Copco turboexpanders provide

reliable solutions that meet your needs.

Waste heat is an often-untapped energy source that

can be converted to useful electric energy using

turboexpanders in closed-loop conversion cycles

such as the Organic Rankine Cycle (ORC).

Potential heat sources to drive this application include

tail gas from industrial furnaces or combustion engines,

waste vapor from chemical and petrochemical processes,

gas turbine exhaust, and solar heat from flat or parabolic

reflectors.

Expander generator for a geothermal power plant in Nevada (USA)

Energy Recovery Applications:• Geothermal

• Organic Rankine Cycle

• KalinaCycle®

• Pressure letdown

• Heat recovery

• Waste-heat recovery

Drivenbyourintegral-gearexpertise,ourturboexpanders

can be configured with one to four stages on a single

gearbox to achieve the lowest cost-per-kilowatt

power-train solution. Power generation reaches up to

25MWperunit.

“Driven by our integral-gear expertise, our turboexpanders are configured to achieve

the lowest cost-per-kilowatt solution.”

Renewable energy is gaining traction across the world.

Our innovative expanders make your plant fit for the future.

Page 11: ATLAS COPCO Catalog

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Your Application

Page 12: ATLAS COPCO Catalog

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Technical Features

“To ensure top efficiency, we use CFD and FEA in impeller design.”

Expander impeller Mechanical center section

High efficiency is a fundamental requirement for all

processes involving turboexpanders. We achieve this

performance through the use of the latest technology

tools and a vast experience base.

Precision That Meets Your Needs

To ensure top efficiency, we utilize computational-fluid

dynamics(CFD)andfinite-elementanalysis(FEA)

inthedesignofourimpellers,andthelatest5-axis

computer-aided manufacturing processes.

As an established turbomachinery manufacturer, we can

choose from a wide variety of proven impeller designs

in our data base to precisely match your process

needs. This combination of experience and technology

ensures that our customers receive maximum efficiency

and the most reliable impellers available in the industry.

Our impeller designs are the most reliable in the industry

and meet a wide range of process requirements.

High-Efficiency Impellers

Page 13: ATLAS COPCO Catalog

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Impellers undergoing a quality check

Page 14: ATLAS COPCO Catalog

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1

0

v =

Velocity ratio v

0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.901.00.90.80.70.60.50.40.30.20.1

0

Flow rate V [%]

Effic

ienc

y

rela

ted

to

max

ii

i

i max 0 20 40 60 80 100 120 140 160 180

i

i max = f (V)i

i max = f (U/C0)

To compensate for the varying operating conditions found

in many processes, turboexpanders must deliver efficient

off-design performance.

Atlas Copco turboexpanders use variable inlet-guide

vanes (IGVs) engineered to produce optimum flow

patterns and provide precise, continuous control across

the full range of operation.

Full Control Over Your Process

Apart from an optimal control range and excellent

efficiency for all parts, our IGVs feature a wide

range of regulation capabilities and excellent partial

performance. Combined configuration ensures

maximum control flexibility.

Technical Features

Variable Inlet-Guide VanesOur inlet-guide vanes adjust to changing process conditions

to maximize expander efficiency.

The typically flat turboexpander efficiency characteristic with various flow rates is illustrated here. Efficiency vs. the velocity ratio v (ratio tip speed to spouting velocity) is also shown.

“Atlas Copco turboexpanders use variable inlet-guide vanes to provide optimum flow patterns and precise, continuous control across the full range of operation.”

Page 15: ATLAS COPCO Catalog

15

Variable inlet-guide vanes

Page 16: ATLAS COPCO Catalog

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Combined radial / axial bearing for a hydrocarbon gas expander

Combined radial / axial bearing for air-separation turbines

Radial bearing for an integrally-geared unit

Technical Features

Active Magnetic Bearings

Bearing SystemsWe offer multiple bearing designs that have a proven operating history for

reliable, continuous use in diverse applications.

Oil Bearings

We offer horizontally-split, high-speed pinion bearings

featuring five self-centering pads that ensure stable

rotation. Horizontally-split bearings are especially easy

to inspect and maintain.

