Gas Generators - Mahler AGS

Gas Generation and Purification

Oxygen generation plants for purities
up to 94% by vol. O2 based
on adsorption by
• PSA process
• VPSA or VSA process
Hydrogen generation plants
based on different feedstocks:
• Natural gas
• LPG
• Naphtha
• Methanol
• Purifi cation of hydrogenrich
gases

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 fi 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 speci-
fi cations for fl ow, 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 for
the system. For more details about our
service capabilities
please ask for our
service brochure.
H i g h l i g h t s
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
The combination of Mahler AGS’ after-sales
service, continuous process improvement,
cooperation with research institutes and cer-
tifi cation of the Quality Management System
(according to DIN EN ISO 9001), will ensure
superior products and highest customers’
satisfaction.
A p p l i c a t i o n s
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
• Glass and enamel industry
• Pharmaceutical industry
• Electronics industry

O u r
T e 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 customer‘s requirements and
can be easily integrated into already
existing processes.
HYDROFORM-C: The Hydrogen Generator
T h e B a s i c P r o c e s s
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 purifi ed 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-fi 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.
The HYDROFORM-C system is
available in a range of capacities
from 100 to 10000 Nm 3 /h hydrogen.
Gas Purifi cation - HYDROSWING ®
The hydrogen-rich gas is sent to
the HYDROSWING ® system which
usually consists of four adsorbers
fi 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.
H i g h l i g h t s
• 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
Feed
1
P l a n t F e a t u r e s
Product fl exibility
Purities up to 99.999+ % by volume
Plant capacities
from 100 to 10000 Nm 3
•
•
/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 fi gures
Optimal heat recovery from fl ue gas
and from different process streams,
e.g. preheating of combustion air,
generation of export steam.
5: Heat exchanger unit
6: Pretreatment of boiler feed water
7: Purifi cation unit - HYDROSWING ® system
4
Air
2
6
5
Boiler feed water Cooling water Condensate
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
7
Hydrogen
Purge
A p p l i c a t i o n s
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 refi ning industry
• Glass and fl oat glass manufacturing
• Chemical and pharmaceutical
industry
• Production of H 2O 2
• Food industry
• Electronics industry

O u r
T e 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 fi 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 customer‘s
requirements.
HYDROFORM-M: The Hydrogen Generator
T h e B a s i c P r o c e s s
The HYDROFORM-M system
is based on reforming of methanol
as feed to produce a hydrogen-rich
gas. The purifi cation 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 Purifi cation - HYDROSWING ®
The hydrogen-rich gas is sent
to the HYDROSWING ® system which
usually consists of four adsobers
fi 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.
The HYDROFORM-M system
is able to cover a demand
up to 6000 Nm 3 /h hydrogen.
H i g h l i g h t s
• 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: Purifi cation unit - HYDROSWING ® system
•
•
•
•
•
P l a n t F e a t u r e s A p p l i c a t i o n s
Product fl exibility
Purities up to 99.999+ % by volume
Plant capacities
from 100 to 6000 Nm 3 /h
Automatic part load operation
Product pressure from 7 to 30 bar
Optional H2-compression
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 fi gures
Optimal heat recovery, e.g.
preheating of combustion air and
recovery of process condensate.
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
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 refi ning industry
• Glass and fl oat glass manufacturing
• Chemical and pharmaceutical
industry
• Production of H2O2
• Food industry
• Electronics industry

O u r
T e 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 purifi cation worldwide,
Mahler AGS has the fl exibility to
provide systems that are tailormade
solutions to meet all customer
requirements.
T h e B a s i c P r o c e s s
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 purifi cation is effected in at least
four adsorber vessels to ensure a
continuous hydrogen product fl ow.
The process is defi ned 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 fl 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.
The HYDROSWING ®
system is available in
a range of capacities
from 100 to 10000 Nm 3 /h
hydrogen.
HYDROSWING ®: The Hydrogen Purification System
H i g h l i g h t s
• 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

•
P l a n t F e a t u r e s A p p l i c a t i o n s
Product fl exibility
Purities up to 99.999+ % by volume
Plant capacities from
100 to 10000 Nm 3 •
/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 effi ciency
Low power consumption
• Minimized maintenance and
operating cost
• Minimized cost for supervision
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
F e e d g a s e s
Hydrogen can be recovered by the
HYDROSWING ® system from very
different feed gases, e.g.
• Hydrogen-rich refi nery 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 fl exibility of the control
system the HYDROSWING ® system
can be adapted to a change in feed
gas composition.
For high purity hydrogen there is a
wide range of industrial applications,
e.g. in the
• Metallurgical and steel industry
• Petrochemical and refi ning industry
• Glass and fl oat glass manufacturing
• Chemical and pharmaceutical
industry
• Production of H2O2
• Food industry
• Electronics industry

