Gas Generation and Purification

Hydrogen generation plants based on different feedstocks: Natural gas LPG Naphtha Methanol Purication of hydrogenrich gases

Oxygen generation plants for purities up to 94% by vol. O2 based on adsorption by PSA process VPSA or VSA process

About Mahler
With 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 the company in 1870 we are located in the Stuttgart area (Germany) and are active in the eld of engineering high quality gas generation plants. Understanding that every application and location is unique, Mahler AGS offers a variety of cost-effective and reliable on-site generation systems. Working with our customers, Mahler AGS engineers will analyze their requirements and propose a system that meets the specications for ow, purity and pressure. Our business activities include not only design, but also manufacturing, installation and start-up of the system. The combination of Mahler AGS after-sales service, continuous process improvement, cooperation with research institutes and certication of the Quality Management System (according to DIN EN ISO 9001), will ensure superior products and highest customers satisfaction.

A service team is always available to provide any necessary service or maintenance for the system. For more details about our service capabilities please ask for our service brochure.

Applications
Users in a wide range of industries can cut the production costs by using Mahler AGS plants, e.g.: Petrochemical industry Steel and metallurgical industry (ferrous and non-ferrous) Chemical industry Pulp and paper industry Food industry

Highlights
Mahler AGS Has built the first remote controlled automatic SMR-hydrogen plant in the world Our oxygen technology guarantees lowest consumption figures Our largest nitrogen generator is one of the biggest on-site supply PSA systems ever built

Glass and enamel industry Pharmaceutical industry Electronics industry

Our Te c h n o l o g y
Mahler AGS has more than 40 years experience and know-how in designing and manufacturing hydrogen generation plants. As one of the internationally leading suppliers of Steam Reforming and Pressure Swing Adsorption technology, Mahler AGS provides systems which are exactly tailored to the customers requirements and can be easily integrated into already existing processes.

The HYDROFORM-C system is available in a range of capacities from 100 to 10000 Nm3/h hydrogen.

HYDROFORM-C: The Hydrogen Generator

The Basic Process
The HYDROFORM-C system is based on Steam Reforming of natural gas, LPG or naphtha as feed to produce a hydrogen-rich gas. The gas is then puried by the subsequent HYDROSWING system. Pretreatment of the Feed The feed is mixed with a small H2-stream, preheated and sent to the desulphurization reactor. After desulphurization the feed is mixed with process steam generated in the steam boiler. Reforming and High Temperature Conversion The feed/steam-mixture is reformed within the top-red reformer furnace into a raw hydrogen-rich gas. The required heat for the reaction is generated by combustion of fuel gas and of purge gas from the HYDROSWING system. The heat from the reformed gas is recovered for steam generation and the gas is fed to the high temperature CO-conversion reactor to produce additional hydrogen. Gas Cooling by Heat Recovery After CO-conversion the converted gas is cooled-down in a series of heat exchangers by simultaneous economical preheating of process streams. The process condensate is separated and can be reused. Gas Purication - HYDROSWING The hydrogen-rich gas is sent to the HYDROSWING system which usually consists of four adsorbers lled with different adsorbents. This process is based on Pressure Swing Adsorption by which the impurities are separated to obtain high-purity hydrogen with purities up to 99.999+ % by volume. The purge gas from depressurization and purging during the regeneration step is used as fuel gas.

Highlights
Hydrogen plants in operation for more than 40 years with original equipment Mahler AGS has built the first hydrogen plants worldwide with remote control over long distances Mahler AGS has built more than 50 hydrogen plants

1: Feed compression unit 2: Feed pretreatment 3: Reforming and steam generation 4: High temperature conversion 3

5: Heat exchanger unit 6: Pretreatment of boiler feed water 7: Purication unit - HYDROSWING system

Hydrogen
7 Air

Feed

Purge Boiler feed water Cooling water Condensate

Plant Features
Product exibility
Purities up to 99.999+ % by volume Plant capacities

