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Axial compressors have been built by MAN Diesel & Turbo since more than 80 years. MAN Diesel & Turbo owns the leading position in the axial compressor market with more than 1000 references until today.
Axial compressors play a key role in the high volume flow industrial applications such as
MAN Diesel & Turbo offers various types of axial flow compressors to meet our customer's specific needs in the air separation sector, the iron & steel industry and fertilizer business. A further market we serve in downstream processes is Fluid Catalytic Cracking (FCC).
AR-MAX1 is a standardized axial/radial (AR) main air compressor equipped with the advanced axial blading generation MAX1. It can deliver volume flows up to 1.5 Mio. cubic meters per hour, pressures up to 25 bar and is uniquely compact, robust and efficient.
MAN Diesel & Turbo has more than 40 years of experience with large axial/radial main air compressors with over 60 references in total until 2013. The latest reference with our conventional AR generation is successfully running in Qatar: QP-Shell Pearl, the world’s largest GTL plant.
MAN Diesel & Turbo has further developed its proven axial/radial main air compressor type AR by equipping it with the advanced axial blading generation MAX1. The MAX1 wide chord blading has a greatly improved robustness against all kinds of mechanical blade loads. Extensive prototype tests and surge tests of the first customer machine have proven impressively that MAX1 exhibits superior surge robustness in the market. Besides the blade geometry itself all parts and design features are well referenced. AR-MAX1 is a fully API compliant standardized modular system with a simple layout and a reduced number of parts.
AR-MAX1 features superior surge robustness. Also regarding compactness AR-MAX1 is a true game changer. Therefore, it is economic in CAPEX and has excellent transport features – the smallest and lightest concept in the market. AR-MAX1 exhibits potential for very high pressures for HP-ASU – also with 2 intercoolings for lowest power consumption – and for very large air compressor trains (7,000 t/d O2 and larger). All components of the main air compressor have been optimized for efficiency with most modern tools and design methods. For the standard ASU pressures AR-MAX1 features only one intercooler between the axial stage group and the radial stage, thus reducing complexity and easing assembly and maintenance.
Axial-flow compressors are used wherever large volumes of gas need to be compressed on the basis of a relatively low intake to discharge pressure ratio. These machines have long been the prime option in, for example, nitric acid plants, fluid catalytic cracking (FCC) production processes, liquid natural gas (LNG) and propane dehydrogenation (PDH) facilities, as blast furnace blowers or fuel gas (Low BTU) compressors and for CO2 compression or CAES applications. Important requirements in these applications, aside from cost-efficiency, are reliability and availability.
MAN Diesel & Turbo is building axial compressors for 80 years and has the biggest amount of accumulated experience in design and manufacturing of industrial axial compressors (over 1000 casings), which makes us the world market leader in axial compressors.
Flows ranging from approx. 50,000 to 1,5 million m³/h can be accommodated in single machines with maximum discharge pressures up to 25 bar. The required size of the compressor and the number of stages are selected according to suction volume flow and thermodynamic head.
All components of the AGM type compressor have been optimized for efficiency. The aero-dynamical design of the axial blading and the subsequent radial diffuser have been optimized with most latest tools and design methods used in the aero engine industry. One main benefit of the AGM type compressor is its superior surge robustness.
Drive and control concepts
Depending on the energy situation of the operator, either steam turbines or electric motors may be used as the drivers of axial-flow compressors. Gas turbines are also employed, although more rarely. The most effective method of control is drive speed regulation. Approx. 60% of axial compressors have been provided with a steam turbine drive featuring speed control, with the remainder being operated at constant speed with variable stator vanes for process regulation.
Whether the variable stator vanes or the speed control system is likely to optimize efficiency depends on the position of the partial loading points in the performance map. Where special requirements have to be fulfilled, it may be advantageous to implement both speed and guide vane control on a sequential basis, provided that this is feasible with the selected driver.
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3D animation of axial flow compressor working principle
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