Customised and

reliable solutions
for process gases
 Contents Customised and
reliable processes
AERZEN – premium in every process
03 Individual and reliable processes 11 Oil-flooded screw compressor VMY
AERZEN – premium in every process For high differential pressures

Air and process gas compressing or handling are required in all The right plant for every application
04 Industrial and key applications 12 Oil-free process gas blowers key industrial sectors – also in critical or demanding areas. The
Sometimes critical. Always challenging For a wide range of applications operating conditions for the blowers and compressors are as Where gases are compressed in highly critical processes, there
varied as the applications themselves. Process gas solutions are only minimal tolerances. Rely on the unique expertise of a
must therefore meet highly specific requirements. We know leading manufacturer in the field of compressed air and pro-
06 Engineering 14 Service solutions the application-specific challenges inside out and support you cess gas handling. We develop pioneering solutions and overall
From the application to your high-end solution Repair, conversions, modernisation with bespoke engineering. concepts for over 100 countries around the world. Process gas
compressors and blowers, modifications, accessories, and spe-
Experienced partner to the process gas industry cial developments that have proven themselves in around 2,000
08 Water-flooded screw compressor VRW 16 Revamp blower and compressor packages installed worldwide.
Into the energy transition with hydrogen System planning using 3D laser scanning AERZEN is one of the pioneers of compressor technology and
technology is recognised as one of the most competent suppliers of tech- Whether optimisation, modernisation or new system construc-
nical solutions for process gas applications. When you talk to tion: we find the best possible solution. For your individual appli-
10 Oil-free screw compressor VR our experts about machine solutions today, you benefit from cation. For your specific process. For all your questions.
Maximum volume flows with extensive more than 160 years of expertise and experience. From an un-
flexibility usually broad portfolio of solutions with a consistent focus on
efficiency criteria. From extremely long service lives and the
internationality of a global player.

"...about the bespoke accessories for your

application"

2 3
 Industrial and key applications AERZEN machines are unbeatable in terms of quality and ser-
vice life and are suitable for almost all media. They impress
Regardless of the type of construction, sizes, and special
equipment: our machines are configured in such a way that

Sometimes critical
with unconditional reliability and maximum availability, are they fulfil all relevant international regulations, building codes
unrivalled in terms of operating efficiency, and are individually or specifications of the most diverse branches of industry or
tailored to your process conditions. approval bodies. Wherever our machines are working – with

Always challenging Focus on safety and reliability

AERZEN you are on the safe side.

Maximum economic efficiency

Whether chemical and petrochemical industry, refineries, ener-
gy production, oil and gas transport, industrial gas production, AERZEN packages stand for low maintenance. They often run
AERZEN offers the process gas industry an enormously wide range of blower and compressor technolo- refrigeration industry, helium cooling and liquefaction, bre- for decades and are extremely low-maintenance. This reduces
gies. The machines work stand-alone in all key industrial applications, in machine or container networks, weries, food and pharmaceutical industry or coking plants: The downtime and saves costs. Maintenance work is planned and
onshore and offshore. They guarantee a reliable, uninterrupted, and economical production process. process industry often involves highly critical processes that carried out in close co-operation with our After Sales depart-
require maximum precautions for process safety. The safety, ment. With our extensive range of service and modernisation
Under any conditions. In all applications, industries, and countries around the world.
hygiene and environmental requirements are correspondingly options, we can keep the service life of the machine at a con-
high. sistently high level.

Downstream refinery Butadiene

PSA pressure swing adsorption Styrene
Flare gas recovery Soda/Sodium carbonate
Offshore Other

Iron Oil Future Chemical and Industrial gases

and steel and gas technologies petrochemical

Process and cooling gas in Water electrolysis Oxygen

direct iron reduction, Green DRI (Green Steel) Refrigeration systems
Blast furnace and coke Semiconductor industry Helium/liquid gas
oven gas compression Nuclear

4 5
 Engineering.
From the application to
your high-end solution
It’s not the machine that determines the process – it’s the process that determines the machine. This is One partner. In all phases of the project
our philosophy. Reflecting on application the AERZEN way means investing a lot of effort in preparations
to understand the business of your customers. The AERZEN process gas competence centres develop The AERZEN engineering teams accompany your system deve- One-stop-shop for your project: In this way, we ensure that you
lopment through all project phases – from the first site inspec- receive the best possible support – from advice, design and ins-
high-performance solutions on this basis. State-of-the-art technologies for the most demanding process
tion to long after commissioning. As your point of contact, they tallation to service. Our claim: we don't just want to supply you
gas applications in a wide range of industries. take over responsibility for your project in all areas of system with the best products and the highest process air quality. We
design, from project management to quality control and system also want to inspire you along the entire line.
integration. Of course, this also includes the documentation and
certification of the machines, as well as packaging and ship-
ment.

