Technology

AERZEN's advanced screw compressors are paving the way for industry decarbonisation

Hydrogen is regarded as the energy carrier of the future, and is a important milestone for the decarbonisation of industry.

As a strong partner to the process industry, AERZEN has been dealing with the topic of hydrogen compression for decades and therefore has a high level of expertise in this field. The compressor specialist's state-of-the-art technologies are in demand worldwide and warrant efficient and safe compression. The VR and VMY series screw compressors have proven particularly successful in this regard.

Hydrogen is the lightest element present, which makes compression fundamentally more difficult. As it has a very low energy density in relation to the volume flow (energy content per volume unit), large electrolysis plants also have to compress correspondingly high volume flows, which has an effect on the sizes and, thus, on the investment costs, footprint, etc. of the machine equipment. In addition, hydrogen is very reactive, i.e. highly flammable. Special attention is, therefore, paid to the required explosion protection. The formation of an ignitable mixture with the atmospheric oxygen must be avoided at all costs.

The advantages of screw compressors for the compression of hydrogen

For the compression of hydrogen in the low-pressure range, screw compressors are a sensible solution or supplement to high-pressure compressors. Due to their design-related internal compression without free inertia forces, screws are above all reliable and flexible endurance runners with very low maintenance intensity and comparatively low operating costs in full and partial load operation. The AERZEN range includes both oil-free (VRA and VRW series) and oil flooded (VMY series) versions and achieves top marks in the fields of efficiency, installation space, economy and process reliability. All solutions are reconciled by the AERZEN process gas specialists to the customer's individual process.

VRW: maximum efficiency and increased differential pressure in one stage

The oil-free compressors of the VRW series (volume flows up to 6,000 m3/h, differential pressures from 3 to 9 bar) have been specially developed for the compression of saturated electrolysis hydrogen with unrivalled efficiency and differential pressure. Compression is based on the principle of oil-flooded screw compressors - with a small but subtle 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 pressures with high efficiency. This stage can, thus, replace a two-stage system with classic oil-free screw compressors and is even more energy-efficient. For the customers, this results in significant advantages in terms of footprint as well as investment and operating costs.

VMY: highest differential pressures, maximum flexibility

The oil-injected screw compressors of the VMY series deliver the highest differential pressures and compression ratios in the AERZEN product portfolio (volume flows from 190 to 23,000 m3/h, differential pressures from 3 to 20 bar) and are characterised by maximum reliability and low operating costs. They are insensitive to fluctuating process parameters and gas compositions and are equipped with a control valve for infinitely variable control of the volume flow. The secondary rotor is not driven by timing gears (as with oil-free compressors), but by direct power transmission from the driven rotor. 

Joseph El Bitar, vice president and general manager of Hexagon. (Image source: Hexagon)

In an exclusive interview with Oil Review Middle East, Joseph El Bitar, vice president and general manager of Hexagon, speaks about the company's vision for the Middle East and its smart digital reality solutions

What are your main activities in the Middle East currently, and how do you view the market for developing your business in the region?

Hexagon is the global leader in digital reality solutions, combining sensor, software and autonomous technologies. We are putting data to work to boost efficiency, productivity, quality and safety across industrial, manufacturing, infrastructure, public sector and mobility applications. Our technologies are shaping production and people-related ecosystems to become increasingly connected and autonomous – ensuring a scalable, sustainable future.

Our main activities in the Middle East focus on supporting the region’s specific needs with advanced digital solutions. We empower customers to unlock data, accelerate industrial project modernisation and digital maturity, increase productivity, and move the sustainability needle.d our footprint by partnering with local stakeholders, governments and industries to accelerate this transformation.

How are your smart digital reality solutions helping companies in the energy sector to enhance safety and efficiency?

Hexagon’s Asset Lifecycle Intelligence division has been instrumental in integrating AI and digital solutions to improve efficiency and enhance safety in energy services. One of our flagship initiatives is the deployment of a digital backbone (which is also called digital twin or Smart Digital Reality™), which creates a virtual replica of physical assets and integrates with existing solutions. This digital twin enables real-time monitoring, predictive maintenance and optimization of operational systems, resulting in significant cost savings and reduced asset downtime. We go beyond a mere physical replica to create a comprehensive digital solution.

For example, our collaboration with leading EPCs on AWP, Smart Materials and Smart Completion has achieved remarkable results in projects. By utilising AI-driven analytics and digital workflows, we have streamlined project production management (PPM) and automation in project material management. This has resulted in a reduction in the project timeline and a decrease in material wastage

What are the benefits of your new HxGN SDx2 solution? Are there any other products or enhancements you would like to highlight, and how are advancements in AI and technology impacting your offering?

