OIL & GAS APPLICATIONS

Gas Lift
Injecting natural gas into the riser reduces the weight of the oil column to the extent that
the pressure existing in the remaining reserves is sufficient to raise the oil-gas mixture as
far as the production platform. The gas is separated from the oil again in downstream
separation plants.

MAN Turbo offers the following machines for these installations:

• Gas lift compressors (centrifugal compressors) in the pressure range from about
100 to 150 bar.
• Compressor/gas turbine unit gas lift compressor and industrial gas turbine in the
THM series)
• Fully operational gas-lift-module with compressors and turbines for offshore use
• Pipeline compressors
• Process gas screw compressors

Gas Injection
Natural gas is injected directly into the oil field. This increases the pressure in the reserve
again, rendering further oil extraction possible.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors with vertical split joint, and gas lift compressors
• Compressor units, e.g. for FPSO (Floating Production Storage Offloading)
• Compressor/gas turbine unit with industrial gas turbine in the THM series

Gas Export
To distribute and export natural gas to different consumers, compressors are used, which
are designed primarily to cover peak demand. The operating conditions associated with
this favour compressors with a high level of flexibility, to cover large volume ranges and
large pressure ranges alike.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors (barrel-type compressors)

• Pipeline compressors
• Process-gas screw compressors
 • THM and FT8 gas turbines

In gas gathering, the quantities of gas occurring in many small gas fields are collected
and compressed. In comparison to gas lift or gas reinjection, different volume flows
occur here at different pressure levels. The compressors have to demonstrate a high level
of flexibility to accommodate constantly changing process pressures and gas
compositions.

MAN Turbo offers the following machines for these installations:

• Multistage centrifugal compressors

• Single-stage centrifugal compressors as fully assembled units
• Process-gas screw compressors
• THM and FT8 gas turbines

Gas Treatment
Following extraction, moist crude gas is cleaned to remove undesirable constituents such
as higher hydrocarbons and traces of mercury. These are separated in so-called gas drying
plants. Subsequent cleaning and separation processes produce commercially usable
natural gas, which is available for further processing thanks e.g. to liquefaction (gas-to-
liquids, natural gas liquids).

Gas Processing
Before natural gas can be fed into a supply network, it has to be processed. Facilities for
processing natural gas are often located in direct proximity to the gas transporting plant.
The composition of the natural gas transported is dependent on the type and depth of the
deposit. Water is present as an attendant substance in the form of deposit water and
condensation water. To prevent corrosion and obstructions in long-distance pipelines, it is
necessary to dry the moist crude gas in so-called gas drying plants.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors (high pressure compressors)

• Process-gas screw compressors
• THM and FT8 gas turbines

Gas Transport
To transport natural gas over very large distances, the compressors are integrated directly
into the main gas pipeline. They are characterised by their compact, sturdy design. All
internals can be removed and inspected without having to separate the casing flange
joints from the gas pipeline. With a view to easy maintenance and lower erection costs,
the pipeline compressors are delivered fully assembled on the base frame.

MAN Turbo offers the following machines for these installations:

• Single- and multistage pipeline compressors (centrifugal compressors mainly of

the barrel type)
• Motor-driven pipeline compressors (MOPICO, HOFIM™, HOFIM™ Sealed) for
throughputs of up to 2,000,000 Nm³/h
• Compressor-gas turbine-unit with industrial gas turbines in the THM series or the
FT8 series

Gas Storage
To even out seasonal variations in demand by gas consumers, gas that is not required is
withdrawn from the pipeline and compressed, stored and then taken from gas storage
facilities at times of peak demand. Compressors are used to store and tap the gas in the
storage facility. If the storage pressure falls below the pipeline pressure, the compressors
are needed to increase it. The necessary capacity and transportation flexibility in
operation of the storage facility is guaranteed by operating complete machinery trains
(e.g. centrifugal compressor / gas turbine unit) or two process stages in a compressor
casing in series and in parallel.

MAN Turbo offers the following machines for these installations:

• Single- and multistage centrifugal compressors (principally high pressure

barrel-type compressors)
• Compressor/gas turbine unit with industrial gas turbine in the THM series or the
FT8 series

Liquefied Natural Gas

If a source of natural gas is located at an extreme distance from gas consumers and
pipeline transportation is uneconomical, the gas can also be liquefied and carried by sea,
for example. To liquefy natural gas, refrigerating compressors that can take up large feed
flows are used. Different temperatures between the main gas and the feed gas call for
homogeneous mixing inside the compressor.

MAN Turbo offers the following machines for these installations:

• Axial compressors
• Single- and multistage centrifugal compressors (primarily high pressure barrel-
type compressors) with up to two process stages in series or parallel operation
 • Process-gas screw compressors
• THM and FT8 gas turbines
• Steam turbines

Gas-to-Liquids
In the gas-to-liquids process, natural gas and synthetic lubricants and propellants are
produced from gaseous substances by means of various petrochemical processes.
The conversion to synthesis gas takes place directly at the natural gas deposits. GTL
technology is also suitable for processing the "waste gas" occurring in mineral oil
extraction.