Training and
service

Commissioning
Initial advice
and warranty

Recording the
Installation and
actual state
system integration
and analysis

Basic Project
engineering management

Oil-free screw compressor of the VR series

Global network, local engineering Understanding your process

Process gas machines have to work in the most demanding Through the development of blowers and compressor techno- ! Engineering services from AERZEN:
applications. The requirements for performance and reliability logies for around 2,000 successfully implemented process gas
are therefore extremely high. In order to meet these require- systems in almost all industries and applications worldwide, Process data calculations Pipeline calculations, including
ments, we are pooling our technical expertise in process gas we have gained an enormous wealth of experience and now
(drive power, cooling requirements, etc.) earthquake calculations
competence centres in Germany, Hungary, the USA, and soon have an incredible depth of expertise. There is almost no appli-
also in India. cation case that AERZEN has not solved. Why does AERZEN FEM analysis Advice on all safety issues
invest so much in your task? Because the performance of the Acoustic calculations (e.g. HAZOP studies)
This international network of experts with teams of excellent- machine determines the performance of the production pro- Torsion and lateral-critical calculations Retrofit and revamp, construction
ly trained specialists forms the knowledge base for our local cess. Also because professionalism, experience and an eye for
Design and development of assemblies and electrical engineering,
engineering – from design and measurement to control and detail are the factors relevant to success.
electrical engineering. incl. MSR technology

6 7
 Water-flooded
screw compressor VRW

The right compressors

are the key to success

Bringing large H2 volume flows to intermediate and discharge

pressures with just a few compressor stages without having to
set up huge piston compressor systems – this is precisely where
the VRW 536 M oil-free screw compressor from AERZEN comes
in.

Compression is based on the principle of oil-flooded screw com-

pressors – with a small but significant difference: the oil was
replaced by water. The water serves both to cool the gas and to
seal the gap, enabling compression to higher differential pressu- AERZEN VRW 536 M package.
res with high efficiency.

This stage can therefore replace a two-stage system with tra-

ditional dry screw compressors, and it is even more energy ef-
ficient. This results in significant advantages for you in terms of
footprint as well as investment and operating costs.

Compressor oil-free Volume flows Differential pressure dp

up to 6,000 m³/h* 3 to 9 bar
(*Depending on the differential
pressure)

! Technical properties ! Your benefits – our promise

• Water for cooling the gas and • Oil-lubricated roller bearing for maximum 100% oil-free compression Pre-drying the moist H2 gas
gap sealing (increased efficiency) speed range or volume flow range is not required
• Stainless steel design for maximum • Speed control for adaptation to fluctuating Maximum efficiency and increased
service life (corrosion resistance) process conditions differential pressure in one stage Ideal as a pre-compressor (booster)
• Water-purged mechanical seals • Gear-synchronised rotors for downstream compressor types
on the conveying chamber for 100 % (no contact between the rotors) Minimisation of installation area
• Oil-free compression • Directly driven or via a Also suitable for other critical gas
• Designed for three-year revision cycle step-up gear Reduced investment applications
(MTBO) and operating costs

8 9
 Oil-free Oil-flooded
screw compressor VR screw compressor VMY

AERZEN VRA 536 package. VMY 836 H package.

Compressor oil-free Volume flows from Differential pressure dp Compressor Volume flows from Differential pressure dp
380 to 75,000 m³/h 1.5 to 25 bar oil-flooded 190 to 23,000 m³/h 3 to 20 bar

Oil-free compression for small and large volume flows, for ne- The VMY oil-flooded compressors with control slide can ensure in-
arly all gases: the dry screw compressors from AERZEN are ex- finitely variable control of the volume flow. This can also be used
tremely versatile. Gear ratios and speed controls maximise the as a start unloading device. The secondary rotor is not driven via
already wide range of applications. A large number of proven timing gears (as with oil-free compressors), but via direct force
sealing concepts and the fully separated oil chambers guaran- transmission from the driven rotor. The oil injection quantity regu-
tee smooth continuous operation – even with dirty gases or lates the outlet temperature and ensures that gases with conden-
gases that tend to polymerise. VR compressors from AERZEN sable components are always compressed above the specific dew
are the ideal choice for fluctuating operational states and oil- point temperatures. VMY compressors are the ideal solution for
incompatible gases. gases with low molecular weights, for refrigerants, and generally
for fluctuating operating conditions under high pressure ratios.