Applications
Mahler AGS HYDROFORM-C system can cut the production costs in a wide range of industrial applications, e.g. in the Metallurgical and steel industry Petrochemical and rening industry Glass and oat glass manufacturing Chemical and pharmaceutical industry Production of H2O2 Food industry Electronics industry

from 100 to 10000 Nm /h Automatic part load operation Product pressure from 10 to 30 bar Optional H2-compression up to 250 bar High operational reliability Many years of experience in plant design, engineering and manufacturing guarantee a high reliability of the HYDROFORM-C system. Modular design The HYDROFORM-C system is preassembled and delivered in prefabricated units. Optimized consumption gures Optimal heat recovery from ue gas and from different process streams, e.g. preheating of combustion air, generation of export steam.

Full automation The HYDROFORM-C system is designed for automatic and unattended operation, e.g. change of capacity. Remote control The HYDROFORM-C system can be designed for automatic start-up and shut-down, control and automatic load adjustment from long distances. High quality and high safety standard Design for long lifetime

Our Te c h n o l o g y
Mahler AGS has more than 40 years experience and know-how in designing and manufacturing hydrogen generation plants and has successfully operated in the eld of Methanol Reforming. As one of the internationally leading suppliers of Methanol Reforming and Pressure Swing Adsorption technology, Mahler AGS provides systems which are characterized by a maximum quality and safety standard and tailored to the customers requirements.

The HYDROFORM-M system is able to cover a demand up to 6000 Nm3/h hydrogen.

HYDROFORM-M: The Hydrogen Generator

The Basic Process
The HYDROFORM-M system is based on reforming of methanol as feed to produce a hydrogen-rich gas. The purication of the hydrogen-rich gas is done by means of the HYDROSWING system. Pretreatment of the Feed Mixture Methanol and fully demineralized water are fed to a storage vessel. Continuous measuring of density and level ensure the availability of the correct ratio of methanol and water. The feed mixture is pumped up and then preheated by heat recovery from raw hydrogen-rich gas. Vapourization and superheating to the optimal reactor inlet temperature is done by thermo-oil in the following heat exchanger. Methanol Reactor The vapourized feed mixture is catalytically reformed within the methanol reactor into a raw hydrogen-rich gas. The reaction is endothermic and the required heat is transferred to the process by thermo-oil, which avoids overheating of the catalyst . The thermo-oil is heated by combustion of purge gas from the HYDROSWING system. Gas Cooling by Heat Recovery The raw hydrogen-rich gas coming from the methanol reactor is cooled down in heat exchangers by simultaneous economical preheating of the feed mixture. The process condensate is separated and sent back to the storage vessel to be reused. Gas Purication - HYDROSWING The hydrogen-rich gas is sent to the HYDROSWING system which usually consists of four adsobers lled with different adsorbents. This process is based on Pressure Swing Adsorption by which the impurities are separated to obtain high-purity hydrogen with purities up to 99.999+ % by volume. The purge gas from depressurization and purging during the regeneration step is used as fuel gas in the thermo-oil system.

Highlights
Hydrogen plants in operation for more than 40 years with original equipment Mahler AGS has built the first hydrogen plants worldwide with remote control over long distances Mahler AGS has built more than 50 hydrogen plants

1: Pretreatment of the feed mixture 2: Methanol reforming and heat exchanger unit 3: Thermo-oil system 4: Purication unit - HYDROSWING system

Plant Features
Product exibility
Purities up to 99.999+ % by volume Plant capacities

Applications
Mahler AGS HYDROFORM-M system can cut the production costs in a wide range of industrial applications, e.g. in the Metallurgical and steel industry Petrochemical and rening industry Glass and oat glass manufacturing Chemical and pharmaceutical industry Production of H2O2 Food industry Electronics industry

from 100 to 6000 Nm3/h

Automatic part load operation Product pressure from 7 to 30 bar Optional H2-compression

Full automation The HYDROFORM-M system is designed for automatic and unattended operation, e.g. change in capacity loading. Remote control The HYDROFORM-M system can be designed for automatic start-up and shut-down, control and automatic load adjustment from long distances. Thermo-oil system to protect the catalyst even in part load High quality and high safety standard Design for long lifetime

up to 250 bar

Low investment cost Modular design High operational reliability Many years of experience in plant design, engineering and manufacturing guarantee high reliability of the HYDROFORM-M system. Optimized consumption gures Optimal heat recovery, e.g. preheating of combustion air and recovery of process condensate.