MAN Turbo offers the following machines for these installations:

• Axial compressors
• Centrifugal compressors
• Isotherm compressors
• Gear-type compressors
• Process-gas screw compressors
• THM and FT8 gas turbines
• Steam turbines.

Other Oil & Gas

MAN Turbo offers solutions for other processes in the oil and gas industry too, such as
gas distribution, natural gas liquids, flare gas.

• Liquefied Petroleum Gas (LPG)

• CO2 Injection

Refinery

Hydrogen Processing
In the refinery post-treatment and refining process, extraction and dewaxing are followed
by refining, in which the remaining pollutants are removed from the oil. To do this, the
feedstock is subjected to a catalytic treatment using hydrogen to improve the product
quality further.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors
• Gear-type compressors
• Process-gas screw compressors
 • Steam turbines

Hydrogen Production
Many industrial applications call for large quantities of hydrogen. Hydrogen can be
obtained by reforming natural gas or higher hydrocarbons. The natural gas supplied is
enriched with hydrogen, desulphurized and then mixed with steam. The result is a
synthesis gas. After the air has been filtered out of the mixture, a gas enriched with
hydrogen remains. Alternatively, the hydrogen can be cleaned using low-temperature
processes.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors
• Expander

Hydrogen Recovery
Using pressure swing adsorption, virtually complete recovery of pure hydrogen is
possible from hydrogen-rich process gases such as those occurring for example in the
refinery process, in petrochemical and chemical processes and in the iron and steel
industry. It can then be used in other industrial processes. Plants used to recover
hydrogen from purge gas supply it to industrial processes, e.g. for gener-ating synthesis
gas or to produce ammonia. Low temperature processes are one of the methods employed
for this. In this process, hydrogen is produced under pressure, making it possible to feed
it into a synthesis gas compressor.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors
• High-pressure compressors
• Process-gas screw compressors
• Steam Turbines

Hydrogen Cracking
Using pressure swing adsorption, virtually complete recovery of pure hydrogen is
possible from hydrogen-rich process gases such as those occurring for example in the
refinery process, in petrochemical and chemical processes and in the iron and steel
industry. It can then be used in other industrial processes. Plants used to recover
hydrogen from purge gas supply it to industrial processes, e.g. for gener-ating synthesis
gas or to produce ammonia. Low temperature processes are one of the methods employed
for this. In this process, hydrogen is produced under pressure, making it possible to feed
it into a synthesis gas compressor.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors
• Process-gas screw compressors
• Steam turbines

Refinery
Desulfurization
To reduce the naturally occurring sulphur content in natural gas, desulfurization has to be
carried out in a hydrofiner during distillation (liquid gas, petrol, diesel fuel, heating oil).
To do this, the distillate is mixed with hydrogen, heated and then routed to a reactor filled
with a catalyst. This produces hydrogen sulphide. The cleaned product, plus the
remaining hydrogen and the hydrogen sulphide are separated repeatedly. The hydrogen is
used afresh as a basic material in the process.

MAN Turbo offers the following machines for these installations:

• Centrifugal compressors
• Steam turbines

Catalytic Cracking
Fluid catalytic cracking plants are basic production units in a refinery and offer one of the
most effective options for converting heavy hydrocarbons (e.g. in mineral oil) into low
boiling products (e.g. diesel, petrol, kerosene etc.). RCC plants process mainly refinery
residues. The efficiency of such an installation helps to determine the profitability of a
refinery.
One key MAN Turbo product, the axial compressor, has been in use in FCC/RCC plants
for many years. The compressor supplies the air here for the regeneration cycle of the
catalyst and is thus at the heart of the entire facility.

MAN Turbo offers the following machines for these installations:

• Axial compressors
• Centrifugal compressors for wet gas and other CH gases
• Expander
• Steam turbines

Propane Dehydrogenation
To convert propane to propylene, the process of catalytic dehydration is used. In this
process, the propane is processed in dehydrating reactors and then separated from the by-
product hydrogen by means of low-temperature processes, for example. Compressors are
required to process and separate these substances.

MAN Turbo offers the following machines for these installations:

• Axial compressors
• Centrifugal compressors
• Gear-type compressor
• Steam turbines

Other Refineries
MAN Turbo offers solutions for a wide range of other refinery processes, such as coal /
oil gasification, crude distillation, platforming, alkylation, isomerization, vacuum
distillation, amine treatment, visbreaking and hydrogen dearomatization.

• Methyl tert butyl ether (MTBE)

• Coken / Delayed Coking

Chemicals &
Petrochemicals

Methanol
Synthesis gas is taken e.g. from an existing ammonia plant and fed into a methanol plant.
Here the ammonia and methanol are separated and subjected to further treatment in
different processes. In the methanol plant, compressors have to implement different
intake and discharge pressures as well as supplying synthesis gas continuously to a
reactor circuit. Thus a single compressor must be able to carry out two different
compressions.