10 11
 Process gas blowers
Two-lobe high-performance machines in
oil-free design
Blower package GMD Blower package GR

The GMD series from AERZEN is the universally applicable gas- The GR series is the flexible all-rounder among the Roots blo-
tight booster solution for the low pressure range up to 7 bar g. wers. This series is suitable for the oil-free handling of almost
The blower is equipped with a maintenance-free magnetic cou- all gases for small and large volume flows. Depending on the
pling or, alternatively, an oil-purged double-acting mechanical local conditions, different sealing concepts can be selected to
seal with locking system. The drive shaft seal enables a low- minimise life cycle costs. The separation of the oil chamber
maintenance machine concept. from the conveying chamber makes this series the optimum
solution, especially for gases that are incompatible with oil.
The separation between the oil and process side is effected by a Depending on the size, the GR blower offers a pressure range
special ring seal. A wide range of sizes ensures optimum opera- of 2.5 to 6 bar g.
ting conditions for every design case.

Blower oil-free Volume flows from Differential pressure dp Blower oil-free Volume flows from Differential pressure dp
30 to 12,000 m³/h 150 to 1,000 mbar 90 to 38,000 m³/h 150 to 1,500 mbar

Blower package GM-HP Blower package GQ

The GM-HP high-pressure series was developed for gas boos- The robust high-performance machines of the GQ series have
ter applications with increased inlet pressures. For explosive been developed for continuous operation. The combination
gases, the design pressure of 25 bar g offers the correspon- of an oil-purged mechanical seal with a preceding, flushable
ding pressure shock resistance (inner EX zone). The drive labyrinth separates the oil and conveying chamber safely and
shaft seal is either maintenance-free via a magnetic coupling effectively over the long term. Designed for continuous ope-
or traditional with an oil-purged, double-acting mechanical ration over several years, GQ blowers are the preferred soluti-
seal on for process applications in iron direct reduction plants. The
operating pressure range of the GQ is 2.5 to 6 bar g, depending
on the size.

Blower oil-free Volume flows from Differential pressure dp Blower oil-free Volume flows from Differential pressure dp
50 to 38,000 m³/h 150 to 2,000 mbar 910 to 104,000 m³/h 150 to 1,500 mbar

12 13
 Service solutions for comprehensive
repairs and modernisations

AERZEN process gas machines are designed for continuous operation. If unexpected problems do occur,
specially trained process gas engineers will support you around the clock. In coordination with AERZEN
After Sales, spare parts deliveries, repairs, and overhauls can be prepared quickly and easily. For the highest
possible availability, the best possible productivity and the longest possible service life of your AERZEN
machine.

In-house repairs at AERZEN AERZEN replacement machine.

• Repairs at the head office in our own repair centre • System availability
• Detailed recording of findings • Reduction of downtimes
AERZEN Service Centre • Rapid retouching of components through internal • As repairs to rotating equipment always take time,
The all-round carefree package. Worldwide service centres manufacturing it is very important – especially with critical
guarantee short lead times thanks to high material • Quick access to spare parts thanks to our own warehouse system components – to give close
availability and perfect testing options • Test run after all assembly work ensures the operation of consideration to this when operating a system
each machine
• Guarantee of the highest quality through testing and Please contact parts-service@aerzen.com
documentation of all necessary requirements
AERZEN spare parts • Worldwide and long-term availability of spare parts
Fast and guaranteed availability in OEM quality guaranteed After-sales service
• Precise planning of the repair possible
• Technical support and customer training
• Vibration analyses
Field service AERZEN spare parts • After-sales service engineers in all specialist areas of
Global service. Fast on site, competent and reliable in mechanic and electrical engineering, measurement, control
action • Support with the selection and scheduling of and regulation technology
Services. spare parts • Coordination of commissioning with the
• Well-founded recommendation for critical components, service technicians
which should be in stock at the customer's premises
AERZEN replacement machine • Definition and creation of customer-specific spare parts Do you need support? Then contact
Maximum system availability with absolute kits service@aerzen.com
planning reliability and minimum downtime • Our production and storage methodology helps you
to plan maintenance and repairs with economically
justifiable effort, and also to survive sudden emergencies

After-sales service Involve us in your planning! Please contact parts-service@

Expertise in analysis and consulting with 160 years of aerzen.com
experience. Our expertise is the value factor for your system

