firmenbroschuere mahler ags gmbh
TRANSCRIPT
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
1/16
Gas Generation and Purification
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
2/16
Hydrogen generation plantsbased on different feedstocks: Natural gas LPG Naphtha Methanol Purification of hydrogen-
rich gases
Oxygen generation plants for pu-rities up to 94% by vol. O2 basedon adsorption by PSA process VPSA or VSA process
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
3/16
About Mahler
sers in a wide range of industries cancut the production costs by using MahlerAGS plants, e.g.:
Petrochemical industry
Steel and metallurgical industry
(ferrous and non-ferrous) Chemical industry
Pulp and paper industry
Food industry
Glass and enamel industry
Pharmaceutical industry
Electronics industry
ith more than 4500 plants in over 70
countries built worldwide, Mahler AGS is
a highly respected manufacturer of on-site
generation plants. Since the foundation of
he company in 1870 we are located in the
Stuttgart area (Germany) and are active in
he field of engineering high quality gas
generation plants.
nderstanding that every application and
location is unique, Mahler AGS offers a
variety of cost-effective and reliable on-site
generation systems.
orking with our customers, Mahler AGS
engineers will analyze their requirements
and propose a system that meets the speci-
cations for flow, purity and pressure. Our
business activities include not only design,
but also manufacturing, installation and
start-up of the system.
A service team is always available to provide
any necessary service or maintenance forhe system. For more details about our
service capabilities
please ask for our
service brochure.
The combination of Mahler AGS after-sales
service, continuous process improvement,
cooperation with research institutes and cer-
tification of the Quality Management System
(according to DIN EN ISO 9001), will ensure
superior products and highest customers
satisfaction.
App l i c a t i o n s
H i g h l i g h t s
Mahler AGS
Has built the first remote controlledautomatic SMR-hydrogen plant inthe world
Our oxygen technology guaranteeslowest consumption figures
Our largest nitrogen generator is oneof the biggest on-site supply PSAsystems ever built
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
4/16
Ou r
Techno l o g y
Mahler AGS has more than40 years experience and know-howin designing and manufacturinghydrogen generation plants.As one of the internationally leadingsuppliers of Steam Reformingand Pressure Swing Adsorptiontechnology, Mahler AGS providessystems which are exactly tailoredto the customers requirements andcan be easily integrated into alreadyexisting processes.
Th e B a s i c P r o c e s s
The HYDROFORM-C system is basedon Steam Reforming of natural gas,LPG or naphtha as feed to producea hydrogen-rich gas. The gas isthen purified by the subsequentHYDROSWING system.
Pretreatment of the FeedThe feed is mixed with a small
H2-stream, preheated and sent tothe desulphurization reactor. Afterdesulphurization the feed is mixedwith process steam generated in thesteam boiler.
Reforming andHigh Temperature ConversionThe feed/steam-mixture isreformed within the top-fired
reformer furnace into a rawhydrogen-rich gas. The required heator the reaction is generated by
combustion of fuel gas and ofpurge gas from the HYDROSWINGsystem. The heat from the reformedgas is recovered for steamgeneration and the gas is fed to thehigh temperature CO-conversion
reactor to produce additionalhydrogen.
Gas Cooling by Heat RecoveryAfter CO-conversion the convertedgas is cooled-down in a series ofheat exchangers by simultaneouseconomical preheating of processstreams. The process condensateis separated and can be reused.
Gas Purification - HYDROSWING
The hydrogen-rich gas is sent tothe HYDROSWING system whichusually consists of four adsorbersfilled with different adsorbents.This process is based on PressureSwing Adsorption by which theimpurities are separated to obtainhigh-purity hydrogen with purities
up to 99.999+ % by volume.The purge gas from depressurizationand purging during the regenerationstep is used as fuel gas.
H i g h l i g h t s
Hydrogen plants in operation for morethan 40 years with original equipment
Mahler AGS has built the firsthydrogen plants worldwide withremote control over long distances
Mahler AGS has built more than50 hydrogen plants
The HYDROFORM-C system isavailable in a range of capacitiesfrom 100 to 10000 Nm3/h hydrogen.
HYDROFORM-C: The Hydrogen Generator
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
5/16
P l a n t F e a t u r e s
Product flexibilityPurities up to 99.999+ % by volumePlant capacitiesfrom 100 to 10000 Nm
3/h
Automatic part load operationProduct pressure from 10 to 30 barOptional H2-compressionup to 250 bar
High operational reliabilityMany years of experience in plantdesign, engineering and
manufacturing guarantee a highreliability of the HYDROFORM-Csystem.
