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Driving Expander Technology Atlas Copco Gas and Process Solutions
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Page 1: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

Driving Expander TechnologyAtlas Copco Gas and Process Solutions

Page 2: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

2

Driving Expander Technology

To achieve this goal, we foster innovation and engage in

a close dialogue with our customers early in the design

process. With thousands of our machines in operation

worldwide, we are your ideal partner to drive turboex-

pander technology well into the twenty-first century.

Building Productive Partnerships

When you choose Atlas Copco turboexpanders for your

process, you initiate a continuing partnership that ex-

tends well beyond design, delivery, and installation. From

project initiation through design, delivery, and commis-

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

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

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

customers achieve superior productivity in their processes.

Overview

sioning, total quality management is fundamental to

every Atlas Copco project.

Utilizing our worldwide manufacturing and packaging

facilities, we provide the highest quality in the custom-

engineered turbomachinery world. Even after our ma-

chine is operating in the field, we maintain our commit-

ment 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.

Page 3: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

3

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)

• Hasproducedmorethan600hydrocarbonturbo-

expanderssince1975

• Knownasthepreferredsupplierofhydrocarbon

turboexpanderstotheworldformorethan35years

Exponential Expander Power

Withthe2007acquisitionofMafi-TrenchCorporation(MTC),AtlasCopcoGasandProcessdidmorethanaddto

itsproductportfolio.Together,AtlasCopcoEnergasandAtlasCopcoMafi-TrenchCompanyLLCmeldtheirlong

histories and extensive experience to form the world’s premier turboexpander technology company.

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

Here’s an overview of our turboexpander technology:

Custom-engineered solutions•

Ultra high efficiency•

Robust construction•

Wide operational range•

Highestquality•

Reliable performance•

Thousands of references worldwide•

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

Page 4: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

4

Hydrocarbon

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

your process requirements.”

YourApplication–Hydrocarbon

Expander compressor with a magnetic bearing for a gas processing plant in Saudi Arabia.

Hydrocarbon applications:

LiquefiedPetroleumGas(LPG)•

NaturalGasLiquids(NGL)•

DewPointControl(DPC)•

LiquefiedNaturalGas(LNG)•

-BaseLoad/PeakShaving

- FPSO

- 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 maxi-

mize machinery performance without sacri-

ficing dependability.

Custom-engineered solutions for the hydro-

carbon industry are designed to meet a wide

variety of customer requirements and provide

many years of reliable service.

Page 5: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Page 6: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Air Separation

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

Your Application – Air Separation

Our solutions for the air separation 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 very smooth 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 air separa-

tion process.

Atlas Copco turboexpanders maximize cold power for

your plant, while at the same time providing simple

installation, operation, and maintenance. We also provide

compressors for air separation plants, giving customers a

complete turboexpander solution.

Single-stage ETB 190 NS

Page 7: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Page 8: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

8

Energy Recovery

Your Application – Energy Recovery

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 turbo-

expanders provide reliable solutions that

meet your needs.

HeatRecoveryisanotherenergysource

that can be converted to useful energy by

employing turboexpanders in Organic Rank-

ineCycles(ORC),KalinaCycles,orotherbinarycycles.

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.

Drivenbyourintegral-gearexpertise,ourturboexpanders

can be configured with one to four stages on a single gear-

box to achieve the lowest cost-per-kilowatt power-train

solution.Powergenerationrangesupto15MWperunit.

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

Energy Recovery Applications

Geothermal•

Organic Rankine Cycle•

KalinaCycle•

PressureLetdown•

HeatRecovery•

Cold Energy Recovery•

“Driven by our integral-gear expertise, our turboexpanders are configured to achieve the lowest cost-per-kilowatt solution.”

Page 9: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Page 10: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Chemical / Petrochemical

YourApplication–Chemical/Petrochemical

“We supply turboexpanders for many applications withinthe highly complex and demanding C/PC market.”

Fewermarketsareascomplexaschemical/petrochemical.

The industry’s broad ranges of applications are all cov-

ered by Atlas Copco Gas and Process turboexpanders.

Our key areas of expertise include Ethylene Olefin

Recovery,AmmoniaPurification,CarbonMonoxide

Purification,PropaneDehydrogenation,and

HydrogenRecovery.

