BORSIG Group - BORSIG GmbH

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BORSIG Group - BORSIG GmbH
BORSIG
LEADING TECHNOLOGY FOR
INNOVATIVE SOLUTIONS
A Member of KNM Group Berhad
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BORSIG
Group
Contents
The BORSIG Group
The BORSIG Group - Leading Technology for Innovative Solutions
Manufacturing
Quality
Global Presence
BORSIG Process Heat Exchanger GmbH - Pressure Vessels and Heat Exchangers
Process Gas Waste Heat Recovery Systems
Synthesis Gas Cooler Downstream of Partial Oxidation of Oil or Natural Gas
Waste Heat Boilers for Nitric Acid, Caprolactam and Formaldehyde Plants
Transfer Line Exchangers
Scraped Surface Exchangers
BORSIG ZM Compression GmbH - Compressors and Blowers
Reciprocating Compressors for Process Gases
Centrifugal Compressors for Process Gases
Reciprocating Compressors for CNG Filling Stations, Roots Blowers, Blower Systems
Compressor Valves
Services
BORSIG Membrane Technology GmbH - Membrane Technology
Emission Control
Product Recovery
Gas Conditioning
Liquid Separation, Services
BORSIG Boiler Systems GmbH - Boiler and Power Plant Technology
Fired Boilers
Heat Recovery Boilers
Combined Heat and Power Systems
Power Plant Engineering, Services
BORSIG Service GmbH - Power Plant and Industrial Services
Power Plant Services
Industrial Services
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BORSIG
Group
Leading Technology for Innovative Solutions
The BORSIG Group
The BORSIG Group, a member of the global
process technology player KNM Group
Berhad, Kuala Lumpur/Malaysia, offers customised solutions for pressure vessels, heat
exchangers, compressors, membrane technology, boiler and power plant technology, as
well as comprehensive industrial services.
Our experience is based on more than 170
years of company history. The resulting competence enables us to successfully master all
economic, technical and social challenges
both today and in the future.
The BORSIG Group - innovative solutions,
state-of-the-art technology, perfectly trained
specialists and comprehensive know-how are
the basis for our position as a “single source”
supplier of leading technology. All BORSIG
products are synonymous for top quality, reliability, optimum technical implementation and
smooth order processing.
The BORSIG Group – your competent partner
for the future.
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BORSIG
Group
Manufacturing
The BORSIG Group
The BORSIG Group with its manufacturing
methods, workshop facilities and equipment
complies fully with the latest state-of-the-art.
BORSIG Process Heat Exchanger GmbH
owns 11,800 m² indoor workshop facilities in
Berlin, equipped with a 250 ton crane capacity. High-tech welding technology is our core
competence, such as laser controlled narrow
gap SAW welding system, robot welding technology for GMAW welding for high pressure
vessels, TIG-hot wire welding, also on ball
valve surfaces, mechanical tube to tubesheet
welding as well as qualified manufacturing of
all steel and nickel-based alloys. Since 2008
the company has a direct water connection,
the Borsig-Harbour, so that pressure vessels
and heat exchangers of every overall size can
be transported easily on the water way.
BORSIG ZM’s fabrication shop has 8,500 m²
area available, equipped with a 100 ton crane
capacity. The heart of the fabrication shop are
two computer numerically controlled boring
machines with traverse paths of 14,000 mm x
4,000 mm x 2,500 mm. These machines are
linked to a modern programming system. That
guarantees, that, after the simulation of complex machining tasks, the manufacturing process is absolutly precise. In combination with
a CNC vertical turning and boring mill,
BORSIG ZM is capable to machine cylinders,
distance pieces and crank cases in-house.
Machining of forged components, steel
castings and modular graphite castings is a
daily routine.
BORSIG Service GmbH offers 3,700 m²
indoor workshop facilities, 33,500 m² open
space and loading capacity up to approx.
100 t.
In Gladbeck the main focus is put on repair
and fabrication, general overhaul of pressure
vessels, apparatus and components, retrofits,
mechanical engineering, valves and revisions.
The manufacturing equipment comprises submerged arc (SAW) welding machines, CNCcarousel winding machine, drillings mills and a
ball winding and grinding machine 6" - 46".
BORSIG
Group
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BORSIG
Group
BORSIG
Group
Quality
The BORSIG Group
Quality assurance and control activities are
independent of the manufacturing process or
product lines and guarantee that machined
and handled materials, components, assemblies, products and service operations are
executed in accordance with all specified
requirements.
Quality assurance surveils adherence to
national and international specifications, statutory and contract provisions as well as the
directives, standards and regulations stipulated by all companies of the BORSIG Group.
In order to ensure even better interaction between quality, work safety and environmental
management, the individual management
systems were merged to form an Integrated
Management System (IMS).
Extract of BORSIG Group certificates:
DIN EN ISO 9001, Environmental Management System DIN EN ISO 14001, SCC, ASME
U, U2, R and S, Manufacturer License of
Special Equipment (Pressure Vessels A1, A2)
PR China, AD 2000 Directives HP0, TRD 201
and DIN EN ISO 3834-2, Comprehensive qualification certificate according to DIN 18800-7,
etc..
Consistent quality monitoring from the analysis of the customer's needs to design, work
preparation, construction, acceptance and
handing over to the customer right through to
after-sales service ensures that materials to
be processed, parts manufactured, products
and services are at all times in conformity with
the applicable requirements.