Modular designThe HYDROFORM-C system is pre-assembled and delivered inprefabricated units.
Optimized consumption figuresOptimal heat recovery from flue gasand from different process streams,e.g. preheating of combustion air,generation of export steam.
Full automationThe HYDROFORM-C systemis designed for automatic andunattended operation, e.g. changeof capacity.
Remote controlThe HYDROFORM-C system can bedesigned for automatic start-up andshut-down, control and automaticload adjustment from long distances.
High quality and high safetystandard
Design for long lifetime
App l i c a t i o n s
Mahler AGS HYDROFORM-C systemcan cut the production costsin a wide range of industrial applicati-ons, e.g. in the
1: Feed compression unit2: Feed pretreatment3: Reforming and steam generation4: High temperature conversion
Air
Boiler feed water Cooling water Condensate
Purge
Hydrogen
Feed
5: Heat exchanger unit6: Pretreatment of boiler feed water7: Purification unit - HYDROSWING system
Metallurgical and steel industry
Petrochemical and refining industry
Glass and float glass manufacturing
Chemical and pharmaceutical
industry
Production of H2 2
Food industry
Electronics industry
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
6/16
HYDROFORM-M: The Hydrogen Generator
O ur
Techno l o g y
Mahler AGS has more than 40 yearsexperience and know-how indesigning and manufacturinghydrogen generation plants and hassuccessfully operated in the field ofMethanol Reforming. As one of theinternationally leading suppliers ofMethanol Reforming and PressureSwing Adsorption technology,Mahler AGS provides systems whichare characterized by a maximumquality and safety standard andailored to the customers
requirements.
Th e B a s i c P r o c e s s
H i g h l i g h t s
The HYDROFORM-M systemis based on reforming of methanolas feed to produce a hydrogen-richgas. The purification of thehydrogen-rich gas is done by meansof the HYDROSWING system.
Pretreatment of the Feed MixtureMethanol and fully demineralized
ater are fed to a storagevessel. Continuous measuringof density and level ensure theavailability of the correct ratioof methanol and water. The feedmixture is pumped up andhen preheated by heat recoveryrom raw hydrogen-rich gas.apourization and superheating tohe optimal reactor inlet temperature
is done by thermo-oil in the followingheat exchanger.
Methanol ReactorThe vapourized feed mixture iscatalytically reformed within themethanol reactor into a rawhydrogen-rich gas. The reaction isendothermic and the required heat is
ransferred to the process byhermo-oil, which avoids overheating
of the catalyst . The thermo-oil isheated by combustion of purge gasrom the HYDROSWING system.
Gas Cooling by Heat RecoveryThe raw hydrogen-rich gas comingrom the methanol reactor is cooled
down in heat exchangers by
simultaneous economicalpreheating of the feed mixture.The process condensate is separatedand sent back to the storagevessel to be reused.
Gas Purification - HYDROSWING
The hydrogen-rich gas is sentto the HYDROSWING system which
usually consists of four adsoberslled with different adsorbents. This
process is based on Pressure SwingAdsorption by which the impuritiesare separated to obtain high-purityhydrogen with purities up to99.999+ % by volume. The purge gasrom depressurization and purging
during the regeneration step is usedas fuel gas in the thermo-oil system.
Hydrogen plants in operation for morethan 40 years with original equipment
Mahler AGS has built the firsthydrogen plants worldwide withremote control over long distances
Mahler AGS has built more than50 hydrogen plants
The HYDROFORM-M systemis able to cover a demandup to 6000 Nm3/h hydrogen.
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
7/16
P l a n t F e a t u r e s App l i c a t i o n s
1: Pretreatment of the feed mixture2: Methanol reforming and heat exchanger unit
: Thermo-oil system: Purification unit - HYDROSWING system
Product flexibilityPurities up to 99.999+ % by volumePlant capacitiesrom 100 to 6000 Nm3/h
Automatic part load operationProduct pressure from 7 to 30 barOptional H2-compressionup to 250 bar
Low investment cost
Modular design
High operational reliabilityMany years of experience inplant design, engineering andmanufacturing guarantee highreliability of the HYDROFORM-Msystem.
Optimized consumption figuresOptimal heat recovery, e.g.preheating of combustion air andrecovery of process condensate.
Full automationThe HYDROFORM-M system isdesigned for automatic andunattended operation, e.g. changein capacity loading.
Remote controlThe HYDROFORM-M system can bedesigned for automatic start-up andshut-down, control and automaticload adjustment from long distances.