O u r
T e 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 fl exibility to
provide the right process, be it PSA,
Vacuum Swing Adsorption (VSA) or a
combination of the two (VPSA), for
the appropriate application.
O X Y S W I N G ® : T h e O x y g e n G e n e r a t o r
T h e B a s i c P r o c e s s
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.
Purifi cation
The ambient (inlet) air is fi 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 fl ow of O2
supply, a surge tank is installed.
The OXYSWING ® systems
are able to cover a demand
up to 200 tpd
of oxygen.
H i g h l i g h t s
• Mahler AGS has built one of the
world‘s biggest single train units
• Mahler AGS has built one of the world‘s
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

•
•
•
•
•
•
•
P l a n t F e a t u r e s
Product fl exibility
Purities up to 94% by volume
(N2 content down to 1% by volume)
Plant capacity up to 200 tpd/
5.000 Nm 3 /h
Automatic partload down to 10%
Delivery pressure as required
High reliability
Many years of experience in
plant design and manufacturing
guarantees high reliability of
all OXYSWING ® systems
Rapid on-line time
All OXYSWING ® systems are
„on-spec“ within minutes
•
•
•
1: air compression unit
2: air separation unit
3: evacuation unit
4: oxygen buffer vessel
5: oxygen compression unit
6: back-up system
Full automation
All OXYSWING ® systems are
designed for unattended operation
and automatic load adjustment
Minimal space requirements
Design and construction methods
minimize the space required
Independent on-site production
Production is not affected by road
transportation or prevailing weather
conditions
Cost effi ciency
• Low power consumption
• No injection water / cooling water
• Minimized maintenance
and operating costs
A p p l i c a t i o n s
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 effl uent grooves
Steel industry
• Arc furnaces
• Cupola melting furnaces
• Holding furnaces
• Forge furnaces
Pulp and paper industry
• Oxygen delignifi cation
• Black liquor oxidation
• Feed gas for the ozone production
at the ozone bleaching stage
•
•
Chemical industry
Oxidation processes such as
prodution of Hydrogen Peroxide
Potable water supply
Feedgas for ozone production
for potable water treatment
Public and private waste water
treatment and waste disposal
industries
• Aerobic waste water treatment
•
Thermal refuse incineration
•
Biotechnology
Fermentation processes

O u r
T e 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 fl exibility to
provide the right packages to meet
all customer requirements.
T h 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' 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.
Purifi cation
The ambient (inlet) air is fi 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 fi 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 fl ow in regard to
both purity and quantity is ensured
by a connected buffer.
All NITROSWING ® systems produce nitrogen
to capacities of more than 200 tpd.
N I T R O S W I N G ® : T h e N i t r o g e n G e n e r a t o r
• Mahler AGS has built one of the
world‘s 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 fi lling of carbon
molecular sieve

1: air compression unit
2: air seperation unit
3: nitrogen buffer vessel
4: back-up system
1
P l a n t F e a t u r e s
Product fl 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
•
•
2
High reliability
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
start-up period less than 5 minutes
•
•
•
•
3
4
Full automation
All NITROSWING ® systems are
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
installation on ships and offshore
platforms, is possible
Independent on-site production
Production is not affected by road
transportation or prevailing weather
conditions
Cost effi ciency
• Low power
consumption
• No cooling water
• Minimized
maintenance
and operating
costs
•
A p p l i c a t i o n s
The Mahler AGS‘ NITROSWING ®
systems gives a broad spectrum
of applications, e.g.:
Shipyards
Purging and blanketing of gas tanks
Metallurgy / Heat treatment
• Annealing
• Hardening and brazing
• Powdered metal sintering
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
manufacturing of semiconductors
and electrical components
Mining industry
Nitrogen plants for explosion
protection and fi re fi ghting
Petrochemical industry

• Capacities up to 1000 Nm 3 /h
• Hydrogen content max. 15 % by vol.
• CO content max. 250 ppm
• CO2 content less than 5 ppm
• Nitrogen: balance
EXO - Gas Generators
• Capacities up to 300 Nm 3 /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.
ENDO - Gas Generators
• Capacities up to 100 Nm 3 /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.
Protective Gas Generators HN
Feed: Natural gas, LPG, other hydrocarbons
Application in heat treatment processes of
ferrous & non-ferrous metals.
NH 3 Dissociators
• Capacities up to 300 Nm 3 /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.
HN Gas Generator 200 Nm 3 /h with
automatic hydrogen analysis control
EXO Gas Generator 125 Nm 3 /h
Combustion and adsorption unit
for simultaneous removal of CO2
and water vapor
NH3 Dissociator 300 Nm 3 /h

Hydrogen generation plants based on
reforming of methanol or purifi cation
of raw hydrogen.
Nitrogen generation plants based
on adsorption by PSA process for
purities up to 99,99 % by vol. N2

Mahler AGS GmbH
Inselstraße 140
D-70327 Stuttgart
Contact
Hydrogen Joachim Heyden
Tel. +49 711 87030-182
joachim.heyden@mahler-ags.com
Ralph GFW Stauß
Tel. +49 711 87030-183
ralph.stauss@mahler-ags.com
Oxygen/
Nitrogen Josef Latzko
Tel. +49 711 87030-181
josef.latzko@mahler-ags.com
Tel.: +49 711 870 30-0
Fax: +49 711 870 30-200
info@mahler-ags.com
www.mahler-ags.com