Turbo-Expanders for cold production and energy recovery booklet

Product catalog summary

Overview of Cryostar and Turbo-Expanders
Cryostar is a prominent company in the turbo-expander industry, focusing on cold production and energy recovery in the gas supply chain. Established in 1966, it is known for its high-quality radial inflow turbine technology, pumps, and compressors, particularly in natural gas processing and petrochemical applications. The company is headquartered in Hesingue, France, with global operations in the USA, UK, Singapore, China, and Brazil.

Technological Innovations and Expertise
Cryostar is a leader in active magnetic bearings (AMB) technology, boasting the largest base of AMB-equipped expanders worldwide. Their expertise includes applications like dew point control, ethane recovery, and LNG production. They offer turbo-expanders ranging from 100 kW to 12,000 kW, with inlet pressures up to 150 bar and temperatures as low as -196°C. The company is ISO 9001/2000 certified and uses advanced technologies such as Finite Element Analysis and Computational Fluid Dynamics for optimal design and performance.

Product Design and Customization
Cryostar designs turbo-expander packages to meet stringent industry and client requirements, adhering to API 617 standards. Each project is managed by a dedicated engineering team to ensure timely delivery and compliance with specifications. They offer various configurations, including turbo-expanders with active magnetic bearings, oil-lubricated bearings, and oil brake systems. Key components include rotating machinery, seal gas systems, and control panels.

Advanced Features and Components
The turbo-expanders feature high-efficiency wheels made from materials like aluminum alloy, stainless steel, or titanium. They include advanced inlet guide vanes for efficient flow control and a special Hirth connection for superior shaft-to-wheel moment transfer. Cryostar provides different shaft seal systems, including labyrinth and dry gas seals, to minimize leakage and improve efficiency.

Control and Monitoring Systems
Cryostar offers customizable control systems for their turbo-expanders, which can include PLCs, vibration and temperature monitoring, and anti-surge control systems. These systems can be installed locally or remotely and are designed to ensure safe and efficient operation.

Commitment to Quality and Testing
Cryostar follows rigorous inspection and testing protocols, including hydrostatic tests, non-destructive examinations, and performance tests, in compliance with API 617 and ASME standards. The company has invested in state-of-the-art testing facilities to ensure high accuracy and reliability.

Continuous Improvement and Investment
To meet increasing customer demands, Cryostar continues to invest in its facilities and technology, enhancing its capabilities in design, manufacturing, and testing to deliver high-quality turbo-expanders efficiently.

Facility Specifications
The testing facility covers a total area of 910 m², with 650 m² for the test facility and 260 m² for air compressors and inverter rooms. The power supply is 6 MW / 6.6 kV / 50-60 Hz, expandable to 8 MW with external generators. It includes two air compressors totaling 2 MW, capable of achieving 20000 Nm3/h at 10 barg, a 6 MW frequency drive, and a water tower with a circuit designed for 550 m3/h. An air compressor supplies dry and clean air for the facility.

Testing Capabilities
The facility enables testing of 'companders' and high-powered TG and MTC turbines (3-12 MW). It features active magnetic bearings and turbo-expander tests for cold production and energy recovery.

Integrated Solutions
Cryostar offers integrated solutions for the LNG supply chain, including boil-off reliquefaction solutions for LNG carriers. This includes boil-off gas compressors, gas heaters and vaporizers, and cryogenic equipment related to re-liquefaction systems. The equipment diversity allows for safe and reliable operations across various propulsion systems.

Training and Development
Cryostar's Training Centre offers bespoke training packages, attracting major companies like Daewoo, Samsung, and Hyundai. The Centre focuses on structured learning through analysis of training needs, production of training materials, and course preparation. Courses cover theoretical basics, construction, technology, and maintenance.

Service and IT Infrastructure
Cryostar invests in state-of-the-art IT systems, including Blade Center and Storage Area Network, to ensure data integrity. The system supports up to 64 processors and 24 Terabytes of data, allowing online changes without downtime. Cryostar emphasizes pre-sales and after-sales service, offering expert advice and long-term maintenance contracts.

Global Presence
Cryostar operates through eight business centers and 14 agents worldwide, ensuring high service levels and short response times.

Catalog excerpts

Turbo-Expanders for cold production and energy recovery booklet-1

TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY Everywhere in the GAS SUPPLY CHAIN Innovation for CONTINUOUS EXPANSION

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Turbo-Expanders for cold production and energy recovery booklet-2

Cryostar – turbo expander expertise for the gas supply chain in natural gas processing and petrochemical applications For more than 30 years Cryostar has been recognized as a world leader for their superior product quality in radial inflow turbine technology, pumps, LNG boil off gas compressors and air separation. Since Cryostar began in 1966 and followed with the production of their first turbine in 1974, their focus and expertise has been to provide their customers with turbo-expander/compressor and energy recovery systems for cold production and liquid recovery with the highest efficiency...