Thermo-oil system to protect thecatalyst even in part load
High quality and high safetystandard
Design for long lifetime
Mahler AGS HYDROFORM-M systemcan cut the production costs in a widerange of industrial applications, e.g.in the
Metallurgical and steel industry
Petrochemical and refining industry
Glass and float glass manufacturing
Chemical and pharmaceutical
industry Production of H2O2
Food industry
Electronics industry
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
8/16
Ou r
Techno l o g y
Mahler AGS has more than 40 yearsexperience and know-how indesigning and manufacturingPressure Swing Adsorption (PSA)plants. As one of the leading
suppliers of this technology forhydrogen purification worldwide,Mahler AGS has the flexibility toprovide systems that are tailormadesolutions to meet all customerrequirements.
Th e B a s i c P r o c e s s
H i g h l i g h t s
Mahler AGS HYDROSWING systemis based on the principle of bondingthe impurities of a hydrogen-richfeed gas with individually designedadsorbent materials to leave a highpurity hydrogen stream.The purification is effected in at leastfour adsorber vessels to ensure acontinuous hydrogen product flow.
The process is defined byfour main steps.
AdsorptionThe feed gas enters the bottomof the adsorber, the impurities areadsorbed by e.g. molecular sievesand high purity hydrogen leavesthe adsorber at the top.
Before the adsorption capabilityof the adsorbents is exhausted,a regenerated adsorber isautomatically switched on toadsorption, thus a continuousproduct flow is guaranteed.
DesorptionThe regeneration is done in
several pressure reduction steps.First hydrogen-rich gas is used forrepressurization and purging thoseadsorbers that are in differentstages of regeneration.By further depressurization theadsorbed impurities are released andfed to a ventline or to a buffer vesselto be used as fuel gas.
PurgingAt the lowest pressure level theadsorber is purged with hydrogen-rich gas from the adsorber which isundergoing desorption. The purgegas is either vented or sent to abuffer vessel.
Repressurization
The pressure of the purged adsorberis gradually increased to adsorptionpressure by depressurization gascoming from other adsorbers andby recycled pure hydrogen.
More than 60 systems installedworldwide
Plants in operation for more than40 years with the original equipment
Short start-up and shut-down times
The HYDROSWINGsystem is available ina range of capacitiesfrom 100 to 10000 Nm3/hhydrogen.
HYDROSWING: The Hydrogen Purification System
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
9/16
Product flexibilityurities up to 99.999+ % by volume
lant capacities from100 to 10000 Nm3/h
roduct pressure from 7 to 30 bar
Automatic part load operation
Optional H2compressionup to 250 bar
High operational reliability
Many years experience in plantdesign, engineering andmanufacturing guarantee a highreliability of the HYDROSWING
system.
High yieldThrough individual design accordingo feed gas composition
se of programmable control systemhich ensures high recovery
even at part load operation
Cost efficiency
ow power consumption
Minimized maintenance andoperating cost
Minimized cost for supervision
Full automationThe HYDROSWING system isdesigned for unattended operationand automatic adaptation of cycletimes according to plant capacity.
Remote controlThe HYDROSWING system can bedesigned for automatic start-up andshut-down, control and automaticload adjustment from long distances.
High quality and high safetystandard
P l a n t F e a t u r e s App l i c a t i o n s
F e e d g a s e s
Hydrogen can be recovered by theHYDROSWING system from verydifferent feed gases, e.g.
Hydrogen-rich refinery waste gas
Waste gas from chemical plants, e.g.ammonia or methanol synthesis
Ammonia dissociated gas
Process gas from Steam Reformingor Methanol Reforming plants
Membrane offgas
Due to the flexibility of the controlsystem the HYDROSWING system
can be adapted to a change in feedgas composition.
or high purity hydrogen there is aide range of industrial applications,
e.g. in the
Metallurgical and steel industry
Petrochemical and refining industry
Glass and float glass manufacturing
Chemical and pharmaceutical
industry
Production of H2 2
Food industry
Electronics industry
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
10/16
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
11/16
Product flexibilityPurities up to 94% by volume(N2 content down to 1% by volume)Plant capacity up to 200 tpd/5.000 Nm /hAutomatic partload down to 10%Delivery pressure as required
High reliabilityMany years of experience inplant design and manufacturing
guarantees high reliability ofall OXYSWING systems
Rapid on-line timeAll OXYSWING systems areon-spec within minutes
Full automationAll OXYSWING systems aredesigned for unattended operationand automatic load adjustment
Minimal space requirementsDesign and construction methodsminimize the space required
Independent on-site productionProduction is not affected by road
transportation or prevailing weatherconditions
Cost efficiencyLow power consumptionNo injection water / cooling waterMinimized maintenanceand operating costs
P l a n t F e a t u r e s
App l i c a t i o n s
sers in wide range
of industrial applications cancut the production costs by usinghe Mahler AGS OXYSWING systems.
