Rotary Lobe Compressors instead of Surface Aerators NEW CONCEPT FOR WASTE WATER TREATMENT AT PCK PCK refinery converted its aeration basin with a size of 2,000 cubic metres from surface aeration by means of surface aerators to areatype aeration on the ground of the basin. In the pilot project, a new container station with three Aerzen rotary lobe compressors series Delta Hybrid makes available the required oxygen. The open doors on the long side of the oxygen-container provide a view of the three Aerzen Delta Hybrid machines. Each rotary lobe compressor can be switched on and off individually from the outside via emergency off switches at the head of the container.PCK in Schwedt/Oder, 100 kilometres north-east of Berlin, is one of the biggest refineries in Germany and one of the top refineries in Europe. With its 1,150 employees it processes every year up to twelve million tons of crude oil and is the most important sup- plier of fuel in Berlin and Brandenburg. Every plane starting in Berlin flies and every tenth car in Germany runs with fuel from Schwedt. Focussed on energy and environmental protectionFor PCK compliance with highest safety standards is obligation same as environmental protection. With its latest investment into the inhouse waste water treatment PCK intends to achieve several targets: A new aeration system on aeration basin 3 is intended to increase the efficiency and the profitability of the water treatment sustainably, to increase the water temperature, to improve the activity of the bacteria in particular during winter months, and finally reduce the development of odour considerably. The waste water cleaning plant works in accordance with the biological principle. In the four aeration basins working in parallel the prepurified water is treated by means of bacteria. In order to ensure intensive work and sufficient reproduction of the bacteria the basins with a depth of about six metres had been supplied with oxygen by means of surface aerators since the 1970s. Intensive swirling of the water surface however involves disadvantages such development of noise and odour, unevenly distributed oxygen contents inside the basin as well as cooling down of the water.Aeration from the bottom instead of from the topTo eliminate these disadvantages first of all in aeration basin 3 a new aeration system was realised and commissioned in October 2012. About 150 to 250 cubic metres of waste water are fed into the basin every hour. Now the basin is no longer aerated from the top but from the bottom by means of nozzle pipes on the ground of the basin. The oxygen required is supplied by three Delta Hybrid machines. PCK-waste water specialist Enrico Schmottlach is expecting substantial advantages from the new technology:• lower energy costs due to constant adherence to the oxygen setpoint value;• generation of oxygen depending on requirements for optimal conditions of the bacteria;• particularly effective and uniform aeration of the entire contents of the basin due to a constant pressure of 480 mbar in the main pipe;• reduced discharge of odourintensive components due to a calm surface;• especially in winter less loss of heat and reduced inclusion of cold due to a calm waste water surface;• considerably improved conditions for the bacteria due to increased temperature inside the basin;• noise reduction to maximum 70 dB(A).Oxygen from the container The new oxygen concept was installed in accordance with the stipulations of the extensive functional specification in close proximity to aeration basin 3 in an accessible special container with a length of about seven metres, the longitudinal wall of which can be opened by means of two folding doors. Three closable openings inside the roof make it possible to assemble and disassemble larger components without any problems. A sound-absorbing internal lining of 100 mm thickness and additional sound absorbing inlet and exhaust air channels at the two front sides reduce the sound pressure level outside the container to the values as required by the operator. Two thermostat-controlled exhaust air fans guarantee an indoor tem- perature of maximum 20 °C above outdoor temperature. The three installed Delta Hybrid machines type D 62 S with a motor rating of 90 kW, 500 V, have been designed for an operating pressure of 700 mbar. Two units are operated speed-controlled via frequency converter (delivery spectrum 18 to 59 m3/min). One unit works with fixed speed and constant delivery quantity of 59 m3/min. The compressed air leaves the units at ambient temperatures of 30 °C with a temperature of 100 °C and at 0 °C with approx. 70 °C. It cools down on the way to the aeration basin, but even at cold winter temperatures it is fed in the basin with temperatures significantly above 0 °C. The three units can be switched on and off via external master switches. The provided frequency converters of the two controlled units were installed in an adjacent building. The container was equipped in Aerzen in accordance with the stipulations of the functional specification and the special requests of divisions ETA (electrotechnology, drives) and MSR (measurement and control technology), completely piped and wired, transported to Schwedt by means of a flatbed lorry and then installed on a prepared foundation plate by means of a crane. Having connected the electrical cables and compressed air pipe the station was immediately ready for operation. It is run via the central control room which can also intervene directly into the processes of the station.Practical experience will bring the definite concept“With this new concept for generating oxygen we have entered new areas”, explains Schmottlach. “For the time being we will gather experiences and find out whether a compressor with regulation can meet the requirement, or whether we have to operate in addition a unit without regulation as base load generator or two compressors with regulation. We have sufficient redundancy in any case.”
