Atlas Copco Gas and Process Solutions

Driving Expander Technology

Overview

Driving Expander Technology
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.
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 turboexpander technology well into the twenty-first century. Utilizing our worldwide manufacturing and packaging facilities, we provide the highest quality in the customengineered turbomachinery world. Even after our machine is operating in the field, we maintain our commitsioning, total quality management is fundamental to every Atlas Copco project.

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 commis-

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.

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” 3 . especially in air separation and integrally-geared applications Atlas Copco Mafi-Trench Company LLC • Located in Santa Maria (USA) • Has produced more than 600 hydrocarbon turbo expanders since 1975 • Known as the preferred supplier of hydrocarbon turboexpanders to the world for more than 35 years ”We foster innovation and engage in a close dialogue with our customers to achieve superior productivity. Here’s a look at the two companies’ history and pedigree: Atlas Copo Energas • Located in Cologne (Germany) • Began in 1936 as the KT Division of Linde AG • Has designed. Atlas Copco Energas and Atlas Copco Mafi-Trench Company LLC meld their long histories and extensive experience to form the world’s premier turboexpander technology company. manufactured. Together. and commissioned thousands of turboexpanders • Market leader in turboexpander technology.Here’s an overview of our turboexpander technology: • Custom-engineered solutions • Ultra high efficiency • Robust construction • Wide operational range • Highest quality • Reliable performance • Thousands of references worldwide Exponential Expander Power With the 2007 acquisition of Mafi-Trench Corporation (MTC). Atlas Copco Gas and Process did more than add to its product portfolio.

Custom-engineered solutions for the hydrocarbon industry are designed to meet a wide variety of customer requirements and provide many years of reliable service. That’s why all of our solutions are created to ensure the highest reliability and satisfy your requirements. Expander compressor with a magnetic bearing for a gas processing plant in Saudi Arabia.FPSO .Your Application – Hydrocarbon Hydrocarbon In the oil and gas business. Hydrocarbon applications: • Liquefied Petroleum Gas (LPG) • Natural Gas Liquids (NGL) • Dew Point Control (DPC) • Liquefied Natural Gas (LNG) - Base Load/Peak Shaving . Incorporating the latest technology.” 4 .Regasification • Nitrogen Rejection ”When you choose Atlas Copco Gas and Process. our aerodynamic designs maximize machinery performance without sacrificing dependability. you are choosing technology solutions that satisfy your process requirements. performance and reliability are the name of the game.

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Furthermore. while at the same time providing simple installation.Your Application – Air Separation Air Separation Our solutions for the air separation market are designed with increased customer value in mind. and maintenance. operation. Single-stage ETB 190 NS Atlas Copco turboexpanders maximize cold power for your plant. the first expander manufacturer that successfully employed dry gas seals in cryogenic applications. our solutions help generate superior cooling capacity in cryogenic processes and subsequently a greater product yield in your air separation process.” 6 . Our expander design is simple and provides very smooth air inlet and outlet. We also provide compressors for air separation plants. giving customers a complete turboexpander solution. In the bigger picture. Compact and highly efficient designs provide our customers with advantages in their process operations. We were. “The highly-efficient Atlas Copco turboexpanders minimize energy consumption. innovative insulation is employed at the expander casing and various other locations within the machine. after all. achieving optimal results.