Tilting-pad bearings, which are used on high-speed shafts,

and sleeve bearings, used on low-speed shafts, ensure

reliable performance, efficiency, and optimal speeds for

each process.

Active Magnetic Bearings

Atlas Copco also offers designs using active magnetic

bearings. Active Magnetic Bearings generate a magnetic

field to align the shaft in its centerline. This eliminates

friction and the need of lubrication. The electromagnets

of Active Magnetic Bearings are controlled with rotor

position sensors by a digital control cabinet.

The resulting combination of lower maintenance, higher

reliability, and increased durability boosts equipment

performance. Our dedicated service team supports

customers at every step, before and after installation.

Atlas Copco Gas and Process bearing designs include

hydrodynamic bearings as well as Active Magnetic

Bearings.Finalbearingselectionsaremadespecifically

for your process applications.

Page 17: ATLAS COPCO Catalog

1717

Shaft Seals

Floating carbon seals

Dynamic dry-gas seals Labyrinth seals

Oil-lubricated seals

Our uniquely tailored shaft-seal solutions ensure maximum efficiency

and prevent gas leakage and air intrusion – even in volatile environments.

Page 18: ATLAS COPCO Catalog

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Our turboexpander configurations provide

the right match for your application.

Technical Features

Atlas Copco Gas and Process turboexpanders are offered in compressor-loaded,

generator-loaded, and hydraulic brake-loaded configurations to accommodate

specific applications. In most cases, the turboexpander is skid-mounted with its

auxiliary support system to simplify transport and help reduce installation costs.

Compressor-loaded expandersExpander is loaded by a single- stage centrifugal compressor through a common shaft.

Typical applications:

Air separation

Ethylene/olefinrecovery

LPG/NGLrecovery

Dew-pointcontrol

Rated power:upto22,000kW

Integrally-geared generator-loaded expandersConnected to an electric generator through speed-reducing gears, integral-gear technology offers the additional benefit of multi-staging (one to four stages) for high efficiency.

Typical applications:

Energy recovery

Chemical/petrochemical

Air separation

Rated power:25,000kW

Configuration Options

Page 19: ATLAS COPCO Catalog

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Generator-loaded expandersExpander stage connected to an electric generator through an epicyclic gear.

Typical applications:

Air separation

Energy recovery

Rated power:4,000kW

Hydraulic-braked expandersExpander is braked by the presence of oil in the chambers surrounding the rotor shaft.

Used for cryogenic applications in low power ranges.

Typical applications:

Air separation

HyCo Syngas (CO2, H2)

Rated power:250kW

Page 20: ATLAS COPCO Catalog

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Products and Applications at a Glance

Hydrocarbon Gas ProcessingExpander compressor with a magnetic bearing installed inalargeLNG-regasificationterminalinLakeCharles(USA).

Frame / type:Single-stageECM-5.0

Speed:10,900RPM

Flow: 461,984kg/hr(1,018,500lb/hr)

Inlet pressure: 96.9bar(a)(1,405psia)

Inlet temperature:-27°C(-16.6°F)

Power: 7,303kW(9,794HP)

Hydrocarbon Gas ProcessingExpander compressor for gas processing installed in Thailand.

Frame / type:Single-stageEC-6.0

Speed:9,300RPM

Flow: 388,275kg/hr(856,000lb/hr)

Inlet pressure: 37.5bar(a)(544psia)

Inlet temperature:-49°C (-56.2°F)

Power: 7,860kW(10,540HP)

Hydrocarbon Gas ProcessingExpander compressor for gas processing installed in Nigeria.

Frame / type:Single-stageEC-5.0

Speed:13,400RPM

Flow: 367,863kg/hr(811,000lb/hr)

Inlet pressure: 79.6bar(a)(1,155psia)

Inlet temperature:-18°C (-0.40°F)

Power: 8,936kW(11,983HP)

Liquefied Natural Gas (LNG) The compander’s expander stage is an essential componentinanon-boardLNG-reliquefactionplant.

