Holzkirchen

With AERsmart made by AERZEN Holzkirchen wastewater treatment plant saves about 50,000 kWh every year

Holzkirchen wastewater treatment plant has a clearly formulated job: “We purify our wastewater optimally.” With its wastewater treatment plant designed for a population equivalent of 50,000, the municipal enterprise, located 40 kilometres south of Munich, not only pursues this target, but also the claim to act as resource-saving as possible. Together with AERZEN they commissioned a blower technology, which, from an energy efficiency perspective, sets a new milestone for the entire industry.

Partial load reduces the efficiency, impairs the energy efficiency and thus increases the operational costs. This context applies for all industries and has a serious effect in wastewater treatment plants mainly in the biology. The electrical energy for the drive of the blowers causes about 80 per cent of the costs in this field of sewage water cleaning. Consequently, efficiency increases and a really tailor-made design of the blowers to the daily requirement pay off accordingly fast. The question remains how the changing air requirement in the aeration basins can be covered optimally and not at the expense of overdimensionings and inefficient partial load.

Beyond cascading

Every blower only reaches its optimal operating point in a clearly defined performance range and works then with maximum efficiency. The air consumption in the biology is subject to considerable variations. The performance cascading with packaged units in a row as well as the variable speed control of the blower drives are important approaches to supply the aeration basins needs-oriented with oxygen. With the new AERsmart control system AERZEN takes another step.

By co-ordinating in partial load operation different blower types with each other on the basis of the required air volume, the new AERsmart solution avoids partial load of individual packaged units to a large extent. Comparable with an autopilot, AERsmart takes over the complete control- and regulating management of a compressor group of up to twelve machines. The new solution goes beyond a simple cascaded connecting or shutdown. The sense of this technology rather is grouping blower units with different operating principles. Messrs. “Gemeindliche Einrichtungen und Abwasser Holzkirchen -GEA” (Municipal facilities and wastewater Holzkirchen), for example, covers the base load requirements with an AERZEN turbo compressor. With a motor rating of 60 kW, type TB75-0.8S supplies an oil-free volume flow of 2,900 cubic metres per hour with a differential pressure of 0.8 bar. As the term base load says the turbo compressor serves for covering the medium requirement. In case of peak loads the machine is not sufficient and with low loads the unit loses considerably in efficiency. 

In Holzkirchen, this context leads to the fact that Messrs. GEA combines the turbo compressor with an AERZEN rotary lobe compressor series Delta Hybrid as well as two Delta Blowers with older manufacture dates. These were already available before the modification and now mainly serve as redundancy for operational reliability. AERsmart ensures that the Delta Hybrid starts with the air supply of the aeration basins, when the oxygen consumption at low load reaches a level where a turbo would be underchallenged and leaves its optimal operational range. In reverse direction Delta Hybrid and Delta Blower help out in case of peak loads. This can occur “particularly on hot summer days, when the oxygen consumption is high,” explains plant manager Markus Spallek. 

Savings of € 10,000.-- every year

In Holzkirchen, AERsmart has been running excellently from the beginning - which reflects in perceptible energy savings of about ten per cent. What the final rate of the saving potential will be mainly depends on how good the plant worked before. “We had already optimised our processes. Therefore, for us, ten per cent is much.” Expressed in figures: In Holzkirchen, every year about 500,000 kWh of electrical energy are spent for the aeration basins. So, the savings of 50,000 kW protect the city’s purse noticeably - by reduced expenditure of EUR 10,000.--. With this, the solution installed consisting of turbo blower and AERsmart will have paid off after about three years. 

AERsmart acts as autopilot

In normal operation the turbo blower runs in “optimal operating point” - which you can see on the AERsmart display with the pointer in the green sector. Looking on the visualisation of AERsmart you can see a conveying volume of 34 cubic metres per minute. If the requirement is between 28 and 16 cubic metres the Delta Hybrid is used. “Starting from 24 cubic metres AERsmart switches the Turbo off,” reports Spallek. According to the plant manager’s experiences the required air volumes are only a part of the design features, as also the necessary blow-in pressures are important for the decision which technology is the most effective one. “If the basins are flatter and consequently the pressure is lower, a positive displacement blower can be an efficient solution.”

