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Driving Expander TechnologyAtlas Copco Gas and Process Solutions
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.
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.”
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.
5
6
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
7
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.”
9
10
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.
11
12
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
13
Impellers undergoing quality check
14
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.”
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
16
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.
17
Floating carbon seals Dynamic dry gas seals
Labyrinth seals Oil-lubricated seals
18
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
19
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
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
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)
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
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
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 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]