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Turbo-Expanders for cold production and energy recovery booklet-3

TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY The key advantages of Cryostar Cryostar: the pioneer company in active magnetic bearings expander with an unequal experience ● Cryostar was the first company to develop an expander equipped with active magnetic bearings (AMB) in 1988. ● Cryostar was the first company to supply 8 AMB expanders for natural gas processing (offshore conditions in the North Sea environment) ● Cryostar has the largest base of expanders equipped with AMB in operation in the world ● Proven expertise of applications: dew point control, ethane recovery, NGL recovery,...

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Turbo-Expanders for cold production and energy recovery booklet-4

Cryostar provides the best configuration to match to the application Cryostar designs all their turbo-expander packages to the strictest of industry and client requirements. Compliance to API 617 is standard and in addition, each machine can be fully customized to meet even the most stringent of client requirements. To assure customers on-time delivery to the agreed specification level, an engineering team is selected at the beginning of each project. The team includes of aero-designers, specialists in rotating machinery, instrumentation and control systems, seal gas and lube oil systems all...

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Turbo-Expanders for cold production and energy recovery booklet-5

TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY General principle of cryostar hydrocarbon turbo-expander equipped with oil lubricated bearings 1 ● Expander casing Designed and built under ASME specifications Hydrostatic test at 1.5 times the MAWP Material selected as per the application 5 ● Labyrinth seals Very safe and reliable system 6 ● Bearings Combined radial tilting pad and axial tapered land bearing Maximum stability and reliability 2 ● Expander wheel Open/closed 3D wheel High efficiency up to 92% Milled from solid Heat treatment for maximum strength and durability Material: aluminium...

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Turbo-Expanders for cold production and energy recovery booklet-6

Inlet guide vanes adjusting mechanism – variable flow nozzles For efficient flow control the expander is equipped with a variable inlet guide vanes assembly. Cryostar expander variable inlet guide vanes are designed to provide zero by-pass losses (no loss of efficiency), precision movement control and high efficiency over a wide operating range. Similar to the wheel design, extensive use is made of superior computer programs for the optimization of the nozzle shapes. It allows the optimal design of the vanes and limits the size of the actuator. Preconditioned materials, matched clearances and...

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Turbo-Expanders for cold production and energy recovery booklet-7

TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY Connections between wheel and shaft: innovation for reliability and efficiency Cryostar has developed a special connection between shaft and wheels: the Hirth connection. It offers a superior moment transfer. This connection is a method that yields excellent results for balancing. It is especially adapted for high power and high tip speed applications. Shaft seal system Cryostar can provide different types of shaft seal arrangement depending on the application and client requirement. They are suitable for atmospheric or pressurized reservoirs....

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Turbo-Expanders for cold production and energy recovery booklet-8

BEARINGS: conventional type (oil lubricated bearings) or active magnetic bearings? Active Magnetic Bearings: not only the solution to decrease the dimensions and weight of the machine (no lube oil system) but also a package with three key advantages: ● no risk of process contamination by oil. ● elimination of vibration: the active bearings cancel synchronous vibrations by letting the shaft free to rotate around its inertia axis. ● no maintenance concept. Cryostar has been the first company to develop and to implement AMB on expander/compressor used in natural gas processing. Electromagnets Electromagnetic...

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Turbo-Expanders for cold production and energy recovery booklet-9

TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY AROUND THE EXPANDER: an oil lubrication system (applicable for compressor loaded expander or generator loaded or oil brake loaded expander) The oil lubrication system is dedicated to ensure a proper and continuous lubrication of all bearings and gears of the machine. Cryostar is able to provide simple and low cost oil lubrication system but also some optimized systems designed as per API 614 standard, latest edition. These systems meet the most stringent technical requirements in term of selection of equipments, materials and test to be...

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Turbo-Expanders for cold production and energy recovery booklet-10

Control system of turbo-expanders Cryostar turbo-expanders can be built with simple or very sophisticated control systems, standard or fully customized. The control system can be installed locally on the skid or can be remote for installation in the control room for instance. In case the client requires the possibility to achieve a local control (local start/stop…) a combination is also possible. The control system may include a PLC (programmable logic controller) which is often redundant with dedicated visual display unit so as to provide all the necessary information for a safe operation. Cryostar...

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Turbo-Expanders for cold production and energy recovery booklet-11

TURBO-EXPANDERS FOR COLD PRODUCTION AND ENERGY RECOVERY TECHNOLOGICAL EVOLUTION: The latest technology to design your turbo-expander During recent years, technological advances have provided modern high tech tools and they have drastically changed the way Cryostar designs its equipment. Cryostar has invested in the latest technology to support the expertise and shorten its response time. Cryostar employees use state-of-the –art tools through the entire process. ● Computer Aided Design/Computer Aided Manufacturing [CAD/CAM] systems are used across the entire design and production process. ● Finite...

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