Pneumatic conveying: Knauf and ISS rely on screw compressors made by AERZEN At the Knauf site Rottleberode AERZEN screw compressors type Delta Screw are used for the pneumatic transport. Knauf has recently invested around €33 million in the Rottleberode site in the southern Harz region - and in 2017 a modern fibreboard plant was taken into operation. Cellulose and stucco are the main components of the boards, which are very versatile in interior design applications. A pipe system is used to transport the fired and finely ground natural stone between the gypsum and fibreboard plants. AERZEN screw compressors type Delta Screw provide the appropriate pressure and volume flow during pneumatic transport. The energy revolution will make the gypsum industry increasingly dependent on natural stone deposits in the future. The entire industry is in a state of upheaval, because the FGD gypsum produced in the desulphurisation plants of lignite-fired power plants is a dying breed due to the shutdown of these power plants. On the other hand, the possible applications of gypsum are becoming more and more diversified for example: fire-retardant or water-repellent gypsum plasterboard, plaster, flowing screed and gypsum fibre board are just some of the applications in the construction industry. No industry can do without gypsum anymore. This makes it all the more important for leading manufacturers, such as Knauf, to use limited raw materials sparingly. The hunger for gypsumThe fibreboard production at Knauf in Rottleberode is supplied with stucco from the gypsum plant via a specially built pipe(line) bridge.At the Rottleberode plant, for example, Knauf returns the edge breaks which occur during the production of gypsum fibreboard to the material flow in the same way as the dust during surface grinding. “Every crumb of gypsum is important for us. This is why raw materials should no longer be disposed of during production,” emphasises plant manager André Materlik. His company is the only one within the Knauf Group which exclusively processes natural gypsum from the quarries in the southern Harz region. In view of the move away from lignite mining, industry experts argue that only those companies which develop and secure mining areas in the long term will continue to exist – and demand for gypsum in Germany alone is already high at around ten million tonnes per year. According to Materlik, around 450,000 tons of finished product leaves the Rottleberode plant every year, with around 100 truckloads a day. Stucco plaster, fine cellulose from waste paper and water: this is the mixture from which gypsum fibreboards are made. ISS Schüttguttechnik GmbH from Wilnsdorf in the Siegerland region plans and builds blow moulding machines to supply the mixers. ISS had already done a good job at Knauf before the new fibreboard plant was built, and had successfully got to grips with the problems involved in conveying and metering pulverised lignite. The fuel develops the necessary heat for calcining the rough stones. In the process, the natural gypsum loses a large part of its crystallised water content. “For uniform thermal processes, the constant transport of lignite without pressure or volume fluctuations is essential,” explains the plant manager. Any deviation from the ideal line is noticeable and can affect the product quality of the stucco, the deposits in the calcining mill, the CO values in the exhaust gas flow or the energy consumption of the screw compressors. “Uniform processes require less air,” says ISS Sales Managing Director Robert Partzsch, who speaks from experience.Process-safe with high efficiencyISS Schüttguttechnik has planned and realised the new stucco supply together with Knauf Engineering.For this reason, ISS has also put all of its know-how into the development of an overall solution for the conveying of stucco plaster, which was developed in Rottleberode together with the plant planners of Knauf Engineering GmbH. The company, under the Knauf umbrella, planned the entire new building at Iphofen and also ordered the conveyor technology. The main focus was on process safety, longevity and energy efficiency. „The high efficiency is due to the AERZEN screw compressors,“ says Partzsch. In addition, the Delta Screw series is recommended because of its pressure range, which is ideally suited for the transport of stucco. It is important to know that according to the experience of the ISS Managing Director in the pneumatic conveying of bulk materials, compressed air with 5 to 6 bar is often first generated in order to feed an air vessel. This makes available an often significantly lower delivery pressure. “Intermediate buffering always results in energy losses,” emphasises Thomas Koch, head of technical mechanics at the Knauf plant in southern Harz. The Joule-Thomson effect is proof of this. Every 100 millibar increase in pressure causes a temperature rise in the compressed air of +10 degrees centigrade, due to the increased friction of the molecules. The effects of this physical connection can be limited if air vessels are dispensed with - as is the case at Knauf. However, since thermal energy cannot be completely prevented during pneumatic conveying, Knauf uses it in winter with recovery for heating purposes.Never wasting any energyDelta Screw units of type VM21 supply a volume flow up to 1200 cubic meters per hour.In view of the fact that it is always better not to use electricity in the first place, rather than returning it later as heat, the goal must be to use compressors in energy-intensive compressed air that deliver the required volume flow with exactly the required pressure without intermediate storage. “AERZEN is simply the leader in the range from 2 to 3.5 bar,“ notes Partzsch and adds: „why should I generate 6 bars when I only need 3 bars?“ The Delta Screw units type VM21 with a motor rating of 90 kW supply a volume flow of 1,200 cubic metres per hour. The maximum pressure is 3.5 bar. The Generation 5 machines of the Delta Screw series installed at Knauf are designed by AERZEN as universal machines - with great attention to efficiency. Developed as a flexible modular system, the different compressor units can be suitably configured with motors of varying performance and an extensive range of accessories. Belt drive adjustment options, for example, provide the basis for accurately adjusting the volume flow even at fixed speeds - with the aim of preventing energy-intensive excess generation. This claim is backed up by the renunciation of redundancy at Knauf. Compressors and conveying systems work so reliably that separate „backup technology“ can be dispensed with. “The plant is designed for a capacity of twelve tons of gypsum per hour,” says Koch. If one assembly is taken off the grid, a temporarily switched bypass solution ensures reliability of supply. “However, our installation generally provides that one compressor always serves one system,” he adds.”ResultIn the course of building Knauf’s new fibreboard factory in the southern Harz, the newly installed blow moulding systems for pneumatic conveyance of stucco highlight some of the most important elements for minimising the consumption of costly energy - the focus was on increased efficiency and optimal design at the point of operation. Knauf has a clear system concept with the equipment at its works. “It is the combination of scientific and technical knowledge which makes up the solution of ISS. Here, everything is as it should be,” says plant manager Materlik.