Our Te c h n o l o g y
Mahler AGS has more than 40 years experience and know-how in designing and manufacturing Pressure Swing Adsorption (PSA) plants. As one of the leading suppliers of this technology for hydrogen purication worldwide, Mahler AGS has the exibility to provide systems that are tailormade solutions to meet all customer requirements.

The HYDROSWING system is available in a range of capacities from 100 to 10000 Nm3/h hydrogen.

HYDROSWING : The Hydrogen Purification System

The Basic Process
Mahler AGS HYDROSWING system is based on the principle of bonding the impurities of a hydrogen-rich feed gas with individually designed adsorbent materials to leave a high purity hydrogen stream. The purication is effected in at least four adsorber vessels to ensure a continuous hydrogen product ow. The process is dened by four main steps. Adsorption The feed gas enters the bottom of the adsorber, the impurities are adsorbed by e.g. molecular sieves and high purity hydrogen leaves the adsorber at the top. Before the adsorption capability of the adsorbents is exhausted, a regenerated adsorber is automatically switched on to adsorption, thus a continuous product ow is guaranteed. Desorption The regeneration is done in several pressure reduction steps. First hydrogen-rich gas is used for repressurization and purging those adsorbers that are in different stages of regeneration. By further depressurization the adsorbed impurities are released and fed to a ventline or to a buffer vessel to be used as fuel gas. Purging At the lowest pressure level the adsorber is purged with hydrogenrich gas from the adsorber which is undergoing desorption. The purge gas is either vented or sent to a buffer vessel. Repressurization The pressure of the purged adsorber is gradually increased to adsorption pressure by depressurization gas coming from other adsorbers and by recycled pure hydrogen.

Highlights
More than 60 systems installed worldwide Plants in operation for more than 40 years with the original equipment Short start-up and shut-down times

Feed gases
Hydrogen can be recovered by the HYDROSWING system from very different feed gases, e.g.
Hydrogen-rich renery waste gas Waste gas from chemical plants, e.g.

ammonia or methanol synthesis

Ammonia dissociated gas Process gas from Steam Reforming

or Methanol Reforming plants

Membrane offgas

Due to the exibility of the control system the HYDROSWING system can be adapted to a change in feed gas composition.

Plant Features
Product exibility
Purities up to 99.999+ % by volume Plant capacities from

Applications
For high purity hydrogen there is a wide range of industrial applications, e.g. in the Metallurgical and steel industry Petrochemical and rening industry Glass and oat glass manufacturing Chemical and pharmaceutical industry Production of H2O2 Food industry Electronics industry

100 to 10000 Nm3/h Product pressure from 7 to 30 bar Automatic part load operation Optional H2 compression up to 250 bar High operational reliability Many years experience in plant design, engineering and manufacturing guarantee a high reliability of the HYDROSWING system. High yield Through individual design according to feed gas composition Use of programmable control system which ensures high recovery even at part load operation Cost efciency
Low power consumption Minimized maintenance and

Full automation The HYDROSWING system is designed for unattended operation and automatic adaptation of cycle times according to plant capacity. Remote control The HYDROSWING system can be designed for automatic start-up and shut-down, control and automatic load adjustment from long distances. High quality and high safety standard

operating cost
Minimized cost for supervision

Our Te c h n o l o g y
Mahler AGS has over 30 years experience and know-how in the design and manufacturing of Pressure Swing Adsorption (PSA) plants. We are in the forefront of this technology and have the exibility to provide the right process, be it PSA, Vacuum Swing Adsorption (VSA) or a combination of the two (VPSA), for the appropriate application.

The OXYSWING systems are able to cover a demand up to 200 tpd of oxygen.