On-site service
Revamp
System planning using 3D laser scanning enables perfect • Rework, repairs, maintenance
engineering for minimum investment costs • Inspection and maintenance work
• Service on all process gas machines
• Supporting the subsidiaries during
staff shortages
• Workshops at the subsidiaries or on site at
customer locations

Contact field-service@aerzen.com

14 15
 AERZEN Revamp
System planning with Installation of an oil-free
screw compressor in the

3D laser scanning
3D environment

True-to-the-original visuali-
sation of the planned plant
design using CAD software
Have you been a loyal customer for many years? Then you know about the high reliability and long service
life of our blowers and compressors from your own experience. But even the best machines require an
update from time to time. With AERZEN Revamp, this is easier than ever before.

View of the compressor unit

Whether automation, efficiency improvement, speed control Precise measurement generated by the combinati-
or upgrading the entire system to a modern standard: anything on of the 3D laser scan data
is possible with AERZEN. Depending on the requirements, a Using ultra-modern scanning technology, the plant and its sur- and the 3D CAD data from
system or parts thereof can be modernised from many diffe- roundings are captured from various perspectives without any AERZEN.
rent perspectives with a focus on preserving what is tried and gaps, generating a complete 3D representation in the highest
tested and/or necessary. resolution and with minimal tolerance.

• Control, instrumentation or upgrade to a • Detailed recording of the existing infrastructure,

basic modern concept supply systems as well as foundations and building parts
• Realisation with the help of modern engineering and
planning tools Thanks to the true-to-original visualisation, design engineers
work directly in the customer's original environment with all
Retrofit made easy actual dimensions and full transparency when converting and
modernising existing systems. This guarantees absolute plan-
Integrating new blower and compressor technology into an ning and design reliability and leads to a considerable reduc-
existing system requires precise planning and perfect engi- tion in investment costs.
neering. Digital innovations such as virtual reality facilitate
this process and are a real game changer for retrofit projects. State-of-the-art control and regulation concepts
AERZEN has been working closely with partners in the field
of 3D laser measurement in system manufacturing for many AERZEN also pays tribute to the fact that innovations in the
years. 3D laser scanners provide perfect planning, engineering control and regulation sector are making great strides. The
and documentation data and simplify the retrofitting and mo- portfolio includes modern control system and regulation con-
dernisation of existing systems. cepts for AERZEN machines that meet today's requirements How you benefit:
for the safety of life and limb, as well as the longevity of the
machines, and which utilise the latest components from the
Maximum added value with minimum expenditure
relevant manufacturers and their standards. Based on this, old
becomes new!

Individual compressors and Security in adhering with pro- Accurate and comprehensive
blowers are replaced within ject goals and budgets documentation with "as built"
the existing package data for further projects and
Safety in design planning correction of inventory data
Significant reduction in
investment costs!
Precise and complete
collision check
The need to dismantle indivi-
dual subassemblies is reduced
Risk minimisation when ins-
talling the new unit
Fast, complete and accurate
data recording of the original
Easier handling of
environment
space restrictions
Short downtimes

Early visualisation of the

target state

16 17
 We secure the future
for generations.
by providing sustainable
solutions for numerous
industries such as water,
food, process engineering,
and renewable energies.

18 19
AERZEN. Compression is the key to our success

The Aerzener Maschinenfabrik GmbH was founded in 1864. In In more than 50 subsidiaries around the world,
1868, we built Europe’s first positive displacement blower. The more than 2,600 experienced employees are working hard on
first turbo blowers followed in 1911, the first screw compressors shaping the future of compression technology. Their technical
in 1943, and in 2010 the world’s first rotary lobe compressor competence, our international network of experts and the con-
package. Innovations “made by AERZEN” keep driving forward tinual feedback from our customers are the basis of our suc-
the development of compressor technology. Today, AERZEN cess. AERZEN products and services set standards. In particu-
is among the world’s longest established and most signifi- lar, with regard to reliability, stability of value and efficiency.
cant manufacturers of positive displacement blowers, rotary Challenge us.
lobe compressors, screw compressors and turbo blowers. And
among the undisputed market leaders in many areas of appli-
cation.

Find your local contact

www.aerzen.com/worldwide

Aerzener Maschinenfabrik GmbH

Reherweg 28 – 31855 Aerzen / Germany
Phone: +49 5154 81 0 – Fax: +49 5154 81 9191
info@aerzen.com – www.aerzen.com

Process gas (A1-008-06)_EN

05|2024