Frame / type:Three-stageGT032N3D0/

Single-stageETG150MS

Flow:94,375Nm3/hr(58,723scfm)

Inlet pressure:56.35bar(a)(817psia)

Inlet temperature:-110°C (-166°F)

Expander cold production:1,096kW(1,469HP)

Oil

and

Gas

Oil

and

Gas

Oil

and

Gas

Oil

and

Gas

Page 21: ATLAS COPCO Catalog

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Products and Applications at a Glance

Pressure LetdownTurboexpander for a pressure letdown application in Heidelberg (Germany).

Frame/Type:ETG190MS-2

Inlet Pressure:45bar(a)(653psia)

Inlet Temperature:75°C(167°F)

Flow:45,000Nm3/hr(28,000scfm)

Fluid: CH4

Recovered Power:2,530kW(3,391HP)

Pressure LetdownIntegrally-geared generator-loaded turboexpander in a pressure-letdown application for the Middle East.

Frame/Type:Two-stageETG360MS-2

Inlet Pressure:50bar(a)(725psia)

Inlet Temperature:125°C (257°F)

Flow:165,000Nm3/hr(102,668scfm)

Recovered Power:9,488kW(12,718HP)

Geothermal PowerSingle-stage integrally-geared generator-loaded turboexpander in a geothermal ORC application in Nevada (USA).

Frame/Type: Single-stage EGI-8

Inlet Pressure: 31.4bar(a)(455psia)

Inlet Temperature: 127°C(260.6°F)

Flow: 707,604kg/hr(1,560,000lb/hr)

Fluid: Isobutane

Recovered Power: 14,541kW(19,500HP)

Pressure LetdownIntegrally-geared generator-loaded turboexpander in a pressure-letdown application in Italy.

Frame/Type: Three-stageETG190MS-3

Inlet pressure: 51bar(a)(740psia)

Inlet Temperature:170°C (338 °F)

Flow: 60,582Nm3/hr(37,699scfm)

Recovered Power: 4,526kW(6,070HP)

En

ergy Recovery

En

ergy Recovery

En

ergy Recovery

En

ergy Recovery

Page 22: ATLAS COPCO Catalog

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Products and Applications at a Glance

Fertilizer ProductionExpander generator for an ammonia-fertilizer plant in Australia.

Frame / type:Single-stageEG-6.0

Flow:141,974kg/hr(313,000lb/hr)

Speed: 3,000RPM

Inlet temperature:-129°C (-200.2°F)

Inlet pressure: 34.5bar(a)(501psia)

Power: 634kW(850HP)

PetrochemicalExpander compressor with magnetic bearing for a petrochemical plant in Saudi Arabia.

Frame / type:Single-stageECM-4.0

Flow: 54,975kg/hr(121,200lb/hr)

Speed:13,000RPM

Inlet temperature:-102°C (-151.6°F)

Inlet pressure: 14.9bar(a)(216psia)

Power: 1,161kW(1,557HP)

Industrial GasesIntegrally-geared generator-loaded turboexpander installed in an air-separation plant in the Netherlands.

Frame / type: Two-stageETB560NS-2

Inlet pressure: 2.8bar(a)(41psia)

Inlet temperature:-90°C (-130°F)

Flow:55,593Nm3/hr(34,590scfm)

Cold production: 1,280kW(1,717HP)

Industrial GasesCompressor-loaded turboexpander installed in an air-separation plant in Chile.

Frame / type: Single-stageETB190NS

Inlet pressure: 7.3bar(a)(106psia)

Inlet temperature:-120.7°C (-184°F)

Flow:11,300Nm3/hr(7,030scfm)

Cold production: 207kW(278HP)

Oil

and

Gas

Oil

and

Gas

Ind

ust

rial

Gas

esIn

du

stri

al G

ases

Page 23: ATLAS COPCO Catalog

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Products and Applications at a Glance

Our Product for Your MarketExpander with

Booster CompressorIndustryExpanderGenerator

ExpanderHydraulic Braked

Oil and GasLPG / NGL recovery

Gas processing

Gas treatment

Dew-point control

Floating LNG FPSO

LNG reliquefaction (nitrogen brayton cycle)