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BORSIG
Group
Global Presence
The BORSIG Group
There are the following 6 locations of the
BORSIG Group in Germany with headquarters at the city of Berlin, capital of Germany:
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Berlin: Pressure Vessels, Heat
Exchangers, Power Plant Services
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Meerane: Compressors, Blowers
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Gladbeck: Membrane Technology,
Industrial Services
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Rheinfelden: Membrane Technology for
Emission Control
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Hamburg: Industrial Boilers and Power
Plant Technology
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Flensburg: Compressor Valves
Additionally, for our customers’ convenience
we have installed a network of representative
offices worldwide, with focus on the main oil
and gas producing and processing countries
as well as China, Italy and Japan.
In 2010 the BORSIG Group set up a new industrial service company, BORSIG Industrial
Services Sdn. Bhd.. The company is established to cater for Malaysia and South East
Asia region in the provision of industrial and
power plant services for the oil, gas, petrochemicals, chemicals, utility, power plant and
general industries.
Being a member of KNM Group Berhad with
headquarters in Malaysia, the BORSIG Group
is in a general position to offer manufacturing
facilities close to the international costumers
and end-users for example in Brazil, Canada,
Saudi Arabia, UAE, China and Malaysia
depending on the requirements of the customers regarding “local content” of selected
items.
BORSIG
Group
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BORSIG
Process Heat Exchanger GmbH
Pressure Vessels and Heat Exchangers
BORSIG Process Heat Exchanger GmbH
BORSIG Process Heat Exchanger GmbH
supplies pressure vessels and heat exchangers for cooling gases at very high temperatures (up to 1,500 °C) and high pressure (up to
35,000 kPa) for the chemical and petrochemical industries.
pressure vessels and heat exchangers which
meet with all requirements, such as stability,
operational safety and long service life.
Our product range:
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These pressure vessels and heat exchangers
are used for process stages in plants for the
production of basic chemicals where they are
installed directly at the downstream end of the
cracking furnaces and/or reactors. BORSIG
technology is also used in up-to-date coal
gasification processes.
Design orientated towards practical application, highly qualified staff as well as state-ofthe-art production and testing methods ensure
the constantly high quality standard of our
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Process Gas Waste Heat Recovery
Systems
Transfer Line Exchangers
Scraped Surface Exchangers
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BORSIG
Process Heat Exchanger GmbH
Process Gas Waste Heat Recovery Systems
Pressure Vessels and Heat Exchangers
For more than 40 years, BORSIG Process
Heat Exchanger GmbH has been supplying
process gas waste heat recovery systems for
high-temperature and high-pressure applications to the petrochemical industry. Thanks to
a wealth of experience, comprehensive knowledge, design orientated towards practical
application, state-of-the-art production and
testing methods and last but not least highly
qualified staff, the company has become the
leading manufacturer in this area worldwide.
Every process gas waste heat recovery
system manufactured by BORSIG Process
Heat Exchanger GmbH is designed exactly in
accordance with the customer’s individual
requirements and is provided with special
design features for the various operating conditions and applications.
The process gas waste heat recovery systems
can be used for gas pressure values of up to
350 bar (35,000 kPa), incoming gas temperatures of up to 1,500 °C and steam pressure
values of up to 150 bar (15,000 kPa).
Applications of BORSIG process gas waste
heat recovery systems include ammonia,
methanol, hydrogen and ethylene plants,
direct reduction plants in iron metallurgy, coal
gasification and gas-to-liquid plants as well as
other applications such as waste heat boilers
in nitric acid, caprolactam and formaldehyde
plants and waste heat boilers downstream of
the partial oxidation of oil or natural gas.
Any combinations can be integrated into any
customer-specific process gas waste heat
recovery system: Reform gas waste heat boiler, steam superheater (1- or 2-stage), HT
SHIFT waste heat boiler, feed water preheater, gas/gas heat exchanger, steam drum,
superheated steam cooler, synthesis gas
waste heat boiler, quench cooler and other
units.
BORSIG
Process Heat Exchanger GmbH
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BORSIG
Process Heat Exchanger GmbH
BORSIG
Process Heat Exchanger GmbH
Synthesis Gas Cooler Downstream of
Partial Oxidation of Oil or Natural Gas
Pressure Vessels and Heat Exchangers
The non-catalytic cracking of hydrocarbons by
partial oxidation of natural gas, oil etc. is carried out at temperatures up to 1,500°C and
pressures up to 8,000 kPa. Besides the resulting reaction components CO, CO2, H2, H2O
and H2S the process gas is loaded with soot
and ash. Depending on the type of feedstock
other impurities like vanadium, nickel and iron
can also be expected. Due to these impurities,
the high particulate burden of the gas and the
hydrogen sulfide the waste heat boiler must
be highly resistant to erosion, corrosion and
fouling.
The process gas is cooled down in the waste
heat boiler from about 1,400°C to 300°C. The
heat of the gas is used to generate steam, the
steam pressures are usually between 3,000
and 10,000 kPa. For special purposes it is
also possible to integrate a superheater into
the boiler.
BORSIG Process Heat Exchanger GmbH
has developed its own boiler design with special design features for example for the most
critical area of the waste heat boiler: the gas
inlet section.
