Turbo Expander

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 a 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

Utilizing our worldwide manufacturing and packaging

in a close dialog with our customers early in the

facilities, we provide the highest quality in the custom-

design process. With thousands of our machines in

engineered turbomachinery world.

operation worldwide, we are your ideal partner to drive turboexpander technology further.

Even after our machine is operating in the field, we maintain our commitment to this partnership: through the

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.

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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.

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

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: Atlas Copo Energas

Atlas Copco Mafi-Trench Company LLC

• Located in Cologne (Germany)

• Located in Santa Maria (USA)

• Began in 1936 as the KT Division of Linde AG

• Has produced more than 700 hydrocarbon

• Has designed, manufactured, and commissioned

turboexpanders since 1975

thousands of turboexpanders

• Known as the preferred supplier of hydrocarbon

• Market leader in turboexpander technology,

turboexpanders to the world for more than 35 years

especially in air separation and integrally-geared

• Global leader in large single-stage

applications

high-horsepower applications

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

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Your Application

Industrial Gases In the industrial-gas industry, efficiency is key. Our expanders boost productivity and maximize cold power for your plant. Our solutions for the industrial-gas market are designed

We were, after all, the first expander manufacturer that

with increased customer value in mind. Compact

successfully employed dry-gas seals in cryogenic

and highly efficient designs provide our customers with

applications. In the bigger picture, our solutions help

advantages in their process operations.

generate superior cooling capacity in cryogenic processes and subsequently a greater product yield

Our expander design is simple and provides even and

in your industrial-gas process.

efficient air inlet and outlet. Furthermore, innovative insulation is employed at the expander casing and various

Atlas Copco turboexpanders maximize cold power

other locations within the machine, achieving optimal

for your plant and are simple to install, operate,

results.

and maintain. We also provide compressors for air-separation plants, giving customers a complete turboexpander solution.

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

Single-stage ETB 190 NS

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Your Application

Oil and Gas Our expanders offer a host of reliable solutions that support every link in the hydrocarbon value chain. In the oil and gas business, performance and reliability are the name of the game. That’s why all of our solutions

Hydrocarbon applications:

are created to ensure the highest reliability and satisfy

• Liquefied Petroleum Gas (LPG)

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.

• Natural Gas Liquids (NGL) • Dew-point Control (DPC) • Liquefied Natural Gas (LNG) - Base load / peak shaving - FPSO – FLNG - Regasification • Nitrogen rejection

”When you choose Atlas Copco Gas and Process, you choose technology solutions that satisfy your process requirements.”

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

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(Photo: Kjetil Alsvik – Statoil)

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Your Application

Chemical / Petrochemical In this complex sector, reliability and safety are more crucial than ever. Our expanders help you meet every challenge. Few markets are as complex as chemical / petrochemical.

Within the realm of oxidation processes and hot gas

The industry’s broad range of applications is covered by

applications, Atlas Copco Gas and Process machinery

Atlas Copco Gas and Process turboexpanders.

covers numerous areas, including terephtalic acid (PTA), phenol, hydrogen peroxide, ammonia, nitric acid, and

Our key areas of expertise include ethylene-olefin

caprolactam.

recovery, ammonia purification, carbon-monoxide purification, propane dehydrogenation, and hydrogen recovery.

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

Expander compressor for an olefin petrochemical plant in Qatar

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(Photo: The Linde Group)

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Your Application

Energy Recovery Renewable energy is gaining traction across the world. Our innovative expanders make your plant fit for the future. For many years, Atlas Copco Gas and Process has

Driven by our integral-gear expertise, our turboexpanders

helped customers around the world in unlocking the

can be configured with one to four stages on a single

vast potential of renewable-energy sources. Whether

gearbox to achieve the lowest cost-per-kilowatt

you want to produce electricity from a geothermal

power-train solution. Power generation reaches up to

resource or recover power in a pressure-letdown

25 MW per unit.

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

Energy Recovery Applications: • Geothermal

turboexpanders in closed-loop conversion cycles

• Organic Rankine Cycle

such as the Organic Rankine Cycle (ORC).

• Kalina Cycle®

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

• Pressure letdown • Heat recovery • Waste-heat recovery

reflectors.

