Turbo Compre Launches 42,000 Nm³/h Air Separation Compressor
Turbo Compre has recently launched a high-efficiency centrifugal compressor designed for 42,000 Nm³/h large-scale cryogenic air separation units (ASUs). The new model features a closed, five-axis milled 3D-flow impeller, targeting two major challenges in large ASU projects: high energy consumption and air venting during low-load operation.
Air Separation Compressor Key Performance
ASU capacity: 42,000 Nm³/h
Rated flow: 217,000 Nm³/h at 0°C standard conditions
Discharge pressure: 4.5 barG
Field-measured power-to-gas ratio: 0.078 kWh/Nm³
Load adjustment range: 75%–105%
Low-load operation: No air venting at 75% load
Core configuration: Closed, five-axis milled 3D-flow impeller
Closed Five-Axis Milled Impeller
The new compressor uses an integrally closed, five-axis milled impeller manufactured from a solid forging with a five-axis CNC machining center. The disk, blades, and shroud are machined as an integral structure without welding or assembly joints, helping improve structural integrity and machining accuracy.
Five-axis machining enables more precise reproduction of the complex 3D blade profiles and aerodynamic surfaces, creating smoother flow passages and helping reduce additional aerodynamic losses during compression. The closed impeller structure also reduces tip leakage, supporting higher overall compressor efficiency and lower operating energy consumption.
75%–105% Wide-Range Operation Without Air Venting
To address frequent load fluctuations in large air separation units, the compressor is equipped with an optimized inlet guide vane (IGV) control system, enabling operation without air venting across a 75%–105% load range.
When downstream gas demand decreases, the compressor can follow the load change without directly releasing already-compressed air through the vent valve. Compared with conventional low-load operation that relies on venting to maintain stable operation, this control strategy helps reduce unnecessary compression and energy losses caused by air discharge.
For large ASU projects serving industries such as steel, chemicals, and photovoltaics, where downstream gas demand can fluctuate, the 75%–105% wide operating range allows the air separation unit to better match actual production requirements while reducing surge risk and additional energy consumption during low-load operation.
Field-Measured Power-to-Gas Ratio of 0.078 kWh/Nm³
The compressor achieves a power-to-gas ratio as low as 0.078 kWh/Nm³ at rated conditions, based on field-measured operating data rather than theoretical calculations or simulation results alone.
For large air separation units, the main air compressor typically operates continuously for extended periods, making compressor efficiency a direct factor in long-term operating costs. Maintaining a low power-to-gas ratio at the rated point while expanding the stable operating range and reducing low-load venting is therefore an important approach to improving overall energy efficiency.
Designed for Large-Scale Air Separation Projects
The product is mainly suitable for:
New 42,000 Nm³/h-class air separation projects
Energy-saving replacement of existing ASU air compressors
EPC turnkey and packaged air separation projects
With a field-measured power-to-gas ratio of 0.078 kWh/Nm³ and 75%–105% operation without air venting as its key features, the new model combines rated-point efficiency with improved economics under variable-load conditions, providing an additional option for main air compressor selection in large-scale ASU projects.
Turbo Compre will continue to focus on large-scale air separation and industrial gas applications, further optimizing centrifugal compressor aerodynamics, impeller manufacturing, and overall unit performance to provide efficient and reliable compressor solutions.
For more information about the performance curve, operating-condition energy analysis, and packaged compressor solution, please contact Turbo Compre for detailed technical information.