With all the technical innovations and a general “We have always paid attention to energy efficiency”, in Holzkirchen first of all the focus is on the water quality. “Our premise is to purify wastewater optimally. And this at a price which is as cost-effective as possible. This approach deviates from the industry. But plants want to purify their wastewater as cost-effective and as good as necessary.” The point that in the southern suburbs efficiency is so important results from the fact that the economical use of resources is one of Andreas Spallek’s hobbies. The plant counts “on reasonable solutions, which increase the efficiency and not on technical gadgets.” It is clear to the expert that water can only be purified reliably by means of a certain energy input. “With a good machinery pool we can reach our goal of generating the required air volume economically.” Consequently, the plants are optimised permanently and the use of energy is improved. 

Wastewater treatment plants as energy centres of tomorrow?

This trend will come, to combine different blower types so, that the overall interaction finally generates the required air volumes with an optimal efficiency and maximum energy efficiency,” Spallek is convinced. In his opinion, wastewater plants only have two chances for improving their sustainability: To reduce the energy consumption by using intelligent technology and to increase the self-energy production. Therefore, Holzkirchen also utilises a block-type thermal power station to convert the sewage gas generated in the digestion tower into electricity and to utilise the heat for heating the bioreactor. Another possible solution for Spallek: Decentralised sewage sludge incineration within a local heat network. “Dry sewage sludge has a similar calorific value to lignite.” As in the disposal industry the task in future will increasingly be to recover phosphate from the residues such solutions would be predestined. Wastewater treatment plants as decentral energy centres of tomorrow - and suitable for meeting baseload requirements also when generating electricity? 

You have questions? LET'S TALK

Find your regional contact and get personal advice.

Aerzener Maschinenfabrik GmbH (Headquarter)

Reherweg 28

31855 Aerzen

Phone: +49 5154 81-0

Fax: +49 5154 81-9191

Emmerthaler Apparatebau GmbH

Langes Feld 4

31860 Emmerthal

Phone: +49 5155 622-0

Fax: +49 5155 622-11

Aerzen Turbo Europe GmbH

Freibusch 2-4

31789 Hameln

Phone: +49 5151 92384 0

Aerzen Digital Systems GmbH

Hefehof 8

31785 Hameln

Phone: +49 5151 40302660

AERZEN Deutschland GmbH & Co. KG (Sales)

Reherweg 28

31855 Aerzen

Phone: +49 5154 81 4000

Aerzen do Brasil Ltda

Rua Dionysio Rito, n° 300, Distrito Industrial III, L14 Q D

13213-189 Jundiaí

Phone: +55 11 4612-2021

Fax: +55 11 4612 0232

AERZEN SLOVAKIA, s.r.o.

Pezinská 18

901 01 Malacky

Phone: +421 34772 5531

Fax: +421 34772 5529

- Sales Office South West

Brückenstraße 2a

66740 Saarlouis-Fraulautern

Phone: +49 6831 76828 0

Fax: +49 5154 81 716410

Aerzen Argentina SRL

Domingo de Acassuso 4743

B1605BFO Munro, Buenos Aires

Phone: +54 11 47622351

AERZEN France S.A.S

Zone Industrielle 10, Avenue Léon Harmel

92168 Antony Cedex

Phone: +33 1 46741300

Fax: +33 1 46660061

AERZEN BELGIUM N.V.

A.De. Coninckstraat 11

3070 Kortenberg

Phone: +32 2 757 22 78

Fax: +32 2 7572283

AERZEN SCHWEIZ AG

Gewerbepark Morgenstern Im Alexander 4

8500 Frauenfeld

Phone: +41 52725-0060

Fax: +41 527250066

AERZEN Nederland B.V.

Bedrijventerrein Nieuwgraaf Fotograaf 3

6921 RR Duiven

Phone: +31 26 3197530

AERZEN INTERNATIONAL RENTAL B.V.

Typograaf 5

6921 VB Duiven

Phone: +31 88 9100050

ASP AERZEN Special Products B.V.

Bedrijventerrein Nieuwgraaf Fotograaf 3

6921 RL Duiven

Phone: +31 26 4463432

Fax: +31 26 4463049

AERZEN FINLAND OY AB

Teollisuustie 15

FI-02880 Veikkola

Phone: +358 9 8194720

Aerzen Colombia S.A.S.

Centro Empresarial Metropolitano, Bodega 27, Módulo 2 (Autopista a Medellín, km 3,4) Cota, Cundinamarca,

Código Postal 250017 Código

Phone: +57 601 841 5730

Fax: +57 601 841 5730

Aerzen Austria Handelsges.m.b.H.