Within the realm of oxidation processes

and hot gas applications, Atlas Copco

Gas and Process machinery covers

numerous areas, including Terephtalic

Acid(PTA),Phenol,HydrogenPeroxide,

Ammonia, Nitric Acid, and Caprolactam.

Expander compressor for an olefin petrochemical plant in Qatar.

Page 11: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Page 12: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Technical Features

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

High-Efficiency Impellers - Precisely Meeting Your Needs

Highefficiencyisafundamentalrequirementforall

processes involving turboexpanders. We achieve this

performance through the use the latest technology tools

and a vast experience base.

To ensure top efficiency, we utilize computational fluid

dynamics(CFD)andfiniteelementanalysis(FEA)inthe

designofourimpellers,andthelatest5-axiscomputer

aided manufacturing processes.

As an established turbomachinery manufacturer, we can

choose from a wide variety of proven impeller designs 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.

Expander wheels

Mechanical center section

Inside Our Technology

Page 13: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

13

Impellers undergoing quality check

Page 14: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Technical Features

Variable Inlet Guide Vanes - Achieving Full Control Over Your Processes

To compensate for the varying operating conditions found

in many processes, turboexpanders must deliver efficient

off-design performance.

Atlas Copco turboexpanders use adjustable inlet guide

vanes engineered to produce optimum flow patterns and

provide precise, continuous control across the full range

of operation.

“Our adjustable IGVs are engineered to produce optimum flow patterns and to provide precise control.”

Page 15: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

15

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.

π √

1

C0

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

Page 16: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Technical Features

A combined radial/axial bearing for a hydrocarbon gas expander

Combined radial/ axial bearing for airseparation turbines

A radial bearing for an integrally geared unit

“We offer multiple bearing designs that have a proven operatinghistory for continuous use in diverse applications.”

A magnetic bearing cutaway

Reliable Machinery Operation

We offer multiple bearing designs that have a proven

operating history for continuous use in diverse applica-

tions. Final bearing selections are made specifically for

your process applications. These designs include hydro-

dynamic(bothjournalandtiltpadtypes)andactive

magnetic bearings.

Page 17: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

17

Floating carbon seals Dynamic dry gas seals

Labyrinth seals Oil-lubricated seals

Page 18: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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Technical Features

Configuration Options - Choosing The Right Match

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

DewPointControl

Rated Power:upto22,000kW

Integrally-geared generator loaded expandersConnected to an electric genera-tor through speed reducing gears, Integral-gear technology offers the additional benefit of multi-staging (onetofourstages)forhighefficiency.

Typical Applications:

Energy Recovery

Chemical/Petrochemical

Air Separation

Rated Power:15,000kW

Page 19: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

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

Used for cryogenic applications in low power anges.

Typical Applications:

Air Separation

HycoSyngas(CO2,H2)

Rated Power:250kW

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

Typical Applications:

Air Separation

Energy Recovery

Rated Power:4,000kW

Page 20: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

20

Hyd

roca

rbo

nH

ydro

carb

on

Hyd

roca

rbo

nH

ydro

carb

on

Hydrocarbon Gas ProcessingExpander compressor with a magnetic bearing installed inalargeLNGregasificationterminalinLakeCharles(USA).

Frame/Type:ECM-5.0

Speed:10,900RPM

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

Inlet Pressure: 96.9bar(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:EC-6.0

Speed:9,300RPM

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

Inlet Pressure: 37.5bar(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:ECM-5.0

Speed:13,400RPM

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

Inlet Pressure: 79.6bar(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-boardLNGreliquefactionplant.

Frame/Type:Three-stageGT032N3D0/

Single-stageETG150MS

Inlet Pressure:56.35bar(817psia)

Inlet Temperature:-110°C (-166°F)

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

Expander Cold Production:1,096kW(1,469HP)

Products and Applications at a Glance

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21

En

ergy R

ecovery

En

ergy R

ecovery

En

ergy R

ecovery

En

ergy R

ecovery

Pressure LetdownTurboexpander for a pressure letdown

applicationinHeidelberg(Germany).

Frame/Type:ETG190MS-2

Inlet Pressure:45bar(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

apressureletdownapplicationfortheMiddleEast.

Frame/Type:Two-stageETG360MS-2

Inlet Pressure:50bar(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(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(740psia)

Inlet Temperature:170°C (338°F)

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

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

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22

Ch

emic

al /

Pet

roch

emic

alC

hem

ical

/ P

etro

chem

ical

Fertilizer ProductionExpander generator for an ammonia fertilizer plant

in Australia.