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BORSIG
Process Heat Exchanger GmbH
Waste Heat Boilers for Nitric Acid,
Caprolactam and Formaldehyde Plants
Pressure Vessels and Heat Exchangers
Waste heat boilers with direct integrated reactors are used within the production process of
nitric acid, caprolactam and formaldehyde.
The feed gas is transferred to the reactor and
reacts at the installed catalysators to the intermediate or final product. The heat that developes/originates during this process is regained by the directly downstream waste heat
boiler.
Waste Heat Boiler Downstream of
Ammonia Combustion in Nitric Acid and
Caprolactam Plants
The catalyst used is a finely woven platinum
gauze containing about 15% rhodium. The
oxidation is an exothermic process, heating
the gas to a temperature around 900°C.
The process operates under a pressure of
about 500 kPa. The heat of the process gas is
recovered by cooling the gas down to 200°C,
generating steam and superheating it.
Superheated steam temperatures up to 500°C
can be obtained. The steam pressures are
usually between 4,000 and 8,000 kPa.
Various designs have been developed and
built to cover a wide variety of applications.
Main criteria for choosing the type of waste
heat boiler are the gas throughput of the plant,
the steam parameters required and the integration of the combustion elements into the
process as a whole.
Waste Heat Boiler Downstream of
Dehydration of Methanol in Formaldehyde
Plants
For the production of formaldehyde the dehydration of methanol to formaldehyde is the
basic catalytic reaction. The general design of
the corresponding waste heat boilers is similar
to the boilers described for the nitric acid
plants.
In this application silver gauzes are used as
catalyst, the gas is heated to a temperature of
600° to 700°C.
BORSIG
Process Heat Exchanger GmbH
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BORSIG
Process Heat Exchanger GmbH
BORSIG
Process Heat Exchanger GmbH
Transfer Line Exchangers
Pressure Vessels and Heat Exchangers
Transfer Line Exchangers (tunnelflow and
linear quench coolers) from BORSIG Process
Heat Exchanger GmbH are used in plants
producing ethylene as the input material for
making plastics.
There are one or more parallel TLEs per furnace cell, which are connected by riser and
downcomer piping with one common, elevated steam drum thereby forming the so called
quench system.
Ethylene (C2H4) and some other byproducts
like propylene are produced by thermal crakking of hydrocarbons in pyrolysis furnaces in
the presence of steam. Predominantly ethane,
naphtha and other mineral oil fractions are
used as feedstocks.
BORSIG Transfer Line Exchangers are the
result of more than 45 years experience and
more than 5,000 units have been supplied
worldwide between 1965 and 2010.
BORSIG Process Heat Exchanger GmbH has
developed two design types of quench coolers, reflecting the customer`s plant concept:
The gas produced by cracking, which leaves
the furnace at a temperature of around 850°C
(1,500°F), must be cooled down rapidly (quenching) after leaving the reaction zone of the
furnace to prevent secondary reactions and to
stabilize the gas composition in order to obtain
the optimum product yield. In all modern ethylene processes this rapid cooling of the crakked gas is done with Transfer Line Exchangers (also known as quench coolers or TLEs)
thereby producing high pressure steam.
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BORSIG Linear Quencher (BLQ),
BORSIG Tunnelflow Transfer Line
Exchanger (TLE).
BORSIG quench coolers excel by their maintenance-friendliness, high reliability and proven design.
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BORSIG
Process Heat Exchanger GmbH
Scraped Surface Exchangers
Pressure Vessels and Heat Exchangers
BORSIG Process Heat Exchanger GmbH
has been producing scraped surface exchangers for more than 75 years. Modern design,
orientated towards practical application, stateof-the-art manufacturing and testing methods
and the staff's expertise add up to a high-quality scraped surface exchanger that fulfils all
requirements in terms of stability, operating
reliability and long service life.
BORSIG Process Heat Exchanger GmbH
supplies scraped surface exchangers for any
desired throughput and thermal capacity with
inside tube diameters of 6 inches, 8 inches, 10
inches and 12 inches. Scraped surface
exchangers are supplied almost exclusively
as compact units, so that installation work on
site is reduced to a minimum.
Furthermore, BORSIG Process Heat
Exchanger GmbH supplies completely new
drive systems and/or drive shafts to upgrade
existing old scraped surface exchangers, as
well as scraped surface exchangers from
other manufacturers.
Applications of the BORSIG scraped surface
exchangers include dewaxing of lube oil, crystallization of paraxylene, continuous mixing
of liquid and semi-solid products under cooling
or heating conditions, heat transfer in the presence of strong product contamination of
transfer surfaces, as well as heat transfer with
high-viscosity products.
BORSIG
Process Heat Exchanger GmbH
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BORSIG ZM
Compression GmbH
Compressors and Blowers
BORSIG ZM Compression GmbH
BORSIG ZM Compression GmbH offers
customized solutions according to customer
specifications for compressors and blowers.
Integrated concepts, from planning to design,
manufacture and assembly are characteristic
of our approach.
BORSIG ZM Compression GmbH warrants
the highest product quality thanks to competent engineering, state-of-the-art manufacturing processes and seamless quality assurance.
Mechanical manufacturing at BORSIG ZM
Compression GmbH excels by considerable
manufacturing depth. This enables us to
respond to all kinds of customer requirements
in a very flexible and quick manner.
