Engineered to the MAXimum

AIRMAX – the new standard for large ASU

 A True Game Changer
AR-MAX1 for large air separation units

Assembly of an AR105/06M MAC with six axial stages and one radial stage featuring a 3-D shrouded-type impeller

AR-MAX1 – the standardized axial/radial main air compressor can deliver volume
flows up to 1.5 Mio. cubic meters per hour, pressures up to 25 bar and exhibits
highest robustness: a piece of equipment our customers can rely on.

The family background

MAN Diesel & Turbo offers leading air compression
solutions for air separation units – ASUs –, either with
a radial main air compressor or an axial/radial MAC for
large units – the compressor type AR. MAN Diesel &
Turbo has more than 40 years of experience with large
axial/radial main air compressors with 62 references
in total until 2013. The latest reference with our con-
ventional AR generation is successfully running in
Qatar: QP-Shell Pearl, the world’s largest GTL plant.
The air separation market for these large train sizes is
continuously growing, driven by future-oriented appli-
cations like Gas-To-Liquid or Coal-To-Chemicals.

2 Engineered to the MAX1mum

Transport of the fully assembled AR105/06M MAC to the test stand

AR-MAX1 – a true game changer All components of the main air compressor have been
MAN Diesel & Turbo has further developed its proven optimized for efficiency. The aerodynamical design of
axial/radial main air compressor type AR by equipping the new axial blading and the subsequent radial dif-
it with the advanced axial blading generation MAX1. fuser have been optimized with most modern tools
Besides the blade geometry itself all parts and design and design methods used in the aero engine industry.
features are well referenced. AR-MAX1 is a fully API The excellent operating range of AR-MAX1 – running
compliant standardized modular system with a simple at constant speed – is achieved by four variable guide
layout and a reduced number of parts. vanes. For the standard ASU pressures AR-MAX1
features only one intercooler between the axial stage
Benefits of AR-MAX1 group and the radial stage, thus reducing complexity
AR-MAX1 features superior surge robustness. Also and easing assembly and maintenance. The diago-
regarding compactness AR-MAX1 is a true game nal inlet, the radial stage itself as well as the exit
changer. Therefore, it is economic in CAPEX and has volute have been significantly improved with respect
excellent transport features – the smallest and lightest to their efficiency; resulting in a superior performance
concept in the market. Furthermore, AR-MAX1 exhib- of AR-MAX1.
its potential for very high pressures for HP-ASU – also
with 2 intercoolings – and for very large air compressor
trains (7,000 t/d O2 and larger). Such a “mega-train”
featuring one AR-MAX1 is extremely economic in
CAPEX compared to two “50%-trains”. A further ben-
efit of a mega-train is the shorter delivery time and
lower effort for site erection, operations and mainte-
nance due to the lower train count in large plants.

Engineered to the MAX1mum 3

 Ensuring the Leadership
AIRMAX – the new standard air compressor train for
large ASU

AIRMAX S train: AR105/06M (MAC), DK080/190R (steam turbine), RG45-6 (BAC)

AIRMAX trains serve the needs of todays and future ASU plants. AIRMAX trains
have already demonstrated their applicability to plants that until recently were
considered large but now have become “standard”.

AIRMAX – the new standard air compressor train Benefits of AIRMAX

In order to extend our leading position in the field of AIRMAX trains are very competitive regarding CAPEX
large ASU, MAN Diesel & Turbo developed its new and transportability due to the higher speed and power
train concept called AIRMAX. AIRMAX trains – stand- density of MAC and steam turbine. Regarding OPEX
ardized in the sizes S to XL – consist of an AR-MAX1 AIRMAX sets the benchmark, since the efficiency of the
and a geared-type BAC, both driven by a steam tur- MAC has been further improved, and the steam turbine
bine positioned between MAC and BAC. is now operating at its optimum speed with respect to
efficiency.

4 Engineered to the MAX1mum

 AIRMAX Selection Diagram

28 AIRMAX S
3,000 tpd
AIRMAX M
24

4,000 tpd

AR100

AR105
AIRMAX K
5,000 tpd

AR115
AR110
AIRMAX L
20

AR130
AR120
6,000 tpd
Pressure Ratio [-]

High pressure ASU

AIRMAX XL
7,000 +tpd

AR150
AR140
16

AR160

AR170
IGCC
12

1st order 2012 2nd order 2013

4 trains 11 trains
8

AIRMAX S AIRMAX M
Standard ASU
4

1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 10,000

Tons per day O2 production in one train [t/d O2]

AIRMAX Volume Flow and Power

AIRMAX Oxygen AR-MAX1 Max.-Production Operation
Size Production [t/d] Size MAC Volume Flow [m³/h] Total Train Power 1) [MW]

S 3,000 100 545,000 49

105 612,000 55
M 4,000 110 686,000 61
115 770,000 69
K 5,000 120 864,000 77
130 970,000 86
L 6,000 140 1,088,000 97
150 1,221,000 109
XL 7,000 160 1,370,000 122
170 1,537,000 137
1) For standard ASU pressure (approx. 6 bar). Assumption: BAC power = approx. 1/3 of total train power

