Process air generation in the Bremervörde sewage treatment plant with highest energy efficiency

COM PRESS

New Address for Process Gas and Refrigeration ProjectsBusiness Unit Ariadne in Hungary

More Pressure for Process Gas CompressorsNew Sizes

Highest Suction Capacity with Positive Displacement BlowerReliable Dust Suction Systems

Aerzen – one step ahead

Dear Readers,

This issue of COM.PRESS provides you once again with a lot of very interesting information about the development of the “Aerzen Group”. Following the market launch of the energy-efficient Delta Hybrid in 2010, Aerzener Maschinenfabrik presented more new technology for the energy-efficient conveyance

and compression of air at the IFAT Trade Fair this year. With the Aerzen Turbo we have cre-ated a unique product programme within a very short time. In addition to Delta Blower and Delta Screw Unit, Delta Hybrid and Aerzen Turbo now complete our product programme. Remarkable energy savings are possible through the use of an intelligent combination of these different tech-nologies, as the example of the sewage plant in Bremervörde demonstrates.

This issue of COM.PRESS also shows that in the process and biogases sector the “Aerzen Group” is developing very positively, both in terms of our product range and in the growth of our organisation.

I hope that you will enjoy reading this issue and that you will get many new ideas from it.

Cordially yours,

Klaus-H. Heller,CEO

View into the blower station of wastewater treatment plant Bremervörde. At the front the AT-turbo blower, behind it two positive displacement blowers Delta Blower, with which process air for the aeration basin (small photo) is generated.

The sewage treatment plant in Bremervörde was designed to have an overall capacity of 30,000 EGW

(population equivalents) and with approx. 29,000 EGW it is now nearly at full capac-ity. At present, up to 3,000 m³ waste water are fed into the sewage treatment plant every day. However, approx. 1,200 up to approx. 1,500 m³ can be generated by one single production, the quantity fluctuates particularly due to the rest from work on weekends. The amount of wastewater generated by the resident population in the catchment area in the course of the working week with approx. 1,500 m³/day is nearly constant.

It is obvious that a wastewater treat-ment system with a wastewater spectrum of 50 up to 100 per cent can only be run with optimal energy utilization when

the selected process air generators adjust fully automatically to all the requirements. Sewage work operator Heiko Müller says: “Therefore in November 2010 we realised a new concept for the generation of process air. Currently, one new speed-controlled Aerzen turbo blower as active base load plant covers, by itself, our process air requirements across the entire spectrum. When so required, we can switch in addi-tion two older model fully automatic posi-tive displacement blowers for generation of the peak load. With this well-tailored distribution of the base load onto an ac-cordingly dimensioned turbo blower and the peak load onto up to two positive dis-placement blowers we are now operating our process air station particularly energy-efficient. The subject ‘energy costs’ is for us extraordinarily important, because for the

process air generation we have to spend about 75 per cent of the total energy costs of our wastewater treatment plant.”

Larger control rangeAlready in the more distant past the proc-ess air for the aeration basin was generated by means of positive displacement blowers made by Aerzener Maschinenfabrik. These old units were replaced in 1999/2000 by two Aerzen blowers series Delta Blower. One unit covered the requirement, the second one served as redundancy. Both units were already speed controlled, so that they could be adjusted to the fluctuating requirement in a range of between approx. 35 and 50 Hz. However, in their lower performance range the blowers could not cover anymore the even lower load re-quirement. Therefore, supplementary units had to be found for Bremervörde’s process air generation requirements. These had to be speed controlled on the one hand and to have a wide performance spectrum on the other. Additionally, if possible they should be able to run 100 % in speed-controlled

A biological municipal wastewater treatment plant with a considerably fluctuating discharge quantity can only perform its function with utmost energy efficiency and reliability if the process air consumption of the aeration basin can be adjusted continuously and is fully automated in order to deal with widely fluctuating load quantities. The example of the wastewater treatment plant shows how this is achieved with the use of a speed controlled Aerzen turbo blower.

A Turbo for the Base Load, Blower for the Peak Load

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New Business Unit “Ariadne”

New Address for Process Gas and Refrigeration ProjectsSince May of this year the gas and refrigeration business has been in the hands of Aerzen Hungaria thanks to the newly established business unit “Ariadne”. They are already working at full speed.