The production portfolio of BORSIG ZM
Compression GmbH includes:
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Reciprocating Compressors
for Process Gases
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Centrifugal Compressors
for Process Gases
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Reciprocating Compressors
for CNG Filling Stations
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Roots Blowers and Blower Systems
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Compressors Valves
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Services
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BORSIG ZM
Compression GmbH
Reciprocating Compressors
for Process Gases
Compressors and Blowers
Based on more than one century of experience in reciprocating compressor manufacturing
BORSIG ZM Compression GmbH now offers
a reciprocating compressor series in vertical
(PV types) and horizontal (boxer - PH and Bx
types) design for the most technical gases and
employing with API 618 design standards.
Power ranges of reciprocating compressors:
discharge pressure:
capacity / flow:
power:
up to 1,000 bara
up to 115,000 m³/h
up to 16,000 kW
Typical fields or operation:
Thanks to the high level of vertical integration
in the manufacturing of compressor components, BORSIG ZM is capable to transfer the
high demands on the parts directly from the
design onto the manufacturing process and
closely monitor this process. The 3D design
tools used by BORSIG ZM are state-of-the-art
and provide the user with numerous possibilities: Complete visualization and design of the
system, but also selective and systematic design of the parts and components. BORSIG
ZM enjoys the benefit of this careful engineering process that provides the compressors
with longer life cycles, better wear resistance
and hence lower life-cycle costs.
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Chemical and petrochemical industries
Oil and gas industries
Crude oil recovery
Natural gas recovery and processing,
transport and storage
Refinery technology
Power stations
Low-temperature engineering
Gas liquifaction, e.g. LPG, LNG
Various industrial processes
BORSIG ZM
Compression GmbH
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BORSIG ZM
Compression GmbH
BORSIG ZM
Compression GmbH
Centrifugal Compressors
for Process Gases
Compressors and Blowers
BORSIG ZM Compression GmbH manufacturers centrifugal compressors for process
gases for almost 50 years.
The BORSIG ZM “T-Jet” series comprises
one- to four-stage integrally geared centrifugal
compressors which comply with the corresponding API design standards, such as API
617, API 672, API 614.
The impeller is the heart of the centrifugal
compressor stage. The BORSIG ZM impellers
are open types and designed with highly
sophisticated CFD tools and are able to reach
a very high efficiency. Special materials for the
impellers and volutes e.g. Stainless Steel or
Titanium, guarantee that the requirements of
the process industry will be met.
Power ranges:
discharge pressure:up to 80 bar 1)
capacity / flow 2): up to 40,000 m³/h
up to 12,000 kW
power 2):
1)
2)
higher pressures on request
referring to atmospheric conditions and air
Typical fields of application:
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Chemical and petrochemical plants
Oil and gas industries
Refinery plants
Fuel-gas delivery for gas turbine plants
Various industrial processes
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BORSIG ZM
Compression GmbH
Reciprocating Compressors for CNG Filling Stations
Roots Blowers, Blower Systems
Compressors and Blowers
With the C200 series BORSIG ZM
Compression GmbH is able to offer a wide
range of efficient reciprocating compressors
for CNG filling stations. From the worldwide
standardized discharge pressure of 250 bar
(up to 300 bar are possible) result following
power ranges:
in storage units which are used as so-called
daughter CNG filling stations.
suction pressure:
(25 bara with leak gas
discharge pressure:
capacity / flow:
power:
discharge pressure:
capacity / flow:
power:
up to 25 bara
recompression)
up to 300 bara
up to 1,700 Nm³/h
up to 250 kW
The reciprocating compressors for CNG filling
stations are offered with four, three or two
compression stages. The cylinders are generally lubricated by mini-lubrication. The drive is
realized by electric motors and gas engines
either directly or by V-belt.
In addition, BORSIG ZM offers complete CNG
filling stations, mainly for the filling of busses
and other large vehicles, e.g. truck trailers for
the transportation of compressed natural gas
The current blower product range includes
blowers with three-blade rotary pistons in ten
sizes for technically oil-free air in following
power ranges:
up to 2.0 bara
up to 5,900 m³/h
up to 210 kW
Typical fields of application:
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Ventilation of settling and activated sludge
tanks, grit-removal tanks, drinking water
reservoirs and others
Dust removal
Exhaust systems
Backflushing of filters in sewage treatment
plants, swimming pools and others
Pneumatic transport of bulk products
Food industry
Position stabilization of cargo and
passenger ships
BORSIG ZM
Compression GmbH
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BORSIG ZM
Compression GmbH
BORSIG ZM
Compression GmbH
Compressor Valves
Compressors and Blowers
BORSIG ZM Compression GmbH offers a
wide range of compressor valves by its subsidiary COMPART Compressor Technology
GmbH.
For more than 25 years COMPART has been
engaged in the development, the production
and sales service as well as reconditioning
and modification of compressor valves.
Additionally the COMPART team of experienced engineers guarantee a service which
is always close at hand so that we quickly can
analyse and solve problems of reciprocating
compressors.
Products and Services at a glance:
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During that time COMPART has analysed
hundreds of reciprocating process gas compressors. About 35% of the existing and new
compressors were in a wrong condition.