Gewerbepark Tresdorf II/1

2111 Tresdorf

Phone: +43 2262 74388

Fax: +43 2262 74399

AERZEN POLSKA Sp. z.o.o.

Al. Niepodleglosci 18

02-653 Warszawa

Phone: +48 22 489 55 22

Fax: +48 22 489 55 27

AERZEN HUNGÁRIA KFT.

Alíz Utca 4

1117 Budapest

Phone: +36 1 4392200

Fax: +36 1 4391922

AERZEN CZ s.r.o.

Hraniční 1356

69141 Břeclav

Phone: +420 519 326 657

Fax: +420 519 326658

AERZEN IBÉRICA S.A.U

Calle Adaptación 15-17

28906 Getafe (Madrid)

Phone: +34 91 642 4450

Fax: +34 91 642 2903

AERZEN IBERICA S.A. SUCURSAL EM PORTUGAL

Rua Alfredo Lopes Vilaverde, 15B Escritório 3

2770-009 Paço de Arcos

Phone: +351 21 468 2466

Fax: +351 21 468 2467

AERZEN MACHINES LTD.

Aerzen House, Langston Road

IG10 3SL Loughton, Essex

Phone: +44 2085028100

Fax: +44 2085028102

AERZEN ASIA PTE LTD

61 Woodlands Industrial Park E9 E9 Premium, #07-01

757047 Singapore

Phone: +65 6254 5080

Fax: +65 6254 6935

asia@aerzen.com

company profile

Aerzen Taiwan Machinery

Branch office of Aerzen Asia No.170, Ln. 879, Guangfu Rd., Bade Dist.,

Taoyuan City 33457

Phone: +886 3 366 6660

Fax: +886 3 366 6536

taiwan@aerzen.com

company profile

AERZEN SCANDINAVIA AB

Östra Bangatan 20

19560 Arlandastad

Phone: +46 8 59441880

Fax: +46 8 59117209

Aerzen Scandinavia Norway

Raveien 320

3184 Borre

Phone: +47 33 29 22 12

Aerzen Scandinavia Denmark

Industrivej 2

5550 Langeskov

Phone: +45 78 72 92 90

AERZEN USA CORPORATION

108 Independence Way

Coatesville, PA 19320

Phone: +1 610 380 0244

Fax: +1 610 380 0278

AERZEN CANADA INC.

980 Rue Valois, Suite 100 Vaudreuil-Dorion

J7V 8P2 Quebec

Phone: +1 450 424 3966

Fax: +1 450 424 3985

Aerzen México S.A. de C.V.

Cerrada Uniroyal # 18-A, Col. La Michoacana

Metepec, 52166

Phone: +52 722 235 9400

Fax: +52 722 235 9401

AERZEN MAKINE San. Ve Tic. Ltd. Sti.

IMES Sanayi Sitesi, C Blok, 308. SK, No:14, Y.Dudullu

34776 Ümraniye Istanbul

Phone: +90 216 420 00 32

Fax: +90 216 420 00 79

turkey@aerzen.com

company profile

AERZEN Machines (India) PVT. LTD.

Plot No. E-115/116, G.I.D.C , Manjusar, Tal. Savli, Dist:

Vadodara-391 775 Gujarat

Phone: +91 2667 264-817

Fax: +91 2667 264-818

india@aerzen.com

company profile

AERZEN ITALIA SRL

Via Raffaello Sanzio, 52

20021 Bollate (MI)

Phone: +39 02 6707 5277

Fax: +39 02 6707 5003

AERZEN MACHINERY (SHANGHAI) CO., LTD

No. 655 Yuan Dian Road, Min Hang District

Shanghai 201108

Phone: +86 21 3323 9000

Fax: +86 21 3323 9199

Aerzen Romania S.R.L.

Sat Tunari Comuna Tunari Sos. De Centura nr. 25A

RO 077180 Judet Ilfov

Phone: +40 21 243 1883

Fax: +40 21 243 1884

Aerzen ME - FZE

DSO-DDP-Office-A1-222 Dubai Silicon Oasis P.O. Box: 341445

 Dubai

Phone: +971 0 432 431 66

Aerzen Adria d.o.o.

Varazdinska ulica, II odvojak 3

42000 Varazdin

Phone: +385 42 370 808

Fax: +385 42 370 018

Aerzen Australia Pty Ltd

57-59 Rodeo Drive

3175 Dandenong

Phone: +61 3 97067702

Fax: +61 3 9706 8584

