CUSTOMER JOURNAL · EDITION 4 • 2015 COM•PRESS

“Absolute growth market” The Asia-Pacific region plays an important role for 2

Extra large for “Jamnagar” Unit for Indian oil refinery 3

Sufficient air in the fixed bed reactor Delta Hybrid in use AERZEN’s energy-efficient blower technology takes over the pneumatic conveyance in Aerzener Brot und 4 Kuchen GmbH from the silo to a scale. With high-pressure in Dear Readers, the mixer In this year’s last edition, we would like to invite you to join AERZEN‘s energy-efficient blower technology Andreas Specht, us on our trip through the mul- Technical Manager of Aerzener Brot und tifaceted world of AERZEN. Kuchen GmbH As you can see from the con- With a blower station as part of the pneumatic conveying unit, tributions, “internationalisa- We need a defined volume flow tion” is a particularly important Aerzener Brot und Kuchen GmbH ensures water-borne supplies with the correct pressure and topic for AERZEN. For decades, in the “bakery“. After a recent modernisation, together with absolutely do not need devices AERZEN has successfully dealt with oil injection. Sebastian with all kind of challenges, AERZEN, a new especially energy-efficient blower unit of type Meißler, made investments in growth Delta Blower E-design, was put into operation. Marketing markets, and used our local know-how to further extend ernisation programme and replaced the the AERZEN brand. AERZEN is following this ccording to the Federal Statisti- over the pneumatic conveyance from the outdated blower for pneumatic convey- path within the framework of Vision 2022, in or- cal Office, annual sales of bakery silo to a scale. ance with a modern unit from AERZEN – der to offer in future, as an application specialist, goods total around EUR 18 billion. Removal of grain from the silo is ef- an energy-efficient Delta Blower E-Design innovative technologies for a variety of industrial A Behind this is an annual consumption of fected by rotary valves at discharge of GM 15 L (700 mbar, 1,038 m³/h, 30 kW). applications. Therefore, we will be very happy to 85 kilogrammes per inhabitant, within the reservoirs, which convey the grain These units are designed for intake vol- welcome you again to one of our forthcoming which the general public prefers bread, into the piping, from where, it is then ume flows from 30 to 1,000 cubicmetres trade fairs world-wide. For now, we say good-bye which accounts for 63 percent of the total. blown into production. „Each part of a per hour and complement the rotary lobe until next year, and present here our outlook on With this type of food being so popular, batter mix is transported individually, so compressors of series Delta Hybrid in the the development of the Asia-Pacific region, news the market is extremely competitive. The that we can weigh it exactly“, explains lower volume flow range. from all over the world, and last but not least, significance of larger medium-sized bak- Andreas Specht, Technical Manager of we are including some interesting user reports Energy-efficient technology from the field of waste water treatment and eries and industrial bakeries is increasing, Aerzener Brot und Kuchen GmbH. For each pneumatics. accompanied by a constantly changing ar- batch, the around 200 employees of the In compressor technology, more than 90 I wish you and your families a Merry Christmas ray of baked goods available in the market. Brotfabrik mix approximately one ton of percent of the life cycle costs can be at- and a Happy New Year 2016! flour and meal into a smooth dough. Five tributed to energy consumption. This high High requirements batches are processed per hour - a daily percentage clearly shows that savings and Yours, Rye meal with bio certificate is a basic production quantity of 80 tons of bread. operation correlate closely with each oth- product, which Aerzen Brot und Kuchen The figures clearly show the importance er. Energy consumption can be reduced by GmbH of stores in an exter- of the demands on the technology be- lower internal pressure losses of a blower, nal silo. If this type of grain is requested ing used. Against this background, the which has a positive effect on the in a bread formula, a blower station takes industrial bakery has undertaken a mod- energy bill. COM•PRESS 4|15 2 COMPACT