Based on this fact, the orientation towards our
customers specific requirements and the continuous development of our acquired knowhow have led us to new products such as software to diagnose reciprocating compressors
and condition monitoring systems.
COMPART´s experience has shown that a
serious compressor and valve analysis and a
tailor made engineering often are able to solve
the customers problems only by recalculating
and modifying the existing parts.
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Engineering and manufacturing of valves
for different services
Valve reconditioning and modification
Replacement parts for compressor valves
Software to analyse compressors and
valves for problem solving and optimization
Real-time condition monitoring and internal
cylinder pressure measuring systems
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Clearance volume systems and reverse
flow actuators for stepless capacity control
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Piston rod packings with directly cooled
sealing elements and oil scrapers
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Check valves with or without housings
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BORSIG ZM
Compression GmbH
Services
Compressors and Blowers
As a leading manufacturer of compressors,
BORSIG ZM Compression GmbH offers you
a comprehensive service from one source.
Our After Sales Service takes care for your
concerns, whether you require service for a
BORSIG ZM product or for compressors
made by other manufacturers.
Competence based on long-time experiences
in the field of compressors and the high quality of our services makes us the partner you
can depend on.
Portfolio of services
- Installation
- Overhauling
- Spare part management
- Engineering
- Maintenance
- Training
Portfolio of products
- Reciprocating compressors for process
gases
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Centrifugal compressors for process
gases
Blowers and blower systems
Portfolio of customers
- Petrochemistry
- Chemical industry
- Gas storage /-transport
- Industrial gases
- Environmental and supply technologies
BORSIG ZM provides its support from the
erection and commissioning of the machine
and equipment to the point of revamp and
remodelling based on its engineering. To keep
the system availability on a high level, a comprehensive maintenance service is provided.
In emergency cases you can rely on prompt
assistance by BORSIG ZM´s service staff. A
short-term supply of spare parts subject to
high quality standards guarantees a minimal
downtime of your compressor.
BORSIG ZM
Compression GmbH
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BORSIG
Membrane Technology GmbH
Membrane Technology
BORSIG Membrane Technology GmbH
BORSIG Membrane Technology GmbH is
an internationally successful company that
offers its customers leading innovative membrane technology solutions for a wide range of
industrial applications.
Our products – membranes, membrane
modules and complete membrane systems –
are synonymous for high quality, competence
and reliability. Our portfolio ranges from process simulation to the delivery of complete
turnkey systems and comprehensive aftersales services.
Taking the highest safety and quality standards into consideration, our membrane technology ensure safe plant operation and enable
maximum efficiency and optimum economic
efficiency in the following applications:
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Emission Control
Product Recovery
Gas Conditioning
Advanced Separations
Our staff have been developing and offering
intelligent process solutions for more than 20
years. At two sites in Gladbeck/Germany and
Rheinfelden/Germany, highly qualified teams
apply state-of-the-art production and engineering methods in order to produce membranes
and to develop new tailor-made solutions for
your processes or to optimise processes already installed.
Our services focus on controlling the entire
production processes and ensuring smooth
workflows and time monitoring. Quality assurance, occupational health and safety, as well
as environmental protection are top priorities
at all times. Our own staff co-ordinate all work
steps, such as technical specifications, purchasing, production, assembly and commissioning.
With an expertise reflected by hundreds of
industry-scale membrane systems delivered
to customers all over the world, BORSIG
Membrane Technology is the professional
partner for your projects.
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BORSIG
Membrane Technology GmbH
Emission Control
Membrane Technology
Volatile Organic Compounds (VOC), defined
as a large family of hydrocarbons with high
volatility, occur naturally and are produced in
many industrial processes. In a wide range of
industrial applications, e.g. such as oil & gas
industry, chemical industry and petrochemical
industry the use of VOC leads to substantial
emissions mainly caused by evaporation,
displacement and purge procedures.
The use, storage and distribution of solvents
and petroleum products have been identified
as the most significant sources for VOC
emissions. Displacement and evaporation
processes affect the release of organic
vapours, which are in most cases mixed with
air or other permanent gas. Typical products
are
• Solvents
• All kind of gasoline
• Additives
• Diesel, jet fuel
• Alcohols
• Bio fuels
• Crude oil
Worldwide corresponding regulations and
emissions laws are implemented to drastically
minimise the VOC emissions by the reduction
of VOC consumption and by the installation of
emission control systems.
BORSIG Membrane Technology GmbH
offers emission control solutions with maximum recovery rates of up to 99.9% and thereby enables compliance with all customary
emission standards worldwide whilst also fulfilling the highest quality, safety and reliability
demands.
BORSIG Membrane Technology's portfolio in
the field of emissions protection includes:
BORSIG Vapour Recovery Unit (VRU)
VOC control for tank farms, marine loading
and refineries
BORSIG Carbon Retrofit Unit (CRU)
Retrofit of existing active carbon based
recovery system
BORSIG Vent Recovery System (VRS)
Product loss reduction at retail stations
BORSIG
Membrane Technology GmbH
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BORSIG
Membrane Technology GmbH
BORSIG
Membrane Technology GmbH
Product Recovery
Membrane Technology
Product recovery systems must meet with
evermore demanding efficiency requirements.
Economic efficiency, productivity, improved
sustainability of technological processes, as
well as optimum utilisation of our resources
are key challenges in this for the industry.
