Turbo expanders

Insights into the Turbo Expander Market Dynamics

Market Overview: The turbo expander market has demonstrated robust growth, expanding from USD 1.36 billion in 2023 to USD 1.47 billion in 2024, with projections indicating a continued upward trajectory at a compound annual growth rate (CAGR) of 8.37%, potentially reaching USD 2.39 billion by 2030, according to 360iResearch™. This growth is largely driven by increasing applications in energy recovery and oil and gas processing, with segments such as radial flow turbo expanders expected to reach USD 806.2 million by 2030, growing at a CAGR of 4.7% during the same period. The U.S. market, valued at USD 270.1 million in 2023, is also noteworthy, along with China, which is forecasted to grow at an impressive 7.9% CAGR to reach USD 304.4 million by 2030, as reported by Global Industry Analysts, Inc.

Competitive Landscape: Key players in the turbo expander market include industry leaders such as Air Products and Chemicals, Inc., Atlas Copco AB, and Siemens AG, who are focusing on innovation and strategic partnerships to enhance their market positions. The competitive dynamics are characterized by a mix of accumulation and fragmentation, where companies are striving to carve out niche markets while facing challenges in maintaining market share. As companies increasingly recognize the importance of energy efficiency and sustainability, there is a noticeable shift in consumer behavior, favoring products that contribute to these goals. Additionally, distribution channels are evolving, with a growing preference for online platforms like Alibaba.com, enabling easier access to a wider array of turbo expanders and fostering a more competitive marketplace.

Types of turbo expanders

A turbo expander is a device in which the flow of high-pressure gas is throttled to lower pressure, producing work or mechanical energy in the form of rotation. Turbo expanders are primarily used in industries like oil and gas, aerospace, power generation, and cryogenics.

There are different types of turbo expanders, as listed below:

• Screw Expander

  This expander uses two intermeshing helical screws. The gas or air coming from the inlet section rotates one of the screws, which causes the second screw to rotate due to their intermeshing. One or both screws can be connected to a generator or used directly for mechanical work. Example applications of the screw expander include refrigeration compression, gas fouling and power recovery, gas turbine and power recovery, and expanders on gas compressors.

• Radial Expander

  This expander comes with a fixed inner blade and a rotating outer shrouded wheel. The gas or air that enters the outer circumference goes through the fixed blades, causing the wheel to rotate. The radial expander is characterized by simplicity of design and a wide range of applications, including refrigeration cycles, waste heat recovery, gas turbine fouling, drive compressors, and Joule-Thompson cooling.

• Axial expander

  Like the radial expander, the axial expander also converts gas pressure to rotation. In this case, the flowing gas goes through a series of moving and stationary blades, which causes the rotor to turn. The axial expander is employed in cryogenic refrigeration, gas turbine, and waste heat recovery, among others.

• Centrifugal expander

  This expander uses the gas or air pressure to rotate a disk or wheel. The pressure difference causes the fluid to flow from the disk's hub to the external part (the rim), turning the disk or wheel. The centrifugal expander is suitable for power generation from high-pressure steam in clean industries, waste heat recovery, and gas pressure reduction.

• Organic Rankine Cycle (ORC) Turbine

  The ORC turbine works similarly to steam turbines, employing a cycle meant to use organic fluids with low boiling points and recovering heat from sources like geothermal heat, waste heat from engines, or solar thermal fluids. It is especially great for industries like waste heat recovery in gas pipelines and medium temperature geothermal energy.

Specifications & Maintenance

Some turbo expanders' specifications are as follows.

• Operation: Turbo expanders operate by expanding high-pressure gas in a controlled manner. This expansion may be done with a twin-screw turbo expander or a turbo expander with a turbine and generator.
• Temperature change: Turbo expanders usually cause a temperature drop between -40 and -60 degrees C. Such a drop may lead to cryogenic cooling.
• Pressure: Turbo expanders work from a high inlet pressure of 2,000 psi to as low as 14.7 psi (atmospheric pressure). A typical outlet pressure will be from 100 to 400 psi.
• Flow Rate: Turboexpanders can process gases between 60,000 to 150 million standard cubic feet per minute. The flow will depend on the type and design of the turbo expander.
• Power: A turbo-expander will make anywhere from 50 kilowatts to 370 megawatts of electric power at the outlet.
• Efficiency: Turbo expanders are highly efficient devices. The overall efficiency of these machines is often between 70% and 80%.

