Firmenbroschuere Mahler AGS GmbH

8/6/2019 Firmenbroschuere Mahler AGS GmbH

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Gas Generation and Purification


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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


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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


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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


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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


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



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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.


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.


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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


Design for long lifetime

Mahler AGS HYDROFORM-M systemcan cut the production costs in a widerange of industrial applications, e.g.in the





industry Production of H2O2

Food industry



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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.


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


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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.


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





industry

Production of H2 2

Food industry



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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



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


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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



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


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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


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.


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.


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


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Mahler AGS GmbH

Inselstrae 140

D-70327 Stuttgart

Tel.: +49 711 87030-0

Fax: +49 711 870 30-200

[email protected]

www.mahler-ags.com

Hydrogen Joachim HeydenTel. +49 711 87030-182

[email protected]

Ralph GFW Stau

Tel. +49 711 87030-183

[email protected]

Oxygen/Nitrogen Josef Latzko

Tel. +49 711 87030-181

[email protected]

Contact

Firmenbroschuere Mahler AGS GmbH

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