BORSIG Membrane Technology GmbH
offers optimum solutions here which helps
minimising losses, to recover valuable raw
materials or products from exhaust air or process gas flows and their recycling into the production process and therefore enables:
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Recovery of valuable feedstock and
product
Significant reduction of waste and flare
gas capacities
Important products and applications include:
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Ethylene monomer from polyethylene
(HDPE, LDPE, etc.), EO or VAM
productions
Propylene monomer from polypropylene
production
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Solvent (Butane, Hexane etc) from slurrytype polymer production processes
Vinyl chloride monomer (VCM) from PVC
production
Aromatics (Benzene, Toluene, Xylene etc.)
from production and storage
MTBE, ETBE
Fluoro & Chloro Hydrocarbons from any
related processes
Methanol, Ethanol
Bio-Fuels from production & storage
Our products include:
BORSIG Ethylene Recovery Unit
Ethylene monomer recovery for polyethylene
(PE), ethylene oxide (EO) production
BORSIG Propylene Recovery Unit
Propylene monomer recovery for polypropylene (PP) production
BORSIG Hydrocarbon Recovery Unit
Recovery of valuable hydrocarbon products
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BORSIG
Membrane Technology GmbH
Gas Conditioning
Membrane Technology
Volatile Organic Compounds (VOC), defined
as a large family of hydrocarbons with high
volatility, occur naturally and are produced in
many industrial processes.
In a wide range of industrial applications, e.g.
such as oil & gas industry, chemical industry
and petrochemical industry the BORSIG
Membrane Technology offers the possibility to
treat gas flows in oil and gas production application. The aim is to condition raw gas flows or
to improve product quality to comply with
customer’s gas specifications, pipeline specifications or calorific-value requirements.
The required gas quality is typically specified
by defining methane content, pressure dew
points, calorific values or a minimum methane
number. These quality parameters are typically determined by the share of higher hydrocarbons (C3+), CO2 or O2 in the gas.
The possibilities offered by BORSIG
Membrane Technology GmbH at a glance:
BORSIG Fuel Gas Conditioning
Gas treatment for pipeline, gas engine and
turbine applications
BORSIG Oxygen Enrichment
Oxygen enrichment for combustion processes
BORSIG Gas Separation
Bulk separation of gas stream
BORSIG Biogas Processing
Membranes and systems for biogas treatment
Process concepts in addition or as an alternative to conventional process solutions.
BORSIG
Membrane Technology GmbH
40
41
BORSIG
Membrane Technology GmbH
BORSIG
Membrane Technology GmbH
Liquid Separation, Services
Membrane Technology
Chemical resistant membrane materials, in
combination with innovative technology to
modify surfaces for specific purposes, enable
a wide range of new promising applications for
membrane separation processes.
Based on these developments Organophilic
Nanofiltration (oNF) offers attractive solutions for challenging separations in the molecular range between ultrafiltration and reverse osmosis, focusing on treatment of organic liquids.
As alternative to or in combination with conventional separation operations, solvent resistant membranes provide the opportunity of
highly efficient process installations for the
selective separation of liquid organic mixtures.
BORSIG Nanofiltration
BORSIG Membrane Technology GmbH provides composite membranes with excellent
performance to meet high requirements in
nanofiltration applications. Based on our
know-how and experience in process design
and engineering various applications have
been already implemented.
Our service team offers its customers in the oil
and gas, refinery, tank farm and petrochemical
industries a complete service package or individual services, so that you can fully focus on
your core competence.
The team is trained according to SCC and
VCA and consists of seasoned engineers and
technicians who are in charge of plants and
installations worldwide. Thanks to our many
years of experience in servicing industrial
plants and the required multidisciplinary competence in process engineering, plant design,
control and instrumentation, as well as explosion protection, we know what matters.
Extract of our service portfolio:
Process development and optimisation, basicand detail engineering, erection and commissioning of plants and systems, maintenance
and trouble-shooting, spare-parts management, standby service and remote-service for
software updates and trouble-analyses,
hazard and operability studies (HAZOP) of
BORSIG and third-party VRUs and other
plants and systems, IPF analysis and a lot
more.
42
BORSIG
Boiler Systems GmbH
Boiler and Power Plant Technology
BORSIG Boiler Systems GmbH
BORSIG Boiler Systems GmbH located in
Hamburg is one of the leading supplier of boiler and power plant technology.
BORSIG Boiler Systems offers a complete
range of products and services related to the
production of boiler equipment to generate
steam and hot water, as well as the required
engineering and a comprehensive range of
additional services in the field of boiler and
power plant. This range of products and services is available to our industrial and communal customers as well as to contractors and
power utility companies.
Depending on the customers’ requirements,
we offer basic and detail engineering services
and also provide the construction, production,
delivery, erection and commissioning of the
boiler equipment as individual components or,
in conjunction with the necessary accessories,
as complete boiler systems.
Decades of experience, state-of-the-art technology and consistent compliance with all
laws, standards, regulations, highly qualified
employees and innovative engineering allow
us always to be able to provide our customers
an optimum solution that is individually tailored to their specific needs. These products
and services make BORSIG Boiler Systems
GmbH a strong partner for you.