ISO-Certificate for Aerzen Mexico At the end of December 2012 Aerzen Mexico was certified in accordance with ISO 9001-2008. Sales, after- sales and maintenance of blowers, compressors and gas meters all comply with the quality management standard. The certificate is valid until the end of 2015
New sales engineer for the Asia-Pacific region In November 2012, Axel Wehling became the new sales engineer for the Asia-Pacific region. Hismain responsibility, together with Regional Manager, Chuck Lim, is to expand Aerzen’s business across the region. As a graduate in technical business administration, and from his time working in the capitalgoods industry, Wehling has international experience in projects involving multiphase positive displacement pumps and systems in the oil and gas sector.
Delta Hybrid D 152 in field testing The extension of the series Delta Hybrid range of products is progressing: in the meantime, the development of the next size D 152 has been completed. This machine can be used with negative pressure up to -700 mbar and with positive pressure up to 1,500 mbar at a volume flow of up to 9,000 m3/h.The first machines D 152 S and D 152 H for field testing have already been supplied and commissioned. Field testing will continue until the end of this year. Supply of the first serial machines D 152 S and D 152 H is scheduled for early 2014.
Aerzener Maschinenfabrik is a Trusted Partner In the middle of last year Aerzener Maschinenfabrik gained the so-called AEO- certificate (“Authorised Economic Operator”) and was thus confirmed as a highly trusted trading partner within the European Union.The advantages of gaining this certification 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 “C-TPAT” in the U.S. which corresponds with “AEO” in Europe.Companies will benefit from quicker inspections and lower costs in respect of customs clearance.
Water-Injected Compressor Series Expands For generating absolutely oil-free compressed air, Aerzener Maschinenfabrik has developed the new VMW-water stage. New, single stage VMW water stages working up to 13 bar have already been tested successfully under practical conditions and in continuous hard operation. Besides considerably improved efficiency they also offer significantly reduced maintenance expenditure, and are available for the time being for driving capacities of 45 to 110 kilowatts, and for maximum intake volume flows of between 13.4 and 17.2 cubic metres per minute. The new Aerzen VMW-water stages were designed exclusively for directly drive. They work at speeds of 1,500 to 5,000 rotations per minute and can be used in plants with constant speed as well as in demand- controlled plants.
New Aerzen subsidiary in Taiwan On 1st January 2013 Aerzener Maschinenfabrik established a new subsidiary in Taiwan. All orders and financial transactions of Aerzen Asia Singapore - Taiwan Representative Office, so the entity’s official name, are settled through Aerzen Asia Pte. Ltd. in Singapore which is the 100 per cent owner of the new entity. A new country manager is now located in Taipei- he replaces C.C. Lin of Tiphery Corp. who has coordinated business in Taiwan for Aerzener Maschinenfabrik for the past 20 years. With the establishment of this new entity, Aerzen will significantly strengthen its presence in Taiwan.
Improved performance: Delta Hybrid D 98 V The requirements for Aerzen machines increase continually – this is due to the constantly increasing fields of application. Aerzener Maschinenfabrik received an order to design a Delta Hybrid-stage which can be used in negative pressure up to-900 mbar.Aerzen met the challenge and developed the Delta Hybrid D 98 V. In this case the “V“ stands for “Vacuum“. The design has been completed and the first field tests will start shortly. In particular,the stage can be used in both stationary as well as in mobile areas.Another advantage, particularly for vehicle manufacturers, is the weight-performance ratio. In the past, a screw compressor or a blower with pre-inlet could be used for a negative pressure of -900 mbar. With the Delta Hybrid D 98 V a negative pressure up to -900 mbar as well as an overpressure of 1.500 mbar at a volume flow up to 5.400 m3/h can be realized.This means that, Delta Hybrid D 98 V combines the advantages of the blower with preinlet and those of the screw compressor – with a low space requirement.
New Managing Director at Aerzen Switzerland Marcel Strotz will take over the management of Aerzen Switzerland as of 1st April 2013. Strotz, who has been working at Aerzener Maschinenfabrik since December 2012, will replace longtime Managing Director, Vito Jahn, who is retiring after many years of loyal service.
New Managing Director at Aerzen do Brazil Rainer von Siegert has become the new Managing Director of the Brazilian subsidiary, Aerzen do Brazil, as of 1st January 2013.Von Siegert has been working for the Aerzen Group since August 2012,when he assumed the MD role on a temporary basis following a sudden change in management at the Brazilian subsidiary.
Poland voted Delta Hybrid “Product of the Year” The Polish specialist journal “Ulrzymanie Ruchu” (Ger. plant engineering) has voted Aerzen rotary piston compressor Delta Hybrid “Product of the Year 2012” in Poland.In the first phase, a jury of four had assessed all the submitted products. Then, in the second phase, the readers of the print and online edition decided on the awarding of the coveted title. This positive assessment of Delta Hybrid was primarily due to its energy efficiency.On 20th March representatives of Aerzen subsidiary in Poland accepted theaward on the fair AUTOMATICON in Warsaw.