Securing subsidies for energy efficiency Thanks to public subsidy programmes, energy efficiency now has a double pay off. In order to exploit this potential, AERZEN will offer its customers comprehensive support in the areas of energy efficiency, energy recovery and resource management together with the state-subsidised e.qua network. The climate protection targets adopted by the German government are accompanied by numerous subsidy programmes that can be used by operators of water management facilities. A distinction must be made between concept and investment subsidies for energy in the context of climate protection.Customer-oriented support by AERZEN and e.qua ranges from measuring volume flow requirements, energy analysis and optimisation and the preliminary clarification of suitable funding options for energy concepts to support in applying for funding.One example is sewage treatment: wastewater treatment plants are among the largest energy consumers in municipalities. With the latest technologies, considerable amounts of energy can be saved. In order to meet the increased requirements of the water and wastewater industry, AERZEN has paid special attention to the energy efficiency of its assemblies. In addition, well thought-out solutions for waste heat utilisation can be provided. AERZEN thus also meets the political targets set for energy efficiency and energy generation.
Delta Blower series extended With the Generation 5 positive displacement blowers AERZEN has set new standards. Now, the series is extended by two new blower stages: GM 110 S and GM 130 S types close the gaps in the volume flow range. The figures “110” and “130” stand for intake volume flows of 110 and 130 m³/min respectively (6,660 and 7,800 m³/h). Previously, there had been a jump from 90 m³/min (5,400 m³/h) to up to 150 m³/min (9,000 m³/h) and with it also a jump in the nominal diameter from DN250 to DN300. With the new blower sizes, this volume flow range is now finer graded, which brings decisive advantages for plant manufacturers and operators in terms of investment costs, dimensions and control range.What is also new: the enhanced Delta Blower series G5plus. Energy efficiency is currently the most important focus, particularly in the field of compressor technology where energy costs exceed 90% of the life-cycle-costs. AERZEN has always been a standard setter to develop more efficient and environmentally friendly processes. To expand upon the success of the AERZEN Delta Blower series, an exciting new design sets energy saving records. The new G5plus series distinguishes itself by increased energy efficiency of up to 5% and significantly reduced dimensions.Experience the new blower sizes at the trade fair stand of Aerzener Maschinenfabrik at the IFAT in Munich and the ACHEMA in Frankfurt.
This is AERZEN Performance³ AERZEN defines Performance. as an individual solution for the oxygen supply of biological aeration in waste water technology. Individual assemblies of Delta Blower positive displacement blowers, Delta Hybrid rotary lobe compressors and Aerzen Turbo blowers of the AERZEN range of products or a combination of assemblies of different efficiencies and regulating ranges can be used. What is so special about Performance³ Every technology has its strengths, but is also subject to physical limitations. By means of a possible technology mix and the use of different sizes, the individual strengths of assemblies can be added to a highly efficient combination with the best control range. The AERZEN Performance³ concept takes into account the respective requirements of a plant and offers you a rightsized solution that suits you and your plant perfectly. You will be supported by AERZEN wastewater experts during the entire process until your Performance³ solution is found. How does AERZEN proceed? In a first step, the load profile of a wastewater treatment plant is evaluated and important parameters for the following calculations are determined. If this load profile is not known it makes sense to record the measured value before. For this purpose, AERZEN uses its AERaudit product which is used to measure the volume flow and other important variables during operation of a plant (see page 2).An analysis of the recorded load profile forms the basis for the Performance³ process. At the beginning, the solution space consists of a multitude of variants. Taking your plant requirements into account, AERZEN will develop the Performance³ solution that best suits you and your plant.
New Head of Opportunity Engineering in Supply Process Gas On 1 September 2017, Carsten Holldack assumed responsibility for the group Opportunity Engineering in the Supply Process Gas division. The graduate mechanical engineer, born in 1970, has more than 20 years of professional experience in the field of rotating equipment. His previous roles were in development, product management and salesmanagement. The “Opportunity Engineering” group at the Aerzen site, led by Holldack, consists of six experienced process gas specialists.
Klaus Peter Glöckner new member of the General Management Since 1 December 2017, the General Management of Aerzener Maschinenfabrik consists again of three persons: Graduate engineer Mr. Klaus Peter Glöckner completes the Management team and has got to know the company intensively over the past few months. Klaus Peter Glöckner is responsible for the EMEA region. He was previously employed as Chief Sales Officer and Managing Director at Messrs. Kelvion.
Aerzen Colombia celebrated its 10th anniversary On 27 September 2017, Aerzen Colombia S.A.S., based near the capital, Bogotá, celebrated its tenth anniversary. The subsidiary, which when it opened was called Aerzen Andina, started out as an agency of Aerzen Iberica. This developed into two separate subsidiaries - Aerzen Colombia, which now has 15 employees, and Aerzen Andina Peru, where four colleagues are currently employed. The markets in Bolivia, Ecuador and Venezuela are supervised by commercial agents. Ricardo Castillo, Managing Director of Aerzen Colombia, is pleased about the tenth birthday celebrations: “We hope to be able to celebrate many more anniversaries and to contribute to the growth of the AERZEN group.”