The BORSIG Boiler Systems product program
comprises:
•
•
•
•
Fired boilers
Heat recovery boilers (HRB, HRSG)
Power plant engineering
Power plant services
44
45
BORSIG
Boiler Systems GmbH
Fired Boilers
Boiler and Power Plant Technology
BORSIG Boiler Systems GmbH provides
fired boilers based on customers’ demand
mainly fed by liquid and gaseous fuels such as
natural gas and crude oil. Experienced combustion technology is also available for the
wide range of fuel combinations e.g. hydrogen, special fuels, several waste production
etc.
The boilers are primarily designed as water
tube boilers to generate saturated and superheated steam as well as hot water. Our boilers
are designed as natural circulation or forcedcirculation boilers in wide range of design and
construction types. We adapt parameters,
dimensions etc. of our boiler concepts to meet
directly the individual requirements and specifications of our customers. In accordance to
the requirement of our customers, we individually design tailor-made constructions in
terms of technical parameters and dimensions.
We provide our fired boilers up to the following
parameters (as of now):
Steam output:
Steam pressure:
Steam temperature:
Hot water output:
up
up
up
up
to
to
to
to
approx.
approx.
approx.
approx.
350 t/h
110 barg
540 °C
200 MW
We have proven references and experience
for natural gas, fuel oil EL, fuel oil S, refinery
gas, hydrogen as well as liquid and gaseous
production residues.
BORSIG
Boiler Systems GmbH
46
47
BORSIG
Boiler Systems GmbH
BORSIG
Boiler Systems GmbH
Heat Recovery Boilers
Boiler and Power Plant Technology
The heat recovery boiler (HRB) of BORSIG
Boiler Systems GmbH generates saturated
or superheated steam as well as hot water. A
variety of heat recovery boilers are manufactured for installation downstream burning
equipment e.g. grate-firing furnaces, fluidizedbed furnaces, rotary-kiln furnaces for municipal waste, special waste, substitute fuels, biomass, sewage sludge etc.
We also design, produce, deliver, assemble
and commission steam and/or hot water boilers for the heat recovery from gas turbines,
combustion chambers, thermal afterburning
systems, diesel/gas engines and a variety of
technological and industrial production processes.
Our heat recovery boilers are designed as
natural circulation or forced-circulation boilers
in wide range of construction types.
Construction of “Drum and Tube” can be multipass vertical boilers as well as horizontal and
tail-end boilers. If the available recovery heat
is not adequate to meet the customers’ requirement, in that case heat recovery boilers are
also equipped with supplementary firing
equipment.
The boilers are designed as water tube boilers
and are tailor-made designed to meet the
customers’ specific requirements and their
individual parameters.
BORSIG Boiler Systems designs heat recovery boilers up to the following parameters:
Thermal output:
up to approx. 150-200 MW
Steam pressure:
up to approx. 110 barg
Steam temperature: up to approx. 540 °C
48
49
BORSIG
Boiler Systems GmbH
Combined Heat and Power Systems
Boiler and Power Plant Technology
BORSIG Boiler Systems GmbH supplies
boiler equipment, required for the installation
of combined cycle plants (CCP) and combined
heat and power (CHP) systems. For these
technologies, we provide the complete range
of products and services from downstream
gas turbine until upstream steam turbine.
In accordance to the requirement of the customers, BORSIG Boiler Systems designs its
Heat Recovery Steam Generators (HRSG)
with or without an auxiliary firing system. The
boiler plant could be operated either with gas
turbine mode or in fresh air mode.
Steam parameters will be adjusted as per the
requirement of existing or newly built steam
turbines. Engineering and technical support
can be provided by BORSIG Boiler Systems
to optimise the steam parameters during engineering and design phases. Our boilers for
combined cycle plants (CCP) and combined
heat and power (CHP) systems are designed
in horizontal or vertical construction forms, as
single- or multi-pressure systems.
We design these boilers up to the following
parameters:
Gas turbine output:
Thermal output
(incl. supplementary firing):
Steam pressure:
Steam temperature:
up to approx. 75 MWel
up to approx. 150 - 200 MW
up to approx. 110 barg
up to approx. 540 °C
BORSIG
Boiler Systems GmbH
50
51
BORSIG
Boiler Systems GmbH
BORSIG
Boiler Systems GmbH
Power Plant Engineering, Services
Boiler and Power Plant Technology
Engineering is one of the core competences of
BORSIG Boiler Systems GmbH. Our specialists have years of experience and extensive
know-how in the field of pressure devices,
steam, water and energy; this expertise is
available to our customers when developing
solutions for complex engineering tasks.
Our specialists provide complex and complete
solutions from one source. The scope of services available ranges from dimensioning
through planning, construction, project
management and the coordination and monitoring of boiler production processes right up
to and including assembly concepts and commissioning activities connected to boiler
systems. The centre of focus is on:
• Designing concepts for new boilers, boiler
conversions and refitting existing boilers
• Performing thermal-related calculations
and procedural design
• Measuring, analysing and performing
acceptance procedures
• Realising construction tasks with highperformance 2D- and 3D-CAD systems
• Management of boiler and power plant
investment projects.
BORSIG Boiler Systems GmbH provides its
customers with in-depth consulting and advice, fast production and/or procurement of boiler spare parts and power plant equipment,
punctual and professional realisation of repairs and competent help ‘around the clock’.
Our power plant and boiler service program
comprises the following:
•
•
•
•
Assembly of new boilers and system
accessories
Conversion of boiler systems including the
engineering (heat equipment, stability
calculations, construction, approval
engineering, etc.)