For 18 years now, Aerzen colleagues in Hungary have been working in the

gas and refrigeration business. For many years Messrs. HAFI have produced gas and refrig-eration machines with Aerzen compressor stages, developed and sold in co-operation with Aerzen Hungaria and the parent company.

When, at the beginning of last year, Messrs. HAFI were having frequent financing and delivery problems, and our cus-tomers were becoming more and more confused, Aerzen Hungaria came up with the idea of manufacturing themselves the gas and refrigeration machines previously purchased from Messrs. HAFI.

All the parties involved soon agreed that with Aerzen stages and technical support

from the parent company Aerzen Hungaria would certainly be able to produce their own process gas and refrigeration machines in Hungary, particularly as former HAFI-colleagues would be able to contribute their engineering and production knowledge. The only thing missing was a production

facility – and thus a new assembly hall, together with an office building, was planned. As Aerzen Hungaria has operated on a financially prudent basis over the last 20 years, the subsidiary company was in a position to finance the construction activities out of its own resources.

Already certifiedThe assembly hall and of-fices were completed in just

a year. The newly formed engineering team only moved in in May and have already prepared more than 200 quotations and supplied several self-produced compressor units within this short period of time.

ISO 9001 certification has also been completed.

load-run operation across the entire requirements

spectrum.

New Aerzen AT-turbo blowersIn November 2010 a new Aerzen turbo blower type AT 100 – 0.6 (driving power 75 kilowatts) was installed. Since it was commissioned the unit has run 10,700 operating hours (as of February 2012) and consequently ran almost entirely without no-load operation periods around the clock in volume controlled load operation – which proves its optimal design. This unit, with a capacity spectrum of 36 up to 80 m³/min, now serves as base load gen-erator for process air supply of the waste-water treatment plant in Bremervörde. The two Aerzen positive displacement blowers of the old supply concept can be connected automatically as stand-by units and as peak load generators. As per in-formation from Heiko Müller about 75 per cent of the electrical energy used in the Bremervörde wastewa-ter treatment plant is used for generating process air. Therefore for the new concept the particularly economi-cal handling of elec-trical energy was an absolute precondition. Before making the decision to purchase they had determined that under considera-tion of the available depth of the basin a discharge pressure of 0.4 bar is sufficient for optimal aeration. Onto this value the impeller of the blower was customized

for the highest possible energy efficiency. Higher pressures up to max. 1.0 bar are possible by using corresponding impellers.

All three units, the new Aerzen AT-turbo blower as well as the two approx. 12 year old Aerzen positive displacement blowers series Delta Blower, were installed optimally in a separate building. The sup-ply air enters from the outside. A filter mat prevents dust from penetrating into the unit. Warm exhaust air supported by a fan escapes the room. All the units supply via a busbar in the station directly into the aera-tion basin. A probe in the basin continu-ously measures the oxygen content and controls the delivery volume of the process air via the speed of the units. At the end of the treatment process the treated water is discharged into the adjacent river Oste with a purity degree of approx. 95 per cent. “With this concept we meet our require-ments optimally and with highest pos-sible energy efficiency. The turbo blower

works with its broad performance spectrum as ideal base load unit in spite of our widely fluctuating in-put quantities between 1,500 and 3,000 m³/day. Depending on the requirements, the Aer-zen positive displace-ment blowers can be connected fully auto-matically as peak load

units”, says Heiko Müller and continues: „With our new concept for generation of process air as per our experience we found an optimal solution with highest possible energy efficiency. Our expenditure on maintenance amounts to just a few min-

utes a year for changing the filter mats. And the specialists from Aerzen guarantee an optimally adapted overall concept. We are convinced that with the present combi-nation with one turbo blower for the base load and two positive displacement blow-ers for peak load and stand-by, we realized an ideal and very commendable concept. With this we can supply our biologically working wastewater treatment plant and make it safe to operate, reliable and espe-cially energy efficient with process air.”

Continued from page 1

New Office Formally InauguratedSince January the sales office of the Saarland has moved into a new and bigger office in Saarlouis. On 6th June it was formally inaugurated.

www.www.aerzen.com/fairs

Exhibition DatesIn the second half of 2012 Aerzener Maschinen­fabrik, its sales companies and representatives will participate in fairs and trade exhibitions worldwide of various industries. All business partners and interested visitors are most welcome to visit our stands.