Typical applications:
Glass and enamel industryMelting of glass in melting endsMelting of enamel in rotary drum typekilns and tank furnaces
eating of effluent grooves
Steel industryArc furnaces
Cupola melting furnacesolding furnacesorge furnaces
Pulp and paper industryOxygen delignification
lack liquor oxidationeed gas for the ozone production
at the ozone bleaching stage
Chemical industryOxidation processes such asprodution of Hydrogen Peroxide
Potable water supplyeedgas for ozone productionor potable water treatment
Public and private waste watertreatment and waste disposalindustriesAerobic waste water treatmentThermal refuse incineration
Biotechnologyermentation processes
1: air compression unit2: air separation unit
3: evacuation unit4: oxygen buffer vessel5: oxygen compression unit6: back-up system
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
12/16
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
13/16
Product flexibilityPurities of 100 ppm to 5% by volumePlant capacities up to 300 tpdAutomatic partload down to 10%Delivery pressure up to 10 barwithout booster
High reliabilityMany years of experience inplant design and manufacturingguarantees high reliability ofall NITROSWING systems
Rapid on-line timeEach NITROSWING system has astart-up period less than 5 minutes
Full automationAll NITROSWING systems aredesigned for unattended operationand automatic load adjustment
Minimal space requirementsackaged units minimize the space
required (containerization possible)
Flexibility of locationOutdoor installation, as well asinstallation on ships and offshore
platforms, is possible
Independent on-site productionroduction is not affected by roadransportation or prevailing weather
conditions
Cost efficiencyow power
consumptiono cooling water
Minimizedmaintenanceand operating
costs
P l a n t F e a t u r e s
App l i c a t i o n s
The Mahler AGS NITROSWING
systems gives a broad spectrumof applications, e.g.:
Shipyardsurging and blanketing of gas tanks
Metallurgy / Heat treatmentAnnealing
ardening and brazingowdered metal sintering
Chemical andpharmaceutical industry
urging of tanks and vesselsiplines blanketingrevention of oxidation during
processing and storage of plasticsneumatic conveyance
Food industryControlled atmosphere storageof fruits and vegetables
ackaging of foodslanketing of wines and oils
Electronics industryitrogen atmosphere for
manufacturing of semiconductorsand electrical components
Mining industryitrogen plants for explosion
protection and fire fighting
Petrochemical industry
1: air compression unit2: air seperation unit
: nitrogen buffer vessel: back-up system
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
14/16
Capacities up to 1000 Nm3/h
ydrogen content max. 15 % by vol.
CO content max. 250 ppm CO2 content less than 5 ppm
itrogen: balance
Feed: Natural gas, LPG, other hydrocarbons
Application in heat treatment processes offerrous & non-ferrous metals.
NH3 Dissociators
Protective Gas Generators HN
ENDO - Gas Generators
Capacities up to 300 Nm3/h
ydrogen content approx. 75 % by vol.
itrogen content approx. 25 % by vol.
H3 content less than 150 ppm
Feed: Ammonia
Application in heat treatment processes of
ferrous & non-ferrous metals and brazing.
Capacities up to 300 Nm3/h
Hydrogen content max. 11 % by vol.
CO content max. 8 % by vol.
CO2 content 50 ppm to 12 % by vol.
Oxygen content less than 10 ppm
Nitrogen: balance
Feed: Natural gas, LPG, other hydrocarbons
Application in heat treatment processes offerrous & non-ferrous metals and brazing.
Capacities up to 100 Nm3/h
Hydrogen content max. 40 % by vol.
CO content max. 20 % by vol.
CO2 content less than 0,2 % by vol.
Nitrogen: balance
eed: Natural gas and LPG
Application in carburization, hardening andsintering of steel.
EXO - Gas Generators
HN Gas Generator 200 Nm3/h withautomatic hydrogen analysis control
EXO Gas Generator 125 Nm3/hCombustion and adsorption unitfor simultaneous removal of CO2and water vapor
NH3 Dissociator 300 Nm3/h
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
15/16
-
8/6/2019 Firmenbroschuere Mahler AGS GmbH
16/16
Mahler AGS GmbH
Inselstrae 140
D-70327 Stuttgart
Tel.: +49 711 87030-0
Fax: +49 711 870 30-200
www.mahler-ags.com
Hydrogen Joachim HeydenTel. +49 711 87030-182
Ralph GFW Stau
Tel. +49 711 87030-183
Oxygen/Nitrogen Josef Latzko
Tel. +49 711 87030-181
Contact