OXYSWING: The Oxygen Generator

The Basic Process
Mahler AGS OXYSWING systems employ the basic principle of air separation at ambient temperatures using Zeolite (a material that adsorbs nitrogen to leave a rich stream of oxygen). The adsorptive separation of air is effected in three main process steps. Purication The ambient (inlet) air is ltered before being compressed, moderately, by a blower system. Adsorption The pre-treated air passes into a vessel containing molecular sieves to remove any moisture and/or CO2 and adsorbs the N2 while O2 passes through the vessel outlet. Before the adsorption capability of the molecular sieve is exhausted the adsorption process is interrupted. Desorption The saturated molecular sieve is regenerated (i.e. the adsorbed gases released) by means of a pressure reduction below that of the adsorption process. This can be achieved by a simple pressure release system (PSA-process) or using vacuum pumps (VPSA/VSA-process). The resultant waste stream is vented to atmosphere. To maintain a constant ow of O2 supply, a surge tank is installed.

Highlights
Mahler AGS has built one of the worlds biggest single train units Mahler AGS has built one of the worlds highest (elevation-wise) plants Mahler AGS supplies plants with the top overall performance and cost ratio: 3 Low electrical energy consumption 3 Highest availability 3 No injection and cooling water Plants in operation for more than 15 years with original equipment

Applications
Users in wide range of industrial applications can cut the production costs by using the Mahler AGS OXYSWING systems. Typical applications: Glass and enamel industry
Melting of glass in melting ends Melting of enamel in rotary drum type

kilns and tank furnaces

Heating of efuent grooves

1: air compression unit 2: air separation unit 3: evacuation unit 4: oxygen buffer vessel 5: oxygen compression unit 6: back-up system

Steel industry Arc furnaces Cupola melting furnaces Holding furnaces Forge furnaces Pulp and paper industry

Oxygen delignication Black liquor oxidation Feed gas for the ozone production

at the ozone bleaching stage Chemical industry

Oxidation processes such as

prodution of Hydrogen Peroxide

Plant Features
Product exibility
Purities up to 94% by volume (N2 content down to 1% by volume) Plant capacity up to 200 tpd/

Potable water supply

Feedgas for ozone production

for potable water treatment Full automation

All OXYSWING systems are

designed for unattended operation and automatic load adjustment Minimal space requirements
Design and construction methods

5.000 Nm3/h Automatic partload down to 10% Delivery pressure as required High reliability
Many years of experience in

Public and private waste water treatment and waste disposal industries Aerobic waste water treatment Thermal refuse incineration
Fermentation processes

minimize the space required Independent on-site production

Production is not affected by road

Biotechnology

plant design and manufacturing guarantees high reliability of all OXYSWING systems Rapid on-line time
All OXYSWING systems are

transportation or prevailing weather conditions Cost efciency

Low power consumption No injection water / cooling water Minimized maintenance

on-spec within minutes

and operating costs

Our Te c h n o l o g y
Mahler AGS has over 30 years experience and know-how in the design and manufacturing of Pressure Swing Adsorption (PSA) plants. We are in the forefront of this technology and have the exibility to provide the right packages to meet all customer requirements.

All NITROSWING systems produce nitrogen to capacities of more than 200 tpd.

NITROSWING: The Nitrogen Generator The Basic Process

Mahler AGS' NITROSWING systems use the basic principle of passing air over an adsorbent material which bonds with oxygen to leave a rich stream of nitrogen. The adsorptive separation of air is affected in three process steps. Purication The ambient (inlet) air is ltered before being compressed by an air compressor and dried by an air dryer system. Adsorption The pre-treated air is passed into a vessel lled with Carbon Molecular Sieve (CMS) where most of the oxygen is adsorbed so that nitrogen, with an adjustable purity down to a residual O2 content of 100 ppm remains in the gas stream. Before the adsorption capability of the CMS is exhausted the adsorption process is interrupted. Desorption The saturated CMS is regenerated (i.e. the adsorbed gases are released) by means of pressure reduction below that of the adsorption process This is achieved by a simple pressure release system. The resultant waste stream is vented into atmosphere. The regenerated adsorbent will now be used again for the generation of nitrogen. Adsorption and desorption take place alternately at equal time intervals.This means that the continuous generation of nitrogen can be achieved with two adsorbers, one being switched at adsorption and the other at regeneration. Constant product ow in regard to both purity and quantity is ensured by a connected buffer.