2)
AR-MAX1 Dimensions and Weight

AIRMAX Oxygen AR-MAX1
Size Production [t/d] Size Length [m] Width [m] Height [m] Weight [t]

S 3,000 100 5.5 4.1 4.2 91

105 5.8 4.3 4.4 107
M 4,000 110 6.2 4.6 4.6 125
115 6.5 4.7 4.8 144
K 5,000 120 6.8 5.0 5.1 169
130 7.2 5.3 5.4 198
L 6,000 140 7.6 5.5 5.7 232
150 8.0 5.9 6.0 272
XL 7,000 160 8.4 6.2 6.3 320
170 8.9 6.5 6.7 375
2) For standard ASU pressure (approx. 6 bar)

Engineered to the MAX1mum 5

 Uniquely Compact Robust Efficient
MAX1 – the hybrid axial-flow compressor blading

AR-MAX1 rotor for standard ASU pressures with advanced axial blading MAX1

The new hybrid blading MAX1 represents a big step forward in power density and
robustness – a unique combination of the advantages of proven industrial design
and gas turbine technology.

MAX1 – the hybrid axial compressor blading significantly smaller impeller diameter. The strongly
MAN Diesel & Turbo has developed MAX1, the new increased power density drastically improves com-
hybrid blading based on proven industrial design and pactness, production cost and rotordynamics due to
gas turbine technology, together with its development the shorter rotor. The novel blading generation com-
partner MTU Aero Engines. MAX1 combines the ad- bines the increased power density with further essen-
vantages of gas turbine technology – greater stage tial advantages, such as very high efficiency, good
pressure ratios, higher speed and fewer stages – with operating range and highest robustness – a unique
the benefits of industrial axial compressors – high combination of features in the market.
efficiency and wide operating range. The robustness
could even be increased significantly. Superior surge robustness in the market
The MAX1 wide chord blading has a greatly improved
Uniquely Compact Robust Efficient robustness against all kinds of mechanical blade
The two main design targets of the MAX1 blading – a loads. MAX1 represents MAN Diesel & Turbo’s latest
big step forward in power density as well as in robust- generation of surge robustness. Extensive prototype
ness – have both been fully achieved. A speed in- tests and surge tests of the first customer machine
crease of approximately one third has led to a reduc- have proven impressively that MAX1 exhibits superior
tion in axial stage count by roughly one third and to a surge robustness in the market.

6 Engineered to the MAX1mum

New Generation of MAN Compressors for the
World’s Largest CTL and GTL Plants
Superior test results of first customer machines

Lifting of AR-MAX1 compressor to MAN Diesel & Turbo’s test stand in Oberhausen

Market success of AIRMAX train concept stresses in the rotor blades. AR-MAX1 is uniquely ro-
The market has shown a tangible interest in the AIR- bust. It is much more surge robust than any other
MAX train concept from MAN Diesel & Turbo. MAN main air compressor in the market.
Diesel & Turbo received an order for four AIRMAX S
trains, for a nominal output of ~3,000 t/d O2, featuring AR-MAX1 for the world’s largest CTL plants
an AR105/06M MAC at the beginning of 2012. In ASU train sizes are constantly growing to take advan-
spring 2013 MAN Diesel & Turbo received another tage of economies of scale and – due to the lower
order for 11 AIRMAX M trains, featuring an AR115/06M train count in huge plants – also of shorter delivery
MAC for ~3,600 t/d O2. time and lower effort for site erection, operations and
maintenance. With the AIRMAX trains – standardized
Superior test results of AR-MAX1 in the sizes S to XL – our customers are prepared for
The final acceptance tests of the first order were suc- train capacities of 7,000 tons of oxygen per day or
cessfully performed in MAN Diesel & Turbo’s test cen- larger, which is an expected size in the foreseeable
ter for large machinery trains in Oberhausen. The test- future.
bed was equipped with the job intercooler. The MAC
was driven on the test stand by an electric motor. The At MAN Diesel & Turbo we are dedicated to innovation
very extensive test series was concluded with the me- and the continuous improvement of our products to
chanical running and performance test. In total 24 in- meet the challenges of tomorrow.
tensive measurement days were completed success- AR-MAX1 – the air compressor technology of the future.
fully. The performance of AR-MAX1 is significantly
better than expected and the high expectations re-
garding robustness have been fully confirmed. In total
155 MAC surges were measured; all showed very low

Engineered to the MAX1mum 7

All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to
changes and will be assessed and determined individually for each project. This
will depend on the particular characteristics of each individual project, especially
specific site and operational conditions. Copyright © MAN Diesel & Turbo.

MAN Diesel & Turbo

Steinbrinkstr. 1
46145 Oberhausen, Germany
Phone +49 208 692-01
Fax +49 208 692-021
[email protected]
www.mandieselturbo.com

MAN Diesel & Turbo – a member of the MAN Group