Turbo blowers made by AERZEN for base load, Delta Hybrids for peak load Step by step towards the ideal sewage plant Turbogebläse aus AERZEN für die Grund-, Delta Hybrid die für SpitzenlastEvery sewage plant has two major cost elements: the sewage duty and the energy costs for the generation of process air for the aeration basins. A sewage plant in Kaiserslautern has succeeded in signifcantly reducing both cost elements in a three step process. Thorsten Jung, Manager Wastewater treatment plant Kaiserslautern By means of a combination of units made by AERZEN, the energy efficiency of process air generation can be optimised considerably. View onto the compressor station with turbo compressor from AERZEN, an old turbo compressor, two rotary lobe compressors Delta Hybrid from AERZEN and two further old turbo compressors (from front)Thanks to the reduced sewage duty resulting from basic changes to the aeration basins in 2008, modification costs of € 1.3 million were amortised after only three years. Replacement of the two existing turbo compressors with two new Aerzen rotary lobe compressors of series Delta Hybrid, led to an additional energy saving of approximately 13 % of process air generation. Since then, the entire energy consumption per month has been reduced from approximately 250,000 kWh to only 140,000 kWh (see also COM. PRESS 3/2011). This shows that the energy efficiency of process air generation can be improved still further by the replacement of other old turbo compressors – however, this time with turbo blowers of the new AERZEN series ‘AT Turbo Generation 5’ provided with air bearings. Appropriate unit An intensive examination of the frequencies of required quantities in basins 1 and 2 had shown that replacement of the large turbo compressors used (delivery volume 10,000 Nm³/h) with a new unit which can meet these demands, will lead to further energy savings. At the end of 2012 they decided for the new turbo blowers made by AERZEN. This unit (delivery volume 6,000 Nm³/h) covered the most frequent operational range of between 5,000 and 6,000 Nm³/h on its own. For lowload operation below 4,100 Nm³/h they used the Aerzen rotary lobe compressor series Delta Hybrid which had already been installed in 2010. In case of a requirement of more than 6,000 Nm³/h, both units work simultaneously. Ideal combination With the new ‘AT-turbo Generation 5’ blowers AERZEN has realised the production of process air for biologically working sewage plants, offering the highest possible energy efficiency and security of supply. As a rule, the process air requirement of a sewage plant can only be satisfied using a combination of various machine types with various capacities, which can be defined as ideal base and peak load units due to their construction features and performance ranges. The physical advantages of turbo machinery – high energy efficiency of the design – can be perfectly combined with the advantages of rotary piston machines – high controllability and good efficiency in part load operation.Here, the units of the new controllable turbo blowers prove to be the ideal base load generators. As optimal generators of peak and low load requirement AERZEN supplies the controllable positive displacement blowers series Delta Blower and the controllable rotary lobe compressors series Delta Hybrid. Additional energy savings “It is a fact that the energy efficiency of the process air generation is continuously optimised”, explained sewage plant manager Thorsten Jung in January 2014, referring to the data already available from the field test and to calculations on the basis of the data from the combination of AERZEN units presently used for basins 1 and 2. The two Aerzen Delta Hybrid rotary lobe compressors, which have been available since 2010, and which, according to Thorsten Jung, have proved successful up to now, are kept available for all three basins as concurrently working redundancy units. But they are also planning to use an additional Delta Hybrid unit in basins 1 and 2 for covering low load requirements.Previous experience has shown that the planned concept will lead to an annual saving in energy costs of around € 60,000. In addition, due to operating only new units, maintenance costs will reduce by about € 15,000. The operators therefore expect a payback period of at most five years. Meanwhile, other sewage treatment plant operators are interested in the new concept operating in Kaiserslautern and the relevant positive experiences.
New service station for Aerzen Polska The Aerzen subsidiary in Poland, Aerzen Polska, officially inaugurated its new service station at the end of last year. After extensive renovation of its spacious, newly acquired building in Katowice, all Aerzen blowers situated in Poland can now be maintained and repaired there. Three new crane systems with a load capacity of up to 10,000 kilograms provide a better and more extensive scope of service. The service team, under the leadership of Przemyslaw Tomczak, has grown to 29 employees. At the official opening ceremony, Aerzen Polska welcomed about 160 customers and guests, besides the Aerzen management and employees of the headquarters. Aerzen Polska is already planning for further growth: The rental machinery business will be developed. Therefore, an agency of AIR will move in within a short time.
New size Delta Hybrid D 152 The new and successful rotary lobe compressor range Delta Hybrid made by AERZEN has now been extended with the addition of a unit of a new size. Customers can select from an extensive range the optimal unit for their application. Delta Hybrid is a synergy of blower and compressor technology, and offers completely new possibili- ties in overpressure and negative pressure gen- eration of air and neutral gases by combining the technical advantages of both concepts.With 16 sizes in all, the Delta Hybrid units now cover intake volume flows of 110 m3/h to 9,000 m3/h and overpressures up to 1,500 mbar. The new sizes D 152 S and D 152 H are used in the upper volume flow range of from 2,400 to 9,000 m3/h with driving powers of up to 400 kW.
Automatic re-lubrication devices AERZEN has for many years been offering service contracts in various categories. These contracts are handled up to twice a year by an Aerzen service technician. Packaged units with high annual operating times may require more service calls for the relubrication interval of the electric motors.AERZEN has included automatic re-lubrication devices in the After Sales Service Programme, in order to offer a solution to the users. These systems are driven by electric motors; the dispensers are provided with the necessary power supply by an integrated removable battery which guarantees an operational period of at least 12 months. Cartridges for the dispensers are available in 3 different sizes and various types of lubrication. The devices can be applied at temperatures from 10 °C to +60 °C. Thanks to corresponding programming, the dispensed quantity can be very accurately dosed and adjusted to the requirements of the electric motor. Therefore, an efficient and safe lubrication without downtime is guaranteed. In this way it can be ensured that the system is permanently available.Retro-fitting of new AERZEN machine lubrication devices is also possible for existing standard motors.
AERZEN goes App Of late, AERZEN has been offering company- designed applications in the famous App stores. These include a unit converter specially for compressors applications, converting important parameters like pressures, temperatures, volume flows and performance data simply and quickly into diverse units. In addition, there are Apps available for the latest products, including Delta Hybrid, Delta Screw and AERZEN Turbo. All Apps are designed for Android as well as for Apple Systems. And best of all: AERZEN Apps are free of charge.
Personnel changes at Aerzen Turbo Mr. Chungsup Um started work as Managing Director of Aerzen Turbo on 2nd December 2013, succeeding Rob Lammers. Prior to taking up this role the 44 year-old had worked as a consultant for various other internationalcompanies. Early in 2014, Lammers returned to Europe to become Director Turbo Business for Aerzen International Sales GmbH. After working for three years in Korea for Aerzen Turbo, which he set up with a number of other colleagues, Lammers is now responsible for sales development, organisation of the Turbo business and improving of the Turbo production network.
New regional manager for America At the beginning of 2014 Friedrich Harten was appointed regional manager within Aerzen International Sales, and he is thus responsible for the control and operational leadership of the sales and servicenetwork of the AERZEN group in America. The graduate engineer in mechanical engineering has many years of experience in the capital goods industry. He has worked in various positions with international orientation, in both big concerns as well as in small and medium-sized enterprises. In his most recent role he worked for a German-American pump manufacturer focussing on the oil and gas industry.