Relocation of boilers / dismantling,
reassembly
Assembly work on power plant systems.
52
BORSIG
Service GmbH
Power Plant and Industrial Services
BORSIG Service GmbH
BORSIG Service GmbH is a national and
international supplier of different industrial services.
BORSIG Service with its two Berlin and
Gladbeck facilities boasts decades of experience when it comes to planning, performing
and implementing all kinds of assembly,
manufacturing and service tasks
BORSIG Service offers a comprehensive services portfolio for applications in power engineering, the chemical and petrochemical industries, as well as oil, gas and water supply.
We offer our customers services related to the
planning, delivery and installation of new components, modification, inspection and maintenance of existing components, spare parts as
well as trouble-shooting within the framework
of a 24-hour standby service.
Our comprehensive service portfolio and the
related engineering services enable us to offer
customised solutions. All services correspond
to the latest state-of-the-art and are performed
in accordance with the applicable national and
international rules and standards.
Our staff's qualifications and experience warrant high quality and adherence to time schedules even under the most difficult conditions.
Competent, quick and near the customer – our
efficient service and installation team makes
this claim reality.
54
55
BORSIG
Service GmbH
Power Plant Services
BORSIG Service GmbH
With more than 160 years of experience in the
construction of steam generators, BORSIG
Service GmbH offers the competence necessary for full-scale services in the field of energy and steam generating plants and systems.
Our services in detail:
- Repair, maintenance and modification
work
- Ongoing maintenance
- Installation and dismantling
- Co-ordination of external contractors
- Supply of spare parts and replacement
components according to third-party
drawings or our own design
- Technical consulting
- 24-hour standby service
Components processed:
- Steam generators
- Low-pressure / high-pressure
heat exchangers
- Containers
- Pipelines
- Air and flue gas systems
- Soot blowers
-
Charging / waste charging
Ash removal / wet slag removers
Flue gas desulphurization plants
DENOX plants
Personnel from the Berlin and Gladbeck facilities and the customer-near branches are
available for work in Germany and abroad.
Additional capacity requirements can be covered by partners with whom BORSIG Service
has been cooperating for many years on a
trustful basis.
BORSIG
Service GmbH
56
57
BORSIG
Service GmbH
BORSIG
Service GmbH
Industrial Services
BORSIG Service GmbH
The Gladbeck facility of BORSIG Service
GmbH offers all the necessary workshop
equipment and qualified staff for the construction and general overhaul of apparatuses for
the chemical and petrochemical industries
and for power engineering applications.
Pressure Vessels / Heat Exchangers
General overhaul, modification, repair, inspection, maintenance, service, trouble-shooting
for waste heat recovery systems, heat
exchangers, collectors, coolers and special
pressure vessels and heat exchangers for the
chemical and petrochemical industries.
Ball Valves / Fittings
Maintenance and repair of ball valves with diameters of 25 to 2,600 mm/DN 1" to 140" as
well as safety and control valves, flaps and
gate valves.
Machines
Service for steam turbines, compressors,
pumps and blowers.
Plant / Pipelines
Service for pipelines in power stations, industrial plants and municipal utilities.
Workshop Services
Mechanical processing and new construction
of spare parts, manufacture of pressure vessels and heat exchangers (low-pressure and
high-pressure) as well as repair and preassembly of plant components.
Your 24-hour service e-mail address:
[email protected]
58
The BORSIG Group - Headquarters
BORSIG GmbH
Egellsstrasse 21
D-13507 Berlin/Germany
Phone +49 (0)30 / 4301-01
E-mail [email protected]
Fax +49 (0) 30 / 4301-2236
http://www.borsig.de
Pressure Vessels, Heat Exchangers
Compressors, Blowers
BORSIG Process Heat Exchanger GmbH
Egellsstrasse 21
D-13507 Berlin/Germany
BORSIG ZM Compression GmbH
Seiferitzer Allee 26
D-08393 Meerane/Germany
Phone
Fax
E-mail
Phone
Fax
E-mail
+49 (0) 30 / 4301-01
+49 (0) 30 / 4301-2447
[email protected]
+49 (0) 3764 / 5390-0
+49 (0) 3764 / 5390-5090
[email protected]
Membrane Technology
Boiler and Power Plant Technology
BORSIG Membrane Technology GmbH
Bottroper Str. 279
D-45964 Gladbeck/Germany
BORSIG Boiler Systems GmbH
Schellerdamm 16
D-21079 Hamburg/Germany
Phone
Fax
E-mail
Phone
Fax
E-mail
+49 (0) 2043 / 4006-01
+49 (0) 2043 / 4006-6299
[email protected]
+49 (0) 40 / 303726-0
+49 (0) 40 / 303726-4050
[email protected]
Power Plant Services
Industrial Services
BORSIG Service GmbH
Egellsstrasse 21
D-13507 Berlin/Germany
BORSIG Service GmbH
Bottroper Str. 279
D-45964 Gladbeck/Germany
Phone
Fax
E-mail
Phone
Fax
E-Mail
+49 (0) 30 / 4301-01
+49 (0) 30 / 4301-2771
[email protected]
+49 (0) 2043 / 4006-00
+49 (0) 2043 / 4006-6066
[email protected]

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