HxGN SDx2 is Hexagon’s next-level, cloud-native SaaS solution that integrates critical data, promoting transparency, efficiency, productivity, and more informed decision-making while mitigating risks and reducing costs. It reshapes operational boundaries for organisations engaged in digital transformation. Its robust features unveil and nurture previously untapped opportunities, positioning organisations for sustainable profitability through engineering and operational excellence.

The key to HxGN SDx2 is unprecedented accessibility and usability of data. It breaks down information silos across the asset lifecycle and improves the relationship between digital and human workflows across projects, assets, and operations. It forms a ‘digital thread’ of information that grows stronger as more systems connect to it and users leverage its power to better inform their day-to-day decisions and responsibilities.

What was your focus at ADIPEC this year?

At ADIPEC this year, our primary focus was on showcasing autonomous technologies and smart digital reality solutions that address the evolving challenges and opportunities in the Middle East region. With the industry's shift towards sustainability and digital transformation, we presented technologies that enhance operational efficiency, improve safety, and support the global transition to cleaner energy.

This year, ADIPEC's theme – “Exploring the power of energy in accelerating an economy-wide transformation that delivers for people, the planet, and our collective prosperity” – aligns seamlessly with our own vision of creating sustainable solutions for the energy industry.

Our theme for this year, “Two worlds, one sustainable reality,” encapsulates our approach to bridging traditional and emerging energy systems. We focus on integrating cutting-edge technologies, digital transformation tools, and advanced data analytics, with existing infrastructures. By doing so, we aim to accelerate the shift toward a sustainable energy reality –one that balances economic growth, environmental stewardship, and social well-being.

In the Middle East, Stream telemetry helped a major operator overcome difficulty in geosteering operations caused by harsh drilling conditions. (Image source: SLB)

SLB has launched Stream high-speed intelligent telemetry that increases drilling confidence and performance for complex wells

Designed to overcome the bottlenecks and limitations of conventional mud pulse telemetry, Stream combines proprietary artificial intelligence (AI) algorithms with SLB’s TruLink definitive dynamic survey-while-drilling service.

This provides uninterrupted, high-speed, high-fidelity real-time subsurface measurements with no data limitations, whatever the depth, in even the most challenging conditions.

“Stream is another example of the step change that digital technologies are bringing to our industry, tantamount to going from dial-up to broadband internet,” said Jesus Lamas, president, Well Construction, SLB. “For complex well profiles, transmission has been a huge bottleneck for the data volumes being generated downhole, often constraining drillers to work with a limited picture of the reservoir. Capitalising on advanced AI algorithms in telemetry eliminates these restrictions — enabling optimal drilling decisions for more consistent, higher-performing wells."

Stream has already been deployed in 14 countries, with more than 370 runs and more than 1.5 million feet drilled. In the Middle East, Stream telemetry helped a major operator overcome difficulty in geosteering operations caused by harsh drilling conditions and poor signal quality. Using Stream, the operator was able to receive high-quality data at depths in excess of 50,000 feet — resulting in one of the longest offshore extended reach wells ever drilled.

Dale McMullin, chief technology officer, IFS Energy & Resources. (Image source: IFS)

IFS, a leading provider of enterprise cloud and Industrial AI software, has launched next-generation oil and gas accounting solution IFS BOLO 15, the latest iteration of IFS BOLO, which possesses the processing power to handle any business scenario

IFS BOLO 15 creates a step change in back-office efficiency through streamlined workflows, a substantial reduction in rework, and the simplification of audits. Powered by IFS.ai and layered with artificial intelligence, this software offers a completely refreshed user interface (UI), multi-layered security and open data access.

IFS Energy & Resources customers can add new AP invoicing capabilities included with the BOLO 15 release to expand their IFS Excalibur, IFS Qbyte, IFS IDEAS, and IFS Enterprise Upstream investments. The AP invoicing module powered by IFS.ai provides open, cutting-edge automation to improve cash flow by increasing productivity through reduced processing time, improved accuracy, and optimised payment cycles. Additionally, vendor relationships are enhanced with a convenient self-service portal.  

Dale McMullin, chief technology officer at IFS Energy & Resources, said, “These advancements and achievements are a testament to our product teams’ innovation and steadfast development toward stronger and more efficient technology. The investment IFS continues to make in the energy and new energy industries is substantial. We’re enabling customers with the tools they need to make an impact in their respective businesses, while also ensuring sustainability is woven into our development practices and the final products we deliver to customers.”