MAN Turbo offers the following machines for these installations:

• Single- or multistage centrifugal compressor (in barrel-type design with integral

gearing)
• Multistage high pressure centrifugal compressors with integral recycled gas stage
as fully assembled units
• Steam turbines
• Gear-type compressor

Olefine
Ethylene is obtained from crude gas in petrochemical processes and forms the basis for
many products in the plastics industry. Ethylene plants are made up of the primary cycle
and a second refrigeration cycle. The raw materials are cracked in the pipe furnace of the
olefin plant and broken down into the main product and other basic materials during the
subsequent distillation processes.

Ethylene is extracted in four stages here:

• Cracking and quenching

• Separation
• Scrubbing
• Separation at low temperature

Terephthalic Acid (PTA)

Terephthalic acid is a basic material used in the production of polyester. MAN Turbo was
closely involved from the outset in developing and optimizing the mechanical
engineering aspects of the terephthalic acid process. The principal machine used in the
oxidation process is the air compressor, while a gas expander recovers energy from the
waste gas. The process heat produced is used to generate steam. The steam turbine and
expander provide the bulk of the power required in the compressor. An electric motor is
used to start the turbomachinery train and then provides the remaining power for the
machinery train, or acts as a generator if there is a surplus of power.

Chlorine
Chlorine is a basic raw material in the chemical and pharmaceutical industry. It is used
for cleaning and disinfection as well as in an antiseptic capacity. The most widespread
application of chlorine is in the manufacture of plastics, with the familiar product
polyvinyl chloride (PVC). At the same time, other chlorine-free plastics such as
polycarbonate are produced on the basis of chlorine. This process simultaneously
generates caustic soda and hydrogen. Compressors are needed primarily in chlorine
processing for the preparation of industrial raw materials.

Other Chemicals & Petrochemicals

MAN Turbo offers solutions for a variety of other chemical and petrochemical processes,
including acetate acid, acrylic acid, adipic acid, butadiene, caprolactam, dimethyl
terephthalate, maleic anhydride, butanediol, polyvinyl chloride, THF, maleic acid and
melamine.

• Styrene Monomer
• Soda Ash

FERTILISERS
Ammonia (NH3)
Fertilizers containing nitrogen can be produced with the aid of ammonia synthesis.
Ammonia is also an important basic material in a number of chemical processes, such as
nitric acid production, as a refrigerant in refrigeration cycles and to provide nitrogen for
nitride treatment of stainless steels. Nitrogen and hydrogen are combined at high
temperatures and high pressure to form ammonia. Natural gas compressors, air
compressors, synthesis gas compressors and ammonia compressors are used in the
process. Steam turbines are suitable machines for driving the turbomachinery trains. Over
50 ammonia plants worldwide currently use compressors and turbines supplied by MAN
Turbo.

Urea
Carbon dioxide (CO2) is rinsed in an upstream ammonia process and mixed with a small
quantity of air. Following subsequent compression, the carbon dioxide mixed gas is
processed with ammonia to produce urea.
As an alternative to the single-shaft machines used hitherto for this application, MAN
Turbo has developed an integrally geared compressor that consumes 20 % less power.
MAN Turbo has also supplied the world’s first ten-stage integrally geared compressor for
a urea plant.

Nitric Acid (HNO3)

This is an important basic material for products manufactured in the chemical and
fertilizer industry. Various production methods are used.
Ammonia oxidizes with the aid of platinum catalysts. The nitrogen oxides contained in
the combustion gases are converted almost completely to nitric acid using water in an
absorber. At the heart of nitric acid plants is the turbomachinery train, which may
comprise an air compressor, nitrous gas compressor, tail gas turbine and steam turbine.
MAN Turbo has been constructing such machinery trains for installations of all sizes,
including the world’s largest nitric acid plant, rated for 2,000 tonnes per day, for almost
50 years.

Blast Furnace
Pig iron is melted with the aid of the blast furnace blast and then processed e.g. in a
steelworks. With the commencement of steel production, MAN Turbo supplied machines
and machinery trains as blast furnace blowers to plants all over the world.

Other Iron & Steel, Mining

MAN Turbo offers solutions for other processes in the iron & steel industry and mining
too, such as direct reduction, top gas expansion and mine ventilation.

Industrial Power Generation

A lack of technical infrastructures prompts industrial companies to decide in favour of
producing their own power. Economic considerations, such as how to utilize the heat
released in the industrial process, also play a part here.

In this case, industrial companies maintain their own power-generating or combined heat
and power plants (CHP), which provide the entire infrastructure of the industrial process
with power and make the company virtually independent of the central energy supply
network.

MAN Turbo offers the following machines for these installations:

• THM Gas Turbine

• FT8 gas turbine (PowerPac and TwinPac variants)
• Steam turbines (generator drive)