LNG liquefaction

LNG peak shaving

Gas aromaticsInorganicRefineriesGas to Liquid

Energy RecoveryPipeline (pressure letdown)GeothermalHeat recoveryCold energy recovery

Industrial GasesCryogenic expansionSteelElectronicsGTL / Syngas

ETB EC ECM ETG EG ETF EHB

Page 24: ATLAS COPCO Catalog

Gas and Process DivisionOur points of contact worldwide

© A

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HeadquartersAtlas Copco Energas GmbHSchlehenweg 1550999 Cologne, GermanyPhone: +49 2236 96 50 0Fax: +49 2236 96 50 [email protected]

Application CentersEurope Thomas BierwirthPhone: +49 2236 96 50 658Fax: +49 2236 96 50 [email protected]

The Americas David A. Smith (Compressors)Phone: +1 518 765 58 28Fax: +1 518 765 33 [email protected]

Randy Dirlam (Expanders)Phone: +1 805 928 57 57 ext. 4139Fax: +1 805 925 38 [email protected]

Michael Tanamachi (Pumps)Phone: +1 949 764 2227Fax: +1 949 548 [email protected]

ChinaSander van SpijkPhone: +86 21 6097 8198Fax: +86 21 6097 [email protected]

India S.S. Vasan Phone: +91 20 39 85 70 80Fax: +91 20 39 85 71 [email protected]

Regional OfficesGermany Ralf Kiefer (North / Central and Southwest)Phone: +49 2235 4639 272 Fax +49 2235 4639 [email protected]

Jörg Wieczorek (Southeast)Phone: +49 89 74 99 49 70 Fax: +49 89 74 99 49 80 [email protected]

North AmericaBart Woodmansee (Northeast / Eastern Canada)Phone: +1 860 477 02 96Fax: +1 860 477 04 [email protected]

Bruce Edstrand (North Central / West Coast / Western Canada)Phone: +1 847 726 98 [email protected]

Tushar Patel (Southeast)Phone: +1 281 261 01 80 Fax: +1 281 208 51 08 [email protected]

South AmericaAndré BrandãoPhone: +55 21 21 56 84 28Fax: +55 11 41 95 70 90 [email protected]

ChinaNick He (Hangzhou)Phone: +86 57 12 80 02 077Fax: +86 57 12 80 02 [email protected]

Yi-Fu (Jerry) Zhang (Beijing)Phone: +86 10 65 28 05 17Fax: +86 10 65 28 05 [email protected]

Customer CentersAlpinePeter von GraffenriedPhone: +41 61 731 37 00Fax: +41 61 733 94 [email protected]

BeneluxJan HopPhone: +31 64 620 37 30Fax: +31 33 299 95 [email protected]

FrancePascal CollinPhone: +33 01 39 09 31 60Fax: +33 06 30 11 72 [email protected]

Great Britain/NordicIan MatherPhone: +44 1442 22 23 35Fax: +44 2074 92 37 [email protected]

ItalyGianfranco MarinelliPhone: +39 02 61 79 94 50Fax: +39 02 66 01 18 [email protected]

JapanMichael Shafer Phone: +81 3 57 65 70 39 Fax: +81 3 57 65 31 97 [email protected]

Middle East/North AfricaSami TabazaPhone: +971 5 044 38 117Fax: +971 4 88 61 [email protected]

RussiaHenning StruckPhone: +7 495 933 55 50 ext. 1904 Fax: +7 495 933 55 60 [email protected]

South AfricaWayne JacobsPhone: +27 11 821 90 00Fax: +27 11 388 32 [email protected]

South KoreaYunwon Lee Phone: +82 2 2189 4081Fax: +82 2 522 [email protected]

Southeast Asia/OceaniaUlrich SchmitzPhone: +65 62 10 80 44Fax: +65 68 62 56 [email protected]

SpainRafael CañetePhone: +34 91 627 91 [email protected]

TurkeyYüksel IsiltanPhone: +90 216 581 05 81Fax: +90 216 581 04 [email protected]


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