150 years AERZEN, part 2 1931–1984 AERZEN breaks records From a local manufacturer of agricultural machines to a global player: with its product innovations, AERZEN has always underlined its international importance and future orientation. AERZEN has always oriented itself to meet the requirements of its customers and has thus been able to set new standards over and over again. An AERZEN worker inspecting screw compressor rotors in the testing appliance.The production of screw compressors, which have since become one of the most important products made by AERZEN, began during the Second World War. At that time, the Reich Ministry for Armaments and War Production instructed Managing Director Karlheinrich Heller to design a screw compressor, intended to serve as an exhaust gas compressor in new submarine types. After a period of negotiations lasting two years, AERZEN was awarded a sub licence by the Swedish company Ljungströms Angurbin, now Svenska Rotor Maskiner AB. During the 1930s, Chief Engineer Alf Lysholm developed the prototype of the modern screw compressors for use in gas turbines. In 1943, manufacturing of the new product line began. As twin-shaft positive dis- placement machines, the screw compressors optimally supplemented the range of products. Concerning oil-free handling with internal compression they achieved higher compression ratios than positive displacement blowers.The first “K60” screw compressor manufactured in Aerzen, called helical blower or rotary positive displacement compressor, had an asymmetrical rotor profile accord- ing to the Lysholm principle. From the beginning, Heller had planned a universally applicable screw compressor which could be equipped according to a modular system. His plan ultimately became a reality. Now, screw compressors made by AERZEN cover all the fields of application of air and gas compression. They are used, for example, for pneumatic conveying, for the industrial generation of compressed air, at chemical companies, power plants, steel production plants and also in the refrigeration industry and in process gas technology. Economic miracle brought prosperity But at the end of the Second World War, instead of complex technologies, it was beetroot juice presses, oil mills and tobacco cutters which were produced. In spite of the difficult post-war situation, AERZEN soon resumed the production of twin-shaft positive displacement machines - dismantling of the production facilities by the allies was avoided. The economic miracle of the 1950s and 1960s also brought prosperity for AERZEN. Numerous new products took the company forward. During the years that followed, AERZEN continued its investment and modernisation strategy. When the company celebrated its 100th anniversary in 1964, the machinery range had been extended with ultra-modern special machines. In 1967, the production of special air compressors for higher pressures began. The VM-series for oil-free compression of air was equipped with ball bearings. The new screw compressors minimised the risk of contamination during the pneumatic transport of grain, cement or chemical bulk material. In 1968, at the Hanover Fair, AERZEN presented for the first time screw compressors with oil-injection for refrigeration technology. The new VMY series were mainly used in refrigerated food warehouses and in air-conditioning systems on ships. With the new VMX series of screw compressors with oil-injection for compressed air technology, the company gained entry into new fields of application in 1971. World’s largest positive displacement blower In 1978, AERZEN presented the world’s largest positive displacement blower, the huge piston of which, with a diameter of 1.5 metres and a drive capacity of 3 mega- watts, could convey 84,000 cubic metres of process gas per hour. To manufacture this giant, the hall doors had to be enlarged and larger piston planing machines and milling machines had to be procured. Regarding volumetric handling of gas, AERZEN successfully extended the previously technically feasible field of application of a positive displacement blower. The new blowers enjoyed and still enjoy today high demand in the steel production sector. AERZEN experienced a similar success story with the development of the world’s largest screw compressor in 1984. With a rotor diameter of 845 millimetres, it could compress about 65,000 cubic metres of process gas per hour. The special machines were supplied to soda factories in France and Italy - consequently to a branch which had relied on turbo compressors before. You can read in our next edition about the product innovations that followed in the ensuing years.
Intelligent G5 logistics in South Africa Airgas Compressors, AERZEN’s South African subsidiary, has taken over the logistics for the import of Generation 5 on the African continent and developed an efficient concept for this:unlike the previous model that had been manufactured and assembled at site except for the stage, now, the G5 packaged units are imported as complete machines and are only partly assembled in South Africa. Thanks to this well thought- out transport and assembly concept, Airgas Compressors is able to serve its customers quickly and efficiently across Africa.