Extension of Delta Screw series

The planned range of four compressors of the new series Delta Screw E compressor has been extended by AERZEN with two additional sizes now available. The new models VM 30 and VML 35 cover the lower volume flow range of the series and are the perfect addition to the Delta Screw Aerial photo of the industrial bakery Aerzener Brot With compressed air the required raw materials Support during commissioning of Delta Blower compressor packages with belt drive. This new und Kuchen GmbH in Lower Saxony reach the “bakery”. E-Design by an AERZEN technician series of E compressor includes 6 sizes in the vol- ume flow range from 330 m³/h to 7,000 m³/h and With the E-Blower, AERZEN has the warmer rear side which has a pressure just a few hours together with an AERZEN drive capacities from 30 to 400 kilowatts. VM 30 been able to increase the efficiency pipe connection. technician. The scope of supply covers and VML 35 cover a volume flow of 330 m³/h to by at least four percent through construc- Andreas Specht points out, that in his the general installation control, as well as 2,590 m³/h and a maximum differential pressure tive optimisations - among other things company, energy efficiency gains play an the analysis of important operating para­ of 2 or 3.5 bar. by flow-optimised direction of the intake increasingly important role in investment meters during test operation with real air in the acoustic hood and the filter si- decisions - „especially in view of the long loads. „We thus ensured, that, after mod- lencer. Moreover, the patented intake runtime of the machines“. In this case, ernisation, the unit works as well as be- cone minimises pressure losses as well AERZEN ensures the continuous applica- fore“, says Specht and notes that Aerzener as sound emissions. Also quickly wearing tion of IE3-motors for assuring the future Brot is pleased to be able to use standard absorption material was not used in the of investments. A further criterion for the components for the technical equipment. E-Blower - an additional protection against selection of the energy-efficient Delta In comparison with special solutions, the contaminations of the downstream proc- Blower was the absolute oilfree convey- use of standard technology means availa- ess system and thereby of the final prod- ance of transport air. „We need a defined bility of spare parts and maintenance. This uct. The E-Blower has further advantages volume flow with the correct pressure and also applies to the blowers of ­AERZEN - The new models VM 30 and VML 35 complete the E with respect to energy efficiency through absolutely do not need devices with oil in- spare parts can easily be purchased world- compressors of AERZEN’s Delta Screw series. its revised cooling concept. In this case, jection“, stresses the Technical Manager. wide and installed without additional ex- an optimally placed and electrically driven penditure on adaptation work. fan replaces the widely spread mechani- Ready availability Energy-efficiency and safe operation, New Managing Director at cally coupled acoustic hood fans. The inde- When designing the new blower, the al- combined with high availability, determine Aerzen India pendent operation enables control of the ready known pressure and volume data the technical equipment of all operational fan power, so that in partial load operation from the exchanged device could be used - ranges at Aerzener Brot und Kuchen GmbH. Ranjit Lala became the new General Manager with low dissipated heat, the fan can be this reduced the expenditure significantly. Against this background, the company at- of AERZEN Machines (India) Private Ltd. in Au- run at lower speed. Also, in order to achieve The modernisation work was limited to the taches great importance to energy-efficient gust 2015. He succeeds Jitendra Mangle. Within more effective cooling, the AERZEN units exchange of the devices: - smaller adap- equipment. Energy consumption is one of the scope of his activities, Lala will also cooper- suck on the cool front side, in order to have tations concerning connection technology the most significant operational costs for ate more intensively with Chuck Lim, Managing a possibly higher Delta T compared with and the commissioning were finished in the bakeries sector. Director of the Asia Pacific region, based in Sin- gapore. In addition, Axel Wehling from the head- quarters will provide support. Ranjit Lala, a grad- uate in engineering and economic sciences from the University of Mumbai, has long experience The Asia-Pacific region plays an important role for AERZEN in leading positions at international companies in the areas of Production, Sales, After Market Service “Absolute Growth Market” and Supply Chain Manage- ment. In 2004, the success story of AERZEN in the Asia-Pacific region be- market, an even more sustainable strat- egy is necessary. We want to explain to our Ranjit Lala became the new gan. Now, four subsidiaries and three sales offices operate in this General Manager of AERZEN customers that we do not only offer excel- Machines (India) Private Ltd. in region. The most recent milestone was the inauguration of the new lent products, but also provide comprehen- August 2015. location of Aerzen China in October 2015. sive solutions”, says Chuck Lim. A special challenge for AERZEN is the hen it took over Azon Engi- trees together with Managing Director competitive situation in the Asia Pacific neering, AERZEN started its Bernd Wöhlken, Chuck Lim (Managing Di- region. Particularly in China, there are nu- Aerzen Turbo Generation 5 - Wcommitment to the Asia Pa- rector Asia Pacific) and Sam Hoo (Manag- merous cost-attractive product providers, now available in Asia cific region. Soon afterwards, Aerzen Asia ing Director Aerzen China) on the occasion but they have considerably lower product and Aerzen China were founded, then of the inauguration. quality than AERZEN: “We therefore have The new turbo series Generation 5 is available in Aerzen India (2006/07) and Aerzen Aus- The new location of Aerzen China offers to manufacture our products more cost- Asia with immediate effect. As a first step, the tralia (2011) followed, as well as sales of- enough space for further expansions and is effectively without losing any quality - as sizes AT150 and AT200 (3,000 - 8,400 m³/h) will fices in Thailand, Taiwan and Vietnam. therefore a strong basis for dynamic devel- quality is, and will remain, the backbone be locally produced by Aerzen Turbo in Korea; the The customers mainly come from the pet- opment in the entire region. Growth poten- of the AERZEN brand”, underlines Stephan sizes AT300 and AT400 (8,000 - 16,200 m³/h) rochemical, chemical, cement and steel tial include, for example, our applications Brand, Manager Marketing International. will follow in the first quarter of 2016. industries, as well as the mechanical en- in waste water treatment, as in populous “It is important to explain to customers in The new series Generation 5 is characterised by gineering industry. “Asia Pacific, with the Asia a tremendous amount of waste water the Asia Pacific region”, says Klaus-Hasso improved fluid mechanics resulting in increased main drivers China and India, is an absolute must be purified. “We are already now the Heller,”that investments in AERZEN prod- energy efficiency, reduced sound levels and less growth market for our company”, empha- first choice concerning many applications. ucts pay off after a short time thanks to maintenance. Space-saving “side-by-side“ instal- sises CEO Klaus-Hasso Heller. But in order to continue to develop the our energy-efficient solutions.” lation is also possible. The head office of Aerzen China in Shanghai, inaugurated on 13th October, Thumbs up for AERZEN in the Asia-Pacific region Festive inauguration: With traditional ceremonies, Aerzen Turbo Generation 5 - available in Asia shows how important the Asia Pacific (from left): Sam Hoo, Chuck Lim, Bernd Wöhlken, Aerzen China officially opened the new location in with immediate effect. Klaus-Hasso Heller Shanghai. market is for AERZEN. A new building was constructed with spacious produc- tion, office and social facilities. 150 guests came to the official opening, among them customers, suppliers, government repre- sentatives and colleagues from Aerzen China and from . “Our guests were impressed by the quality of the building”, says Klaus-Hasso Heller, who planted four COM•PRESS 4|15 COMPACT 3