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

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

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Technical Features

High-Efficiency Impellers Our impeller designs are the most reliable in the industry and meet a wide range of process requirements. High efficiency is a fundamental requirement for all

As an established turbomachinery manufacturer, we can

processes involving turboexpanders. We achieve this

choose from a wide variety of proven impeller designs

performance through the use of the latest technology

in our data base to precisely match your process

tools and a vast experience base.

needs. This combination of experience and technology ensures that our customers receive maximum efficiency

Precision That Meets Your Needs

and the most reliable impellers available in the industry.

To ensure top efficiency, we utilize computational-fluid dynamics (CFD) and finite-element analysis (FEA) in the design of our impellers, and the latest 5-axis computer-aided manufacturing processes.

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

Expander impeller

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Mechanical center section

Impellers undergoing a quality check

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Technical Features

Variable Inlet-Guide Vanes Our inlet-guide vanes adjust to changing process conditions to maximize expander efficiency. To compensate for the varying operating conditions found

Full Control Over Your Process

in many processes, turboexpanders must deliver efficient Apart from an optimal control range and excellent

off-design performance.

efficiency for all parts, our IGVs feature a wide Atlas Copco turboexpanders use variable inlet-guide

range of regulation capabilities and excellent partial

vanes (IGVs) engineered to produce optimum flow

performance. Combined configuration ensures

patterns and provide precise, continuous control across

maximum control flexibility.

the full range of operation.

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

Efficiency i related to i max

0.45 0.50

i i

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.

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max

1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0

0.55

0.60

0.65

0.70

0.75

0.80

0.85 0.90

v=

1 0

0 20 40 60 Flow rate V [%]

80

100 i i

max

120

= f (U/C0)

140

160 180 i i

max

= f (V)

Variable inlet-guide vanes

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Technical Features

Bearing Systems We offer multiple bearing designs that have a proven operating history for reliable, continuous use in diverse applications. Atlas Copco Gas and Process bearing designs include

Oil Bearings

hydrodynamic bearings as well as Active Magnetic Bearings. Final bearing selections are made specifically

We offer horizontally-split, high-speed pinion bearings

for your process applications.

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

Active Magnetic Bearings

performance. Our dedicated service team supports customers at every step, before and after installation.

Combined radial / axial bearing for a hydrocarbon gas expander

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Radial bearing for an integrally-geared unit

Combined radial / axial bearing for air-separation turbines

Shaft Seals Our uniquely tailored shaft-seal solutions ensure maximum efficiency and prevent gas leakage and air intrusion – even in volatile environments.

Dynamic dry-gas seals

Labyrinth seals

Floating carbon seals

Oil-lubricated seals

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Technical Features

Configuration Options Our turboexpander configurations provide the right match for your application. 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 expanders Expander is loaded by a singlestage centrifugal compressor through a common shaft. Typical applications: Air separation Ethylene / olefin recovery LPG / NGL recovery Dew-point control Rated power: up to 22,000 kW

Integrally-geared generator-loaded expanders Connected 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: 25,000 kW

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Generator-loaded expanders Expander stage connected to an electric generator through an epicyclic gear. Typical applications: Air separation Energy recovery Rated power: 4,000 kW

Hydraulic-braked expanders Expander 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: 250 kW

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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). Frame / type: Single-stage ECM-5.0 Speed: 10,900 RPM Oil and Gas

Flow: 461,984 kg/hr (1,018,500 lb/hr) Inlet pressure: 96.9 bar(a) (1,405 psia) Inlet temperature: -27 °C (-16.6 °F) Power: 7,303 kW (9,794 HP)

Hydrocarbon Gas Processing Expander compressor for gas processing installed in Nigeria. Frame / type: Single-stage EC-5.0 Speed: 13,400 RPM Flow: 367,863 kg/hr (811,000 lb/hr) Oil and Gas

Inlet pressure: 79.6 bar(a) (1,155 psia) Inlet temperature: -18 °C (-0.40 °F) Power: 8,936 kW (11,983 HP)

Hydrocarbon Gas Processing Expander compressor for gas processing installed in Thailand. Frame / type: Single-stage EC-6.0 Speed: 9,300 RPM