Frame/Type:EG-6.0

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

Speed: 3,000RPM

Inlet Temperature:-129°C (-200.2°F)

Inlet Pressure: 34.5bar(501psia)

PetrochemicalExpander compressor with magnetic bearing for a

petrochemical plant in Saudi Arabia.

Frame/Type:ECM-4.0

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

Speed:13,000RPM

Inlet Temperature:-102°C (-151.6°F)

Inlet Pressure: 14.9bar(216psia)

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

Air

Sep

arat

ion

Air

Sep

arat

ion

Air SeparationIntegrally-geared generator-loaded turboexpander

installed in an air separation plant in the Netherlands.

Frame/Type: Two-stageETB560NS-2

Inlet Pressure: 2.8bar(41psia)

Inlet Temperature:-90°C (-130°F)

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

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

Air SeparationCompressor-loaded turboexpander installed in an

air separation plant in Chile.

Frame/Type: Single-stageETB190NS

Inlet Pressure: 7.3bar(106psia)

Inlet Temperature:-120.7°C (-184°F)

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

Cold Production: 207kW(278HP)

Products and Applications at a Glance

Page 23: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

23

ETB EC ECM ETG EG ETF EHB

Expander withBooster Compressor

ExpanderGenerator

ExpanderHydraulic Braked

HydrocarbonLPG / NGL Recovery

Gas Processing

Gas Treatment

Dew Point Control

Floating LNG FPSO

LNG Reliquefaction (Nitrogen Brayton Cycle)

LNG Liquefaction

LNG Peak Shaving

Energy RecoveryPipeline (Pressure Letdown)GeothermalHeat RecoveryCold Energy Recovery

Chemical/Petrochemical Gas AromaticsInorganicRefineriesGas to Liquid

Air SeparationCryogenic expansionSteelElectronicsGTL/Syngas

Our Product for Your Market

TurboexpanderMatrix

Page 24: Atlas Copco Gas and Process Solutions Driving Expander ... · tail gas from industrial furnaces or combustion engines, ... box to achieve the lowest cost-per-kilowatt power-train

Gas and Process DivisionOur points of contact worldwide

© A

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Cop

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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 Bierwirth (Energas)Phone: +49 2236 96 50 658Fax: +49 2236 96 50 [email protected]

The Americas Nasser Sadeghzadeh (Comptec)Phone: +1 518 765 58 38Fax: +1 518 765 33 [email protected]

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

Far EastSander van Spijk (Shanghai)Phone: +86 21 220 848 58Fax: +86 21 621 519 [email protected]

India S.S. Vasan (Pune)Phone: +91 20 39 85 23 09Fax: +91 20 27 14 59 [email protected]

Regional OfficesGermany Ralf Kiefer (North)Phone: +49 2227 90 99 920Fax +49 2227 90 99 [email protected]

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

United StatesTim Shaw (Southwest)Phone: +1 281 216 60 10Fax: +1 281 984 74 [email protected]

John Peranteaux (West Coast)Phone: +1 805 928 57 57 ext. 4125Fax: +1 805 925 38 [email protected]

Bruce Edstrand (North Central / Northeast)Phone: +1 847 726 98 [email protected]

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

CanadaTushar Patel (Western Canada)Phone: +1 403 259 60 69 Fax: +1 403 253 34 [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 33 299 95 05Fax: +31 33 299 95 [email protected]

BrazilRoberto G. BeckerPhone: +55 11 34 78 87 11 Fax: +55 11 41 95 70 90 [email protected]

FrancePatrick CoupelPhone: +33 1 39 09 31 60Fax: +33 1 39 09 30 [email protected]

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

IranAli Rakhshani MoghaddamPhone: +98 21 66 93 77 11 322Fax: +98 21 66 92 73 [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: +966 3 88 24 440 ext. 305Fax: +966 3 88 27 [email protected]

NordicHeikki AlankoPhone: +358 8 51 67 64Fax: +358 8 51 58 [email protected]

RussiaPeter KrausPhone: +7 495 933 55 50 ext. 15 99Fax: +7 495 933 12 [email protected]

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

South KoreaSeungHoon YangPhone: +82 2 21 89 40 80Fax: +82 2 522 19 [email protected]

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

SpainRafael CañetePhone: +34 91 627 91 00Fax: +34 91 627 91 [email protected]


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