Sales Office West Correct planning!

At the request of many customers, we have reis- Energy summit on the occasion sued the “planning folder waste water”. System manufacturers, engineering offices and custom- ers receive with this folder extensive information of the anniversary about the products Delta Hybrid, Delta Blower and AERZEN Turbo. Technical drawings, detailed The sales office West invited loyal customers to an energy place during the energy summit, the performance descriptions and detailed informa- summit on the occasion of its 50th anniversary. A big celebration AERZEN products Delta Hybrid, Delta tion about our accessories programme will help Blower, Delta Screw and AERZEN Turbo you to configure and design the most energy- took place, as well as an in-house exhibition. were in focus. Energy consumption data efficient solution for your application. of the various AERZEN products was al- You can order the new waste water folder free his year, the sales office West of Rhineland-Palatinate, Saarland and Lux- so highlighted and they were compared of charge using the attached order form. AERZEN celebrates its 50th anni- embourg were invited to an energy summit against each other. In addition, the energy Tversary. 120 loyal customers from on 17th September 2015 in Essen-Werden. mix of AERZEN was presented to custom- the sales areas North Rhine-Westphalia, At the in-house exhibition, which took ers, involving different combinations of the products (i.e. Delta Hybrid, Delta Blower, Delta Screw and AERZEN Turbo). By using this approach, AERZEN can supply optimal solutions in terms of energy-efficiency for the particular application of the customer. Besides giving product information, the 50th anniversary of the sales office West Planning folder waste water was also celebrated, and this will surely be a reason why the energy summit and the Klaus-Hasso Heller, CEO of AERZEN, welcomed the Together with loyal customers the sales office West 50th anniversary will be an enduring mem- guests. celebrated its 50th anniversary. ory for the customers. Aerzen USA has a new General Manager

VMY-unit for Indian oil refinery To continue the positive trend in growth and devel- opment, Aerzen USA has Extra large for “Jamnagar” appointed a new General Manager. On 1st September AERZEN was given an order, by 2015 Tony Morris assumed a big Indian concern, for the de- this role. Morris, who has an academic degree in En- velopment of an extremely large gineering and a Master of Tony Morris, new VMY-unit for the “Jamnagar” oil Business Administration, General Manager of Aerzen USA refinery. For this huge project, is very experienced in in- dustry and in business development in an inter- enormous expenditure was nec- national environment. He succeeds Pierre Noack, essary. who returns to the company’s headquarters after 30 years to further push the Process Gas Division.