Highlights
Mahler AGS has built one of the worlds biggest nitrogen plants with a total capacity of 210 tpd Mahler AGS has installed more than 190 industrial plants in the range of 1-210 tpd worldwide Plants in operation for more than 20 years with initial lling of carbon molecular sieve

1: air compression unit 2: air seperation unit 3: nitrogen buffer vessel 4: back-up system

Applications
The Mahler AGS NITROSWING systems gives a broad spectrum of applications, e.g.: 2 3 Shipyards
Purging and blanketing of gas tanks

Metallurgy / Heat treatment

Annealing Hardening and brazing Powdered metal sintering

1 4

Chemical and pharmaceutical industry Purging of tanks and vessels Piplines blanketing Prevention of oxidation during processing and storage of plastics Pneumatic conveyance Food industry

Controlled atmosphere storage

of fruits and vegetables

Packaging of foods Blanketing of wines and oils

Electronics industry
Nitrogen atmosphere for

Plant Features

manufacturing of semiconductors and electrical components Mining industry

Nitrogen plants for explosion

Product exibility Purities of 100 ppm to 5% by volume Plant capacities up to 300 tpd Automatic partload down to 10% Delivery pressure up to 10 bar without booster High reliability

Full automation
All NITROSWING systems are

protection and re ghting Petrochemical industry

designed for unattended operation and automatic load adjustment Minimal space requirements
Packaged units minimize the space

required (containerization possible) Flexibility of location

Outdoor installation, as well as

Many years of experience in

plant design and manufacturing guarantees high reliability of all NITROSWING systems Rapid on-line time
Each NITROSWING system has a

installation on ships and offshore platforms, is possible Independent on-site production

Production is not affected by road

start-up period less than 5 minutes

transportation or prevailing weather conditions Cost efciency

Low power

consumption
No cooling water Minimized

maintenance and operating costs

Protective Gas Generators HN

Capacities up to 1000 Nm3/h Hydrogen content max. 15 % by vol. CO content max. 250 ppm CO2 content less than 5 ppm Nitrogen: balance Feed: Natural gas, LPG, other hydrocarbons Application in heat treatment processes of ferrous & non-ferrous metals.

HN Gas Generator 200 Nm3/h with automatic hydrogen analysis control

EXO - Gas Generators

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 of ferrous & non-ferrous metals and brazing. EXO Gas Generator 125 Nm3/h Combustion and adsorption unit for simultaneous removal of CO2 and water vapor

NH3 Dissociators
NH3 Dissociator 300 Nm3/h Capacities up to 300 Nm3/h Hydrogen content approx. 75 % by vol. Nitrogen content approx. 25 % by vol. NH3 content less than 150 ppm Feed: Ammonia Application in heat treatment processes of ferrous & non-ferrous metals and brazing.

ENDO - Gas Generators

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 Feed: Natural gas and LPG Application in carburization, hardening and sintering of steel.

Hydrogen generation plants based on reforming of methanol or purication of raw hydrogen.

Nitrogen generation plants based on adsorption by PSA process for purities up to 99,99 % by vol. N2

Contact

Hydrogen

Joachim Heyden Tel. +49 711 87030-182 joachim.heyden@mahler-ags.com Ralph GFW Stau Tel. +49 711 87030-183 ralph.stauss@mahler-ags.com

Oxygen/ Nitrogen

Josef Latzko Tel. +49 711 87030-181 josef.latzko@mahler-ags.com

Mahler AGS GmbH Inselstrae 140 D-70327 Stuttgart Tel.: +49 711 870 30-0 Fax: +49 711 870 30-200 info@mahler-ags.com www.mahler-ags.com