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Potential heat sources to drive this application include tail gas from industrial furnaces or combustion engines. and solar heat from flat or parabolic reflectors. Driven by our integral-gear expertise. or other binary cycles. gas turbine exhaust. Heat Recovery is another energy source that can be converted to useful energy by employing turboexpanders in Organic Rankine Cycles (ORC). Atlas Copco turboexpanders provide reliable solutions that meet your needs. our turboexpanders are configured to achieve the lowest cost-per-kilowatt solution. or recover power in a pressure letdown application. Whether you want to produce electricity from a geothermal resource.Your Application – Energy Recovery Energy Recovery For many years. our turboexpanders can be configured with one to four stages on a single gearbox to achieve the lowest cost-per-kilowatt power-train solution. Atlas Copco Gas and Process has helped customers around the world in unlocking the vast potential of renewable energy sources.” 8 . waste vapor from chemical and petrochemical processes. Power generation ranges up to 15 MW per unit. Kalina Cycles. Energy Recovery Applications • Geothermal • Organic Rankine Cycle • Kalina Cycle • Pressure Letdown • Heat Recovery • Cold Energy Recovery Expander generator for a geothermal power plant in Nevada (USA) “Driven by our integral-gear expertise.

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and Caprolactam. Atlas Copco Gas and Process machinery covers numerous areas. Phenol. “We supply turboexpanders for many applications within the highly complex and demanding C/PC market. Within the realm of oxidation processes and hot gas applications.Your Application – Chemical / Petrochemical Chemical / Petrochemical Fewer markets are as complex as chemical/petrochemical. Our key areas of expertise include Ethylene Olefin Recovery. including Terephtalic Acid (PTA). Carbon Monoxide Purification. Ammonia Purification. Ammonia. and Hydrogen Recovery. The industry’s broad ranges of applications are all covered by Atlas Copco Gas and Process turboexpanders. Propane Dehydrogenation. Expander compressor for an olefin petrochemical plant in Qatar. Hydrogen Peroxide.” 10 . Nitric Acid.

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and the latest 5-axis computer aided manufacturing processes.Technical Features Inside Our Technology High-Efficiency Impellers Precisely Meeting Your Needs High efficiency is a fundamental requirement for all processes involving turboexpanders. As an established turbomachinery manufacturer. 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 “To ensure top efficiency. we use CFD and FEA in impeller design.” 12 . To ensure top efficiency. we utilize computational fluid dynamics (CFD) and finite element analysis (FEA) in the design of our impellers. We achieve this performance through the use the latest technology tools and a vast experience base. we can choose from a wide variety of proven impeller designs to precisely match your process needs.

Impellers undergoing quality check 13 .

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. continuous control across the full range of operation. “Our adjustable IGVs are engineered to produce optimum flow patterns and to provide precise control.” 14 . Atlas Copco turboexpanders use adjustable inlet guide vanes engineered to produce optimum flow patterns and provide precise.

2 0.3 0.5 0.70 0.7 0.9 0.1 0 v= 0.55 0.0 0. Efficiency vs.Velocity ratio v 0.65 0.50 0.45 0.4 0.80 i i max 1.90 1 Efficiency i related to i max C 0 0 20 40 60 Flow rate V [%] 80 100 120 140 160 180 The typically flat turboexpander efficiency characteristic with various flow rates is illustrated here.85 0.75 π √ 0.60 0. the velocity ratio v (ratio tip speed to spouting velocity) is also shown. 15 .8 0.6 0.

A combined radial/ axial bearing for a hydrocarbon gas expander A magnetic bearing cutaway Combined radial/ axial bearing for air separation turbines A radial bearing for an integrally geared unit “We offer multiple bearing designs that have a proven operating history for continuous use in diverse applications. These designs include hydrodynamic (both journal and tilt pad types) and active magnetic bearings. Final bearing selections are made specifically for your process applications.” 16 .Technical Features Reliable Machinery Operation We offer multiple bearing designs that have a proven operating history for continuous use in diverse applications.

Floating carbon seals Dynamic dry gas seals Labyrinth seals Oil-lubricated seals 17 .