Replacement after 30 years In 1984, AERZEN supplied an oil-free screw com- pressor, type VRo 936L, to the Italian chemical company Versalis. This machine had been used in a process for the manufacture of polystyrene foam. Apart from periods when it was undergoing regular servicing, the compressor had been in continuous operation for 30 years!More than a quarter of a million operating hours had been reason enough for the customer to replace the machine with a new compressor stage from AERZEN. As a result, the course has been set for the future, in order to keep the work at this production plant running without any problems. The key challenge in the production of this compressor stage VR, which was delivered in January, was its tremendous weight: almost 34 tons!
The service fleet has a new look Our new brand positioning AERZEN also includes the service vehicles: the cars have so far been branded with the new logo and given a special white varnish paint treatment. For the transport of spare parts and tools for assembly work, the car boots have all been equipped with special vehicle floor-plates. With a view to the well-being of the service technicians who have to drive many thousands of kilometres every year, the service cars have been equipped with special health seats.
A helping hand is natural One of the most devastating fires in the history of Chile raged on 12th April in the mountains around Valparaiso and destroyed at least 2,500 houses. Also a colleague of Aerzen Chile was directly affected and lost his house in the disaster. “Team spirit and social commitment are among the basic values of AERZEN, therefore, for us as a team, we took it for granted that we must help our colleague”, Octavio Alarcón V., managing director Aerzen Chile, comments.The employees collected donations in kind, organised a new accommodation and helped with the cleaning up.A total of 11,000 people were made homeless as a result of the fire, another 6,000 had to be evacuated. 15 people died in the fire and 10 more were seriously injured.
Delta Blower in new E-Design Energy efficiency is a key issue today, especially in compressor technology, where energy costs amount to more than 90 percent of product life cycle costs (considered over a period of ten years). Now AERZEN has complemented its blower series Delta Blower Generation 5 with new design, characterised by top marks in terms of energy saving. The new E-Design uses up to four percent less energy, depending on volume flow and differential pressure. This improved energy efficiency is the result of numerous enhancements, such as a flow-optimised guide for the intake air in the acoustic hood and in the filter silencer. The patented intake cone minimises both pressure losses and sound input. Furthermore, the cooling system design has been revised. Instead of a mechanically driven acoustic hood fan, an electrical fan is now used, which ensures perfect ventilation at lowest power consumption. As with all AERZEN series, the E-Blower is also characterized by absolute reliability and longevity. It is a robust endurance runner in innumerable compression processes where air and neutral gases have to be conveyed oilfree. It is available in six sizes for intake volume flows from approximately 30 m3/h up to 1.000 m3/h and overpressures up to 1000 mbar resp. negative pressures up to 500 mbar.
Certifications for Emmerthal Emmerthaler Apparatebau, a subsidiary of AERZEN, is pleased about receiving three new certifications: the first of these came when, TÜV Nord granted certification for the integration of the working and health protection management system BS OHSAS 18001 into the existing quality management system DIN EN ISO 9001:2008 in October.Then, at the beginning of December, Emmerthaler Apparatebau received its China- Manufacturer-License for a further four years, with no deviations found during the audit. In January 2014, the Joint-Review and the extension to the U2-stamp followed, necessary for ASME- U-stamp for pressure vessels in higher pressure stages (>200 bar). Emmerthaler Apparatebau was also duly certified in this case.
New logistics concept The new AERZEN logistics centre is nearing completion. With the opening of the logistics centre, the trucks will follow a new route on the premises. The position of the entrance for trucks which deliver goods will be relocated from the entrance at the federal highway B1 to a new entrance at the street called Wiesenweg, including a new gatehouse.The planning for a high-performance high-bay storage facility, with a picking zone in front, to be situated next to the logistics centre, has started in parallel with the final building measures.With the new logistics concept AERZEN takes into account the permanent, worldwide growth of the company.