Oil and Gas

Flow: 388,275 kg/hr (856,000 lb/hr) Inlet pressure: 37.5 bar(a) (544 psia) Inlet temperature: -49 °C (-56.2 °F) Power: 7,860 kW (10,540 HP)

Liquefied Natural Gas (LNG) The compander’s expander stage is an essential component in an on-board LNG-reliquefaction plant. Frame / type: Three-stage GT 032 N3D0 / Single-stage ETG 150 MS

Oil and Gas

Flow: 94,375 Nm3/hr (58,723 scfm) Inlet pressure: 56.35 bar(a) (817 psia) Inlet temperature: -110 °C (-166 °F) Expander cold production: 1,096 kW (1,469 HP)

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Energy Recovery

Pressure Letdown Integrally-geared generator-loaded turboexpander in a pressure-letdown application in Italy. Frame/Type: Three-stage ETG 190 MS-3 Inlet pressure: 51 bar(a) (740 psia) Inlet Temperature: 170 °C (338 °F) Flow: 60,582 Nm3/hr (37,699 scfm) Recovered Power: 4,526 kW (6,070 HP)

Energy Recovery

Geothermal Power Single-stage integrally-geared generator-loaded turboexpander in a geothermal ORC application in Nevada (USA). Frame/Type: Single-stage EGI-8 Inlet Pressure: 31.4 bar(a) (455 psia) Inlet Temperature: 127 °C (260.6 °F) Flow: 707,604 kg/hr (1,560,000 lb/hr) Fluid: Isobutane Recovered Power: 14,541 kW (19,500 HP)

Energy Recovery

Pressure Letdown Integrally-geared generator-loaded turboexpander in a pressure-letdown application for the Middle East. Frame/Type: Two-stage ETG 360 MS-2 Inlet Pressure: 50 bar(a) (725 psia) Inlet Temperature: 125 °C (257 °F) Flow: 165,000 Nm3/hr (102,668 scfm) Recovered Power: 9,488 kW (12,718 HP)

Energy Recovery

Pressure Letdown Turboexpander for a pressure letdown application in Heidelberg (Germany). Frame/Type: ETG 190 MS-2 Inlet Pressure: 45 bar(a) (653 psia) Inlet Temperature: 75 °C (167 °F) Flow: 45,000 Nm3/hr (28,000 scfm) Fluid: CH4 Recovered Power: 2,530 kW (3,391 HP)

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Products and Applications at a Glance

Fertilizer Production Expander generator for an ammonia-fertilizer plant in Australia. Frame / type: Single-stage EG-6.0 Flow: 141,974 kg/hr (313,000 lb/hr) Speed: 3,000 RPM Oil and Gas

Inlet temperature: -129 °C (-200.2 °F) Inlet pressure: 34.5 bar(a) (501 psia) Power: 634 kW (850 HP)

Petrochemical Expander compressor with magnetic bearing for a petrochemical plant in Saudi Arabia. Frame / type: Single-stage ECM-4.0 Flow: 54,975 kg/hr (121,200 lb/hr) Speed: 13,000 RPM Oil and Gas

Inlet temperature: -102 °C (-151.6 °F) Inlet pressure: 14.9 bar(a) (216 psia) Power: 1,161 kW (1,557 HP)

Industrial Gases Compressor-loaded turboexpander installed in an air-separation plant in Chile. Frame / type: Single-stage ETB 190 NS Inlet pressure: 7.3 bar(a) (106 psia) Industrial Gases

Inlet temperature: -120.7 °C (-184 °F) Flow: 11,300 Nm3/hr (7,030 scfm) Cold production: 207 kW (278 HP)

Industrial Gases Integrally-geared generator-loaded turboexpander installed in an air-separation plant in the Netherlands. Frame / type: Two-stage ETB 560 NS-2 Inlet pressure: 2.8 bar(a) (41 psia) Industrial Gases

Inlet temperature: -90 °C (-130 °F) Flow: 55,593 Nm3/hr (34,590 scfm) Cold production: 1,280 kW (1,717 HP)

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Our Product for Your Market Industry