In most cases. Typical Applications: Energy Recovery Chemical/Petrochemical Air Separation Rated Power: 15. Compressor-loaded expanders Expander is loaded by a single stage centrifugal compressor through a common shaft. generator-loaded.000 kW 18 .Technical Features Configuration Options . the turboexpander is skid-mounted with its auxiliary support system to simplify transport and help reduce installation costs.000 kW Integrally-geared generator loaded expanders Connected to an electric generator through speed reducing gears. Typical Applications: Air Separation Ethylene/Olefin Recovery LPG/NGL Recovery Dew Point Control Rated Power: up to 22. Integral-gear technology offers the additional benefit of multi-staging (one to four stages) for high efficiency.Choosing The Right Match Atlas Copco Gas and Process turboexpanders are offered in compressor-loaded. and hydraulic brakeloaded configurations to accommodate specific applications.

Used for cryogenic applications in low power anges. Typical Applications: Air Separation Energy Recovery Rated Power: 4. Typical Applications: Air Separation Hyco Syngas (CO2.000 kW Friction-braked expanders Expander is braked by the presence of oil in the chambers surrounding the rotor shaft.Generator-loaded expanders Expander stage connected to an electric generator through an epicyclic gear. H2) Rated Power: 250 kW 19 .

000 lb/hr) Inlet Pressure: 37.860 kW (10.096 kW (1.540 HP) Liquefied Natural Gas (LNG) The compander’s expander stage is an essential component in an on-board LNG reliquefaction plant. Frame/Type: ECM-5.794 HP) Hydrocarbon Gas Processing Expander compressor for gas processing installed in Nigeria.0 Speed: 9.375 Nm3/hr (58.900 RPM Hydrocarbon Hydrocarbon Hydrocarbon Hydrocarbon Flow: 461.5 bar (544 psia) Inlet Temperature: -49 °C (-56.2 °F) Power: 7.275 kg/hr (856.405 psia) Inlet Temperature: -27 °C-16.0 Speed: 10.500 lb/hr) Inlet Pressure: 96.9 bar (1.6 °F) Power: 7.018. Frame/Type: ECM-5.723 scfm) Expander Cold Production: 1.Products and Applications at a Glance Hydrocarbon Gas Processing Expander compressor with a magnetic bearing installed in a large LNG regasification terminal in Lake Charles (USA).303 kW (9.469 HP) 20 .863 kg/hr (811.155 psia) Inlet Temperature: -18 °C (-0.000 lb/hr) Inlet Pressure: 79.300 RPM Flow: 388.6 bar (1.40 °F) Power: 8.400 RPM Flow: 367.984 kg/hr (1.983 HP) Hydrocarbon Gas Processing Expander compressor for gas processing installed in Thailand.0 Speed: 13.35 bar (817 psia) Inlet Temperature: -110 °C (-166 °F) Flow: 94. Frame/Type: EC-6. Frame/Type: Three-stage GT 032 N3D0 / Single-stage ETG 150 MS Inlet Pressure: 56.936 kW (11.

4 bar (455 psia) Inlet Temperature: 127 °C (260.6 °F) Flow: 707.530 kW (3.488 kW (12.000 lb/hr) Fluid: Isobutane Recovered Power: 14. Frame/Type: Two-stage ETG 360 MS-2 Inlet Pressure: 50 bar (725 psia) Inlet Temperature: 125 °C (257 °F) Flow: 165.699 scfm) Recovered Power: 4. Frame/Type: Single stage EGI-8 Inlet Pressure: 31.500 HP) Energy Recovery Pressure Letdown Integrally-geared generator-loaded turboexpander in a pressure letdown application for the Middle East.070 HP) Energy Recovery Geothermal Power Single-stage integrally-geared generator loaded turboexpander in a geothermal ORC application in Nevada (USA).000 Nm3/hr (102.000 scfm) Fluid: CH4 Recovered Power: 2.541 kW (19.582 Nm3/hr (37.391 HP) 21 . Frame/Type: Three-stage ETG 190 MS-3 Inlet pressure: 51 bar (740 psia) Inlet Temperature: 170 °C (338 °F) Flow: 60.560.000 Nm3/hr (28.668 scfm) Recovered Power: 9.604 kg/hr (1.Energy Recovery Pressure Letdown Integrally-geared generator-loaded turboexpander in a pressure letdown application in Italy. Frame/Type: ETG 190 MS-2 Inlet Pressure: 45 bar (653 psia) Inlet Temperature: 75 °C (167 °F) Flow: 45.526 kW (6.718 HP) Energy Recovery Pressure Letdown Turboexpander for a pressure letdown application in Heidelberg (Germany).