ANEAS, Querétaro/Mexico 16th – 19th October 2012KIMEX, Seoul/Korea 16th – 19th October 2012Maintain, Munich/Germany 16th – 18th October 2012Aquarama, Leuven Brabanthal/Belgium 18th October 2012Maintenance Expo, Paris/France 6th – 9th November 2012Schüttgut, Dortmund/Germany 7th/8th November 2012Ecomondo, Rimini/Italy 7th – 10th November 2012BioEnergy, Hanover/Germany 13th – 16th November 2012Pollutec, Lyon/France 27th – 30th November 2012Meister Erfahrungsaustausch (exchange of experiences of foremen), Travemünde/Germany 4th/5th December 2012

The AT-turbo blower at the front generates the base load – the positive displacement blowers Delta Blower behind generate the peak load.

VMY-methane gas compressor

Dirk Koob, Klaus Heller and Markus Leidinger (from left) cut the ribbon.

New Managing Director in IndiaThe new Managing Director of Aerzen India is Jitendra Mangle, who assumed the position on 1st May. The 52­year old has more than two decades of experience in different sectors, includ­ing automobile suppliers, the plastics industry and compres­sor manufacturers. Mangle has extensive knowledge of business strategy, supply chain management, logistics, production process­es, sales and marketing, and business operations and has worked for international companies includ­ing GKN Sinter Metals and Atlas Copco.

Jitendra Mangle

Heiko Müller, sewage work operator at Bremervörde

»We are convinced that with the pre-sent combination with one turbo blower for the base load and two posi-

tive displacement blowers for peak load and stand-by, we have realised an ideal and very recommendable concept.«

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Due to a new bearing and shaft design it is possible to increase the maximum admissible differential pressures to 25 bar in the process gas

compressors VRa 236 H and VRa 336 H. Thus, with a multi-stage unit discharge pressures of up to 53 bar abs. can be reached. Consider-able cost savings and reductions in space usage are possible as higher pressures with fewer individual compressors and corresponding acces-sories can now be achieved. Moreover, the new types of the H-variant can ideally be used for pre-compressions. Customers in the chemical, petrochemical and process-ing technology industries can select the compressor unit optimally for their needs from one of the most extensive ranges available. Particularly in the case of multi-stage applications there are ideal combination possibilities

which also offer advantages in volume control. With a total of 20 compressor stages, the Aerzen process gas machines cover intake volume flows of from 550 up to 120,00 cubic metres per hour. Practically all gases are compressed, if contaminated, polymerised, supplied with liquids or with low molecular weight. In the case of single-stage compression, differential pressures of between 7.12 and now also 25 bar but also vacuums smaller Pe up to 0.9 bar can be realised.

The Aerzen Process Gas Compressors consist of an extensive modular system which can fulfill many different requirements using special and individually designed units. Building regu-lations and specifications of various industrial branches and inspection companies such as API or works standards are consid-

ered customer-specific. For adaptation to many different situations, process gas rotors can be selected in steel or stainless steel and housed in a nodular iron, steel or stainless steel casting. The Aerzen modular system offers carbon labyrinth as well as oil-and gas-purged

mechanical seals for the sealing of the conveying chamber, which can be se-lected without modification of the housing design. The

same applies to most of the different driving methods. Whether direct drive, drive via an

intermediate gear, or by electric motors or by steam turbines, the application of proven components ensures maximum possible safety and reliability.

The successful process gas compressors VRa of Aerzener Maschinenfabrik GmbH have been extended by new sizes. The innovative types VRa 236 H and VRa 336 H supplement the compressor series in the lower volume flow range of from 750 to 2,800 cubic metres per hour.

New Sizes with 25 bar Differential Pressure

More pressure for Aerzen Process Gas Compressors

3Building Site Takes ShapeStep by step the construction work is proceeding for the new office building in Aerzen. The progress schedule submitted by the architects Werner Brandstetter provides that the steel framework for the new building will be completed by the end of October. In November the expansion starts and the so­called technical units such as ventilation, heating, lighting, air conditioning and sprinkler systems will be installed.

According to the schedule of works, the interior fittings will be completed by March/April 2013. In May 2013 it is planned that our first group of col­leagues will be able to move into their new offices.