Maintenance requirements:

• Regular checks: Every month, the users should check the turbo expander or air compressors for signs of leakage or damage to parts like gaskets and seals. A turbo expander with flaws may lead to gas leakage with disastrous environmental consequences.
• Lubrication: An ideal maintenance requirement for a turbo expander or compressor is continuous lubrication. The lubricating parts include bearings and sealing devices. Lubricants like grease or oil may be used, depending on the type of compressor.
• Balancing: The moving parts, such as rotors, shafts, and turbines, should be balanced to avoid vibration. Unstable parts may cause uneven wear and damage to the equipment.
• Cleaning: Precise cleaning of turbo expanders helps to avoid dirt and debris buildup. Bacterial growth inside the turbines will also be prevented. Cleaning the air filters of turbo expanders is also very important.

Scenarios of turbo expanders

• Natural gas processing plants:

  In the natural gas industry, turbo expanders are frequently used in gas processing facilities to extract NGL. The turbo expanders operate on the principle of rectifying refrigerant gas to separate various hydrocarbons like ethane, propane, butane, and natural gasoline.

• Cryogenic gas cooling:

  A cryogenic turbo expander can be used to cool gas down to cryogenic temperatures by employing Joule-Thompson refrigeration cycles. Turbo expanders are widely used in the natural gas industry to produce cryogenic refrigeration.

• Refinery operations:

  Turbine expanders play a crucial role in refineries, notably in the creation of hydrogen through the steam reforming of hydrocarbons. Hydrogen serves as an essential component in refineries for various purposes, including desulfurization and the treatment of certain chemicals and catalysts.

• Industrial manufacturing:

  Turbine expanders have a multitude of applications in manufacturing industries. These include the production of ammonia fertilizer, which employs turbo expanders in the Haber process, the synthesis of various chemical compounds utilizing turbo expanders in exothermic processes, and the operation of turbo expanders in steam systems for power generation. Turbo expanders also find application in the recovery of waste heat from gas turbines.

• Aerospace industry:

  The aerospace industry utilizes turbo expanders in rocket propulsion systems that run on cryogenic propellants such as liquid oxygen and liquid natural gas. These turbo expanders serve the purpose of pressurizing cryogenic fluids for rocket engines.

How to choose turbo-expanders

• Process requirements analysis

  Assess the specific process requirements of the application, including the gas type, initial temperature and pressure, expansion target (cooling, power generation or other), capacity and other parameters. This may include considering the characteristics of the working medium, the nature of the process, and the desired outcome.

• Capacity and pressure drop

  Select a turbo expander with the proper capacity to meet the cooling or power generation needs of the process. Additionally, analyze the pressure drop that the turbo expander can provide and ensure that it matches the requirements of the process.

• Temperature and cooling requirements

  If the primary purpose of the turbo expander is to provide cooling, select an expander capable of achieving the required temperature and cooling capacity. Consider the position of the turbo expander in the process flow to ensure it meets the cooling needs of the entire process.

• Material and design

  Choose suitable materials and designs for the turbo expander based on the temperature and pressure conditions of the process. This ensures the equipment's reliability, durability, and safety in operating under the specific process conditions.

• Integration and combination

  Consider the integration and combination of the turbo expander with other equipment in the process. For example, whether it can be effectively combined with heat exchangers, compressors, and other devices to form a complete process system.

• Cost and performance analysis

  Finally, a comprehensive cost and performance analysis of different turbo expanders is necessary to select the one that best meets the process requirements.

FAQ

Q1: What is the difference between a turbo expander and a turbine?

A1: A turbo expander differs from a turbine in that the turbine shaft is driven by a working fluid. In contrast, a turbo expander drives the shaft of an associated generator or compressor by expanding a gas.

Q2: What is the difference between turbo expanders and turbochargers?

A2: While turbo expanders and turbochargers both extract energy from gases, their purposes differ. Turbochargers are primarily used to increase an engine's horsepower by forcing more air into the combustion chamber. Turbo expanders, on the other hand, convert thermal energy from gas expansion into mechanical work.

Q3: Are turbo expanders and gas extractors the same thing?

A3: Not really. A gas extractor is a device that extracts gas from a petroleum reservoir, while a turbo expander is a device that expands gas into work or energy.