161 kW (1.5 bar (501 psia) Petrochemical Expander compressor with magnetic bearing for a petrochemical plant in Saudi Arabia.200 lb/hr) Speed: 13.590 scfm) Cold Production: 1.557 HP) Air Separation Compressor-loaded turboexpander installed in an air separation plant in Chile.Products and Applications at a Glance Fertilizer Production Expander generator for an ammonia fertilizer plant Chemical / Petrochemical Chemical / Petrochemical Air Separation Air Separation 22 in Australia.0 Flow: 141.717 HP) .300 Nm3/hr (7.030 scfm) Cold Production: 207 kW (278 HP) Air Separation Integrally-geared generator-loaded turboexpander installed in an air separation plant in the Netherlands.2 °F) Inlet Pressure: 34.0 Flow: 54.593 Nm3/hr (34.000 RPM Inlet Temperature: -102 °C (-151.000 lb/hr) Speed: 3.9 bar (216 psia) Power: 1.6 °F) Inlet Pressure: 14.974 kg/hr (313. Frame/Type: Single-stage ETB 190 NS Inlet Pressure: 7.280 kW (1.000 RPM Inlet Temperature: -129 °C (-200. Frame/Type: EG-6.7 °C (-184 °F) Flow: 11. Frame/Type: Two-stage ETB 560 NS-2 Inlet Pressure: 2. Frame/Type: ECM-4.8 bar (41 psia) Inlet Temperature: -90 °C (-130 °F) Flow: 55.975 kg/hr (121.3 bar (106 psia) Inlet Temperature: -120.

Turboexpander Matrix Our Product for Your Market Expander with Booster Compressor ETB EC ECM Expander Generator ETG EG Expander Hydraulic Braked ETF EHB Hydrocarbon LPG / NGL Recovery Gas Processing Gas Treatment Dew Point Control Floating LNG FPSO LNG Reliquefaction (Nitrogen Brayton Cycle) LNG Liquefaction LNG Peak Shaving Energy Recovery Pipeline (Pressure Letdown) Geothermal Heat Recovery Cold Energy Recovery Chemical/Petrochemical Gas Aromatics Inorganic Refineries Gas to Liquid Air Separation Cryogenic expansion Steel Electronics GTL/Syngas 23 .

mather@uk.van.com Application Centers Europe Thomas Bierwirth (Energas) Phone: +49 2236 96 50 658 Fax: +49 2236 96 50 899 thomas.com Bruce Edstrand (North Central / Northeast) Phone: +1 847 726 98 66 bruce.com Customer Centers Alpine Peter von Graffenried Phone: +41 61 731 37 00 Fax: +41 61 733 94 40 peter.com Southeast Asia/Oceania Ulrich Schmitz Phone: +65 62 10 80 44 Fax: +65 68 62 56 28 ulrich. B03/004/24/0909 Italy Spain Rafael Cañete Phone: +34 91 627 91 00 Fax: +34 91 627 91 62 rafael.atlascopco.com Japan Michael Shafer Phone: +81 3 57 65 70 39 Fax: +81 3 57 65 31 97 michael.atlascopco.atlascopco.bierwirth@de.com Russia Peter Kraus Phone: +7 495 933 55 50 ext.atlascopco.atlascopco.com France Patrick Coupel Phone: +33 1 39 09 31 60 Fax: +33 1 39 09 30 51 patrick.woodmansee@us.atlascopco.atlascopco. 4139 Fax: +1 805 925 38 61 randy.atlascopco.hop@nl.com Far East Sander van Spijk (Shanghai) Phone: +86 21 220 848 58 Fax: +86 21 621 519 63 sander.com United States Tim Shaw (Southwest) Phone: +1 281 216 60 10 Fax: +1 281 984 74 63 tim.marinelli@it.atlascopco.atlascopco.com Great Britain Ian Mather Phone: +44 1442 22 23 35 Fax: +44 2074 92 37 30 ian.com © Atlas Copco 12/2009 Printed in Germany. Vasan (Pune) Phone: +91 20 39 85 23 09 Fax: +91 20 27 14 59 48 ss.atlascopco.com Yi-Fu (Jerry) Zhang (Beijing) Phone: +86 10 65 28 05 17 Fax: +86 10 65 28 05 25 jerry.kraus@de.atlascopco.Gas and Process Division Our points of contact worldwide Headquarters Atlas Copco Energas GmbH Schlehenweg 15 50999 Cologne.atlascopco. 4125 Fax: +1 805 925 38 61 john.com Regional Offices Germany Ralf Kiefer (North) Phone: +49 2227 90 99 920 Fax +49 2227 90 99 922 ralf.com John Peranteaux (West Coast) Phone: +1 805 928 57 57 ext.com China Nick He (Hangzhou) Phone: +86 57 12 80 02 077 Fax: +86 57 12 80 02 070 nick.com Iran Ali Rakhshani Moghaddam Phone: +98 21 66 93 77 11 322 Fax: +98 21 66 92 73 14 ali.vasan@in.shafer@jp.tabaza@bh.com Bart Woodmansee (Northeast / Eastern Canada) Phone: +1 860 477 02 96 Fax: +1 860 477 04 61 bart.atlascopco.zhang@cn.atlascopco.atlascopco.com Gianfranco Marinelli Phone: +39 02 61 79 94 50 Fax: +39 02 66 01 18 90 gianfranco.atlascopco-gap.com Nordic Heikki Alanko Phone: +358 8 51 67 64 Fax: +358 8 51 58 24 heikki.g.com South Africa Wayne Jacobs Phone: +27 11 821 90 00 Fax: +27 11 388 32 64 wayne.jacobs@za.atlascopco. Becker Phone: +55 11 34 78 87 11 Fax: +55 11 41 95 70 90 roberto.dirlam@us.graffenried@ch.com India S.com Randy Dirlam (Mafi-Trench) Phone: +1 805 928 57 57 ext. Germany Phone: +49 2236 96 50 0 Fax: +49 2236 96 50 899 atlascopco.atlascopco.com The Americas Nasser Sadeghzadeh (Comptec) Phone: +1 518 765 58 38 Fax: +1 518 765 33 57 nasser. 305 Fax: +966 3 88 27 606 sami.com Jörg Wieczorek (South) Phone: +49 89 74 99 49 70 Fax: +49 89 74 99 49 80 joerg. 15 99 Fax: +7 495 933 12 50 peter.atlascopco.atlascopco.com Canada Tushar Patel (Western Canada) Phone: +1 403 259 60 69 Fax: +1 403 253 34 52 tushar.atlascopco.kiefer@de.shaw@us.com Middle East/North Africa Sami Tabaza Phone: +966 3 88 24 440 ext.atlascopco.schmitz@sg.atlascopco.spijk@cn.atlascopco.von.canete@es.S.atlascopco.atlascopco.com Brazil Roberto G.wieczorek@de.energas@de.atlascopco.atlascopco.peranteaux@us.atlascopco.rakhshanmoghaddam@ ir.coupel@fr.atlascopco.com www.patel@ca.becker@br.alanko@fi.edstrand@us.com South Korea SeungHoon Yang Phone: +82 2 21 89 40 80 Fax: +82 2 522 19 79 shyang@kr.com Benelux Jan Hop Phone: +31 33 299 95 05 Fax: +31 33 299 95 06 jan.sadeghzadeh@us.he@cn.com .

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