Then, the old “new administration” will be refurbished completely and adapted to the stand­ard of the new office block, so that both buildings become one unit.

One particular objective of the future concept is this: all employees should feel comfortable at their workplace and be able to work especially creatively and effectively – both for themselves as well as in collaboration with others. Finally, the office layout will not look the same as it did before – there will be a mixture of small and large offices, creativity zones, meeting zones, etc. Aerzener Maschinenfabrik will be able to offer its employ­ees an optimal working environment and presents itself to customers and suppliers as an innovative company.

Tour around the Factory for Staff of Tecklenburger Sewage Plant Neighbourhood

Sewage Plant Employees Were ImpressedStaff of the “sewage plant neighbourhood 4 Tecklenburg” – the biggest in North Rhine-Westphalia – spent their 45th Neighbourhood Day at Aerzener Maschinenfabrik. The highlight of this event was the guided tour around the factory in Aerzen.

After the guided tour around the factory

One of the new process gas compressors with view of its inner workings

A total of 21 communities belong to the sewage plant neighbourhood of Tecklenburg. Twice a year, the em-ployees of the corresponding plants attend training, in

order to exchange information and share experiences.The latest meeting, which had 44 participants, including two

employees of a Dutch plant, took place in Aerzen on 25th April. Stefan Pröschold of, Sales Office West, provided our visitors with interesting facts about Aerzener Maschinenfabrik. Then, Björn Heuer introduced the Delta Hybrid and Frank Glöckner informed them about the maintenance of Aerzen rotary piston machines.

During a guided tour around the factory, our visitors got a good idea of what Aerzener Maschinenfabrik is all about. They

expressed their surprise about the manufacturing range, variety and size of machines produced in Aerzen.

Two options for holding spontaneous meetings (above and below).

A Million SuccessesSince beginning production back in 1868, all twin­shaft positive displacement machines have been numbered. A screw compressor stage VML 95 has recently received the impressive number 1,000,000. The stage was manufactured in the summer of 2010 and afterwards assembled into one unit. Then, the anniversary product of Aerzener Maschinenfabrik went on a long journey to Asia, along with other machines, and the service staff at our Chinese subsidiary installed the units in Daqing, Northern China, and made them operational. The unit, which pneumatically conveys polyethylene particles for the production of plastics, consists of two production lines with a total of 18 Aerzen Screw Compressors and Positive Displacement Blowers.

CEO Klaus-Hasso Heller and the technicians of the assembly team at the parent company.

During the theoretical section, the participants gained useful information about Aerzener Maschinen-fabrik and its products.

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AERZEN COM· PRESSCustomer Journal of Aerzener Maschinenfabrik GmbH Edition 3/2012

Publisher Aerzener Maschinenfabrik GmbH Reherweg 28 · D­31855 Aerzen

Editorial staff VM/Stephan Brand (v.i.S.d.P.) VM/Wilfried BönickAndreas Gattermann, Steffen Glindhaus, Frank Glöckner, Klaus Grote, Klaus Heller, Bernd Wöhlken

Pictures Aerzener Maschinenfabrik, Barlmeyer, Aerzen Hungaria, Bene, Aerzen China, Emde Realization Maenken Kommunikation GmbH Von­der­Wettern­Straße 25 51149 Köln Number of copies 3.800

imprint

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New Structure

New Business Unit – Biogas

A erzener Maschinenfabrik, the leading manufacturer of blowers and screw compressors for use in

environmental technology, is a new face in the biogas industry. With the establish-ment of its new biogas business unit, Aer-zener Maschinenfabrik hopes to tap into the steadily increasing demand for special products in this sector.

Projects for biogas treatment and feed-ing are the new unit’s main target. In future, all Aerzen products in the biogas

range will be sold via the new business unit and processed accordingly. The business unit will be supported by the sales activi-ties of Aerzen sales offices and subsidiaries.

For the biogas market, Aerzener Maschinenfabrik offers blower and compres-sor packages up to 3,5 bar g (oil-free) as well as oil-injected compressors up to 20 bar g.

For further information, please contact Dipl. Ing. Axel Cichon by telephone on +49 (0) 5154/81-9131 or by e-mail: axel.cichon@aerzener.de.