Exhibition dates

A module of the VMY 536M- In the first half of 2016, AERZEN will participate unit for the “Jamnagar” oil in the following fairs and trade exhibitions: refinery in India Aqua Pro Gaz, Bulle/Switzerland 20th to 22nd January 2016 he “Jamnagar” oil refinery, in the its partners. So, in February of this year, a high and extensive quality demands in the New England Water Environment Association, western state of Gujarat in India, is nearly identical follow-up order was placed customer specifications, verified during Boston/USA 24th to 27th January 2016 Tat present the largest oil refinery in with AERZEN. more than 30 visits. New York Water Environment Association, the world. Furthermore, for many years it Only by means of special equipment New York/USA 2nd to 4th February 2016 New dimensions has been counted among the world’s larg- could all three skids be loaded in - ANEAS, Mexico 28th to 29th February 2016 est industrial sites. AERZEN was entrusted With a weight of more than 80 tons, and thal in September. Due to the external di- AquaTherm, by the operator for recycling purposes with an installation surface of about 140 square mensions of the seaworthy packed VMY- Tashkent/Uzbekistan 2nd to 4th March 2016 a so-called Pressure Swing Adsorption metres, distributed over three so-called unit for transport to the Port of Hamburg, Water Expo 2016, (PSA) application, which realises the sepa- “skids”, for AERZEN and Emmerthaler only the Mittelland Canal was considered. Chennai/India 3rd to 5th March 2016 ration of poisonous carbon/ hydrogen gas Apparatebau GmbH this order represented Procurement, inspection and transfer of Missouri Water, mixtures under pressure. a new dimension. documents for the follow-up order are Missoula/USA 14th to 17th March 2016 The technical concept of the Process By means of an extension of the work currently in full swing. As of January 2016, Aqua Nederland Vakbeurs, Gas Division, based on an oil-injected VMY surface in , the parallel con- construction and pipework fabrication in Gorinchem/Netherlands 15th to 17th March 2016 536M-solution, including an extensive con- struction of the three skids could be guar- Emmerthal will begin again. Asiawater 2016, trol system, convinced our customer and anteed. In addition, there were particularly Kuala Lumpur/Malaysia 6th to 8th April 2016 The seaworthy packed unit is loaded on a container SC Environmental Conference, At great expense, the large VMY-unit was transported to its destination. ship near the Mittelland Canal. Myrtle Beach/USA 6th to 9th April 2016 AWEA, Orange Beach/USA 6th to 9th April 2016 Texas Water, Corpus Christi/USA 14th to 17th April 2016 Neftegaz, Moscow/Russia 18th to 21st April 2016 Maintenance, Antwerp/Belgium 20th to 21st April 2016 ECWATECH, Moscow/Russia 26th to 28th April 2016 COM•PRESS 4|15 4 COMPACT

Questions, Suggestions, Ideas?

We are looking forward to all your queries, com- ments and suggestions on our customer journal and we are at your disposal for further informa- tion on AERZEN products and services. Give us a visit on our website:

WWW.www.aerzen.com/news Thanks to modern technology made by AERZEN, the wastewater treatment plant will save a consid- erable amount of energy. . Emmerthaler Apparatebau twice recertified:

During this year’s recertification audit pursuant to ISO 9001 and BS OHSAS 18001, Emmerthaler Apparatebau GmbH demonstrated once again its Especially energy-efficient - AERZEN blowers of series Delta Hybrid. excellent management systems for quality, occu- pational health and safety. The audit was carried out by the TÜV Nord and by the internal quality management, under the supervision of Michael Delta Hybrid rotary lobe compressors made by AERZEN Stewig. The results showed that no deviations were found. In the course of the continuous im- provement process, however, further potential Sufficient air in the fixed bed reactor improvements were identified, and these now need to be realised. Thanks to this recertification, and the already The wastewater treatment plant located in Beggen, Luxembourg, is considered a model of high quality attained certifications such as ASME, TR/TS 032, in respect of sewage water cleaning. In order not to place an undue burden on the plant’s electricity bill, DNV, China License and H/H1, customers will be highly energy-efficient rotary lobe compressors of series Delta Hybrid made by AERZEN are in use. provided with the best possible service with re- gard to planning, calculation and manufacturing of pressure equipment, with everything coming hat about the typical sewage and 2,000 m³/h at a slight overpressure quires 15 percent less current than existing from a single source. water smell? No chance! Visi- between plus 550 and 620 mbar. compressors. In addition, the air conveying tors to the “station d’epuration” is absolutely oil-free which is an important W Long-life operation located in the district of Beggen have to feature in wastewater treatment. pay close attention in order to realise that As part of a large-scale modernisation of a wastewater treatment plant is in the the ventilation technology, the wastewa- More than promised neighbourhood - and one wich processes ter company had an AERZEN service team The effects of this operating method in a daily water volume between 30,000 and size up and install more powerful rotary practice are reflected in the power con- 40,000 m³. In order to avoid bad smells lobe compressors. The packaged units of sumption of the wastewater treatment emanating from the plant, the city of Lux- series Delta Hybrid have a connected load plant in Luxembourg. “Prior to retrofitting, embourg has enclosed all cleaning stages, of 75 kW. However, they are operated with AERZEN promised us energy savings of Emmerthaler Apparatebau GmbH has successfully even the biological processes. In combi- only a nominal power of 40 kW via the fre- 8 kW per plant. This will result in annual passed the recertification audit pursuant to ISO 9001 nation with a powerful exhaust air sys- quency converters. This means that the savings of almost EUR 50,000” reports and BS OHSAS 18001. tem, the malodorous air is led through a Delta Hybrid systems produce the required Luc Ley as he looks his amortisation cal- chemical scrubber prior to delivery to the volume running at 5,000 rpm, instead of culations. A period of five years had been outside world. “The fans run continuously 9,000 rpm. “Today, the packaged units forecast before a return on the invest- at 30 kW,” Production Manager, Luc Ley, are designed in such a way that they get ment would be achieved. Such a period will notes pragmatically. He knows that low bored as far as wear and tear is concerned,” probably not apply in Luxembourg though, emissions come at a price, especially look- Ley notes with a smile. Although it might as the actual savings will not be 8 kW as IMPRINT ing at the operating costs which arise from seem paradoxical at first, the overdimen- expected, but are more likely to be 15 kW! AERZEN COM•PRESS power consumption. “Therefore, for us, sioning provides tangible advantages, such And the corresponding longer maintenance Customer journal of only the application of IE3-motors makes as for longevity and maintenance intervals. intervals have not even been taken into ac- Aerzener Maschinenfabrik GmbH sense.” The previous equipment required mainte- count yet. Edition 4 • 2015 nance every three years. This has changed, Today, the wastewater treatment plant Editor More air for microorganisms as the Delta Hybrid systems only require in Beggen is an example of highly available Aerzener Maschinenfabrik GmbH Due to EU-wide stipulated limit values, service every five years. “Assuming a life- plant technology, jointly developed by us- Reherweg 28 31855 Aerzen GERMANY especially with regard to nitrogen and time of ten years, I will save one complete ers and manufacturers. Against the back- phosphorus, the municipality had to face maintenance sequence,” adds Ley. ground of maximal operational reliability, Editorial staff M/Stephan Brand (v.i.S.d.P.), Sebastian Meißler, the challenge of modernising the existing Another positive effect of the new units the design was characterised by a healthy Andreas Gattermann, Frank Glöckner, plant. Due to limited space, an increase is the reduction in energy costs, thanks level of power reserves. According to Luc Klaus Grote, Klaus Heller, Ingo Kammeyer, in capacity was not the only option. “This to the special operating principles of the Ley, the confidence in AERZEN is “very Bernd Wöhlken is why we are today using fixed bed reac- Delta Hybrid units. high” as no other planning office had been Picture credits tors,” explains Ley. The procedure works Here, AERZEN combines the operating involved in the retrofitting. Aerzener Maschinenfabrik, Aerzen Asia, properly, but for nitrogen degradation, con- methods of both positive displacement Aerzen USA Corporation, Aerzen Machines (India), siderably more air is required. “We need an blowers and screw compressors. The result The wastewater treatment plant, located in Beggen, Aerzen Turbo oxygen saturation between 7 and 8 mg/l. is an efficient unit - the world’s first rotary Luxembourg, is considered a model of high quality in Realisation respect of sewage water cleaning. Maenken Kommunikation GmbH The standard is between 1 and 1.5 mg/l.” lobe compressor. The economical use of Von-der-Wettern-Straße 25 The high oxygen requirement results from results from the fact that the Delta Hybrid 51149 Cologne the special cleaning procedure in the fixed series calls for the Roots-Principle of iso- Auflage 5.500 bed reactors. If the air quantity is not suf- choric compression in low pressure applica- ficient, the microorganisms run out of tions and the screw compressor principle, breath. For the air supply, one AERZEN with its internal compression, becomes the Delta Hybrid rotary lobe compressor D62 S preferred choice for its energy efficiency in is applied with each reactor. The packaged higher pressure ranges. AERZEN has calcu- units supply a volume flow between 1,700 lated that the rotary lobe compressor re-