Expander with Booster Compressor ETB

EC ECM

Expander Generator ETG

EG

Expander Hydraulic Braked ETF

EHB

Oil and Gas LPG / NGL recovery Gas processing Gas treatment Dew-point control Floating LNG FPSO LNG reliquefaction (nitrogen brayton cycle) LNG liquefaction LNG peak shaving

Gas aromatics Inorganic Refineries Gas to Liquid

Energy Recovery Pipeline (pressure letdown) Geothermal Heat recovery Cold energy recovery

Industrial Gases Cryogenic expansion Steel Electronics GTL / Syngas

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Gas and Process Division Our points of contact worldwide

Headquarters

Regional Offices

Customer Centers

Atlas Copco Energas GmbH Schlehenweg 15 50999 Cologne, Germany Phone: +49 2236 96 50 0 Fax: +49 2236 96 50 899 [email protected] www.atlascopco-gap.com

Germany

Alpine

Russia

Ralf Kiefer (North / Central and Southwest) Phone: +49 2235 4639 272 Fax +49 2235 4639 278 [email protected]

Peter von Graffenried Phone: +41 61 731 37 00 Fax: +41 61 733 94 40 [email protected]

Henning Struck Phone: +7 495 933 55 50 ext. 1904 Fax: +7 495 933 55 60 [email protected]

Benelux

South Africa

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

Jan Hop Phone: +31 64 620 37 30 Fax: +31 33 299 95 06 [email protected]

Wayne Jacobs Phone: +27 11 821 90 00 Fax: +27 11 388 32 64 [email protected]

North America

France

South Korea

Pascal Collin Phone: +33 01 39 09 31 60 Fax: +33 06 30 11 72 08 [email protected]

Yunwon Lee Phone: +82 2 2189 4081 Fax: +82 2 522 1979 [email protected]

Great Britain/Nordic

Southeast Asia/Oceania

Ian Mather Phone: +44 1442 22 23 35 Fax: +44 2074 92 37 30 [email protected]

Ulrich Schmitz Phone: +65 62 10 80 44 Fax: +65 68 62 56 28 [email protected]

Italy

Spain

Gianfranco Marinelli Phone: +39 02 61 79 94 50 Fax: +39 02 66 01 18 90 [email protected]

Rafael Cañete Phone: +34 91 627 91 54 [email protected]

Japan

Yüksel Isiltan Phone: +90 216 581 05 81 Fax: +90 216 581 04 30 [email protected]

Thomas Bierwirth Phone: +49 2236 96 50 658 Fax: +49 2236 96 50 899 [email protected]

The Americas David A. Smith (Compressors) Phone: +1 518 765 58 28 Fax: +1 518 765 33 57 [email protected] Randy Dirlam (Expanders) Phone: +1 805 928 57 57 ext. 4139 Fax: +1 805 925 38 61 [email protected] Michael Tanamachi (Pumps) Phone: +1 949 764 2227 Fax: +1 949 548 3476 [email protected]

China Sander van Spijk Phone: +86 21 6097 8198 Fax: +86 21 6097 8144 [email protected]

India S.S. Vasan Phone: +91 20 39 85 70 80 Fax: +91 20 39 85 71 09 [email protected]

Bart Woodmansee (Northeast / Eastern Canada) Phone: +1 860 477 02 96 Fax: +1 860 477 04 61 [email protected] Bruce Edstrand (North Central / West Coast / Western Canada) Phone: +1 847 726 98 66 [email protected] Tushar Patel (Southeast) Phone: +1 281 261 01 80 Fax: +1 281 208 51 08 [email protected]

South America André Brandão Phone: +55 21 21 56 84 28 Fax: +55 11 41 95 70 90 [email protected]

China Nick He (Hangzhou) Phone: +86 57 12 80 02 077 Fax: +86 57 12 80 02 070 [email protected] Yi-Fu (Jerry) Zhang (Beijing) Phone: +86 10 65 28 05 17 Fax: +86 10 65 28 05 25 [email protected]

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

Turkey

Middle East/North Africa Sami Tabaza Phone: +971 5 044 38 117 Fax: +971 4 88 61 885 [email protected]

B03/004/24/0512

Europe

© Atlas Copco 05/2012 Printed in Germany.

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