A Curious Encounter at the Airport

On his flight back from ser­vice at the Borouge project near Abu Dhabi our service technician Dirk Wolfschmidt was most impressed while queuing at passport con­trol during a stopover in Istanbul. A group of about 20 African people were attracting attention. In the

middle, protected by a large, colourful umbrella, he saw the reason for the commotion: a man dressed in African costume and draped in gold jewellery from head to toes. When Wolfschmidt asked one of the group who this person might be, he was told that it was none other than His Majesty “King Bansah of Hohoe Ghana”, the Regent of the Lake Volta region in the East of Ghana.

Dust Suction Systems

Highest Suction Capacity with Aerzen Positive Displacement Blower

Next Delta Hybrid Size

D 98 in Field Test

A reliable and energy efficient design of Positive Displacement Blowers for dust suction systems is worked out by the technical depart-ments of EMDE Industrie-Technik GmbH in co-operation with Aerze-ner Maschinenfabrik.

Only regular cleaning with dust suc-tion systems can guarantee a clean factory and safe working areas for

the handling of bulk materials. Large, plane areas are cleaned by sweepers. Operational areas which are difficult to access , can be reached by a central piping network with minimum space requirements and then be connected with a stationary or mobile dust suction system. Floor and wall surfaces, as well as plants, are cleaned at regular in-tervals by means of suction kits with flex-ible, electrically conductive suction tubes. An oil-free positive displacement blower with minimal maintenance requirements provides, on a permanent basis, the neces-sary negative pressure for safe operation. The ventilation calculation of the piping system and positive displacement blower is ensured through a proven calculation

programme and many years of experience with various media. Many kinds of dust such as flour, sugar, coal and fertilising agents are classified as explosives and re-quire very safe dimensioning of the system. If an external ignition source should be fed into the system and cause an explosion, the negative pressure generator would be protected by a safety valve. The filter sepa-rator is offered in two versions – pressure surge protected or with a pressure release.

The mobile dust suction system shown in the picture is operated at various cen-

tral piping networks in the power plant. To discharge the dust from the coarse and filter separator, the mobile unit is docked into a central unloading station where the dust is humidified. A tube chain conveyor guarantees safe evacuation of the tanks. The plant operates with up to a 300 me-tres long piping network and a connected load of the blower of 45 kilowatts. The acoustic hood ensures a maximum sound pressure level of less than 80 decibels at a distance of one metre according to DIN EN ISO 2151.

Typical compressor applications in biogas

feed-in systems.

A mobile dust suction system with Positive Displacement Blower of Aerzener Maschinenfabrik

Aerzener Maschinenfabrik is a Trustworthy PartnerIn April, Aerzener Maschinenfabrik gained the so­called AEO­certificate (“Authorised Economic Operator”). Aerzener Maschinenfabrik is thus con­firmed as a very trustworthy trading partner within the European Union. Advantages of the certificate include fewer goods controls and accelerated customs proce­dures.

Since 1st July an agreement has come into force between the U.S. and the EU, which simplifies imports and exports considerably. Consequently, the U.S. and the EU will mutually recognise their author­ised economic operators ­ with “C­TPAT” in the U.S. which corresponds with “AEO” in Europe. Companies will benefit from quicker inspections and lower costs in respect of customs clearance.

Ever since the introduction of the Delta Hybrid at the IFAT 2010, the number of enquiries for rotary lobe compressors with ever increasing volume

flows has continued to increase. This, ultimately, was the reason behind the development of the next size D 98 (up to 1,500 mbar / 5,800 m³/h). After only one year of development the Delta Hybrid D 98 S and H units were completed. In order to meet the high expectations of the customers concerning quality Aerzener Maschinen-fabrik decided to test the units extensively prior to production of the series. The first field test units were supplied at the end of 2011, more than 30 units in total. Field tests will continue until the end of this year. The

first series-production units will be supplied in 2012. The next size D 152 (up to 1,500 mbar / 9,000 m³/h) is be-ing developed at the moment and the first field test machines D 152 S and H will be commissioned this year. The goal is to be able to offer Delta Hybrid up to a volume flow of 15,000 m³/h next year.

Undergoing extensive field testing: Delta Hybrid D98S

A King from Ghana (r.)

www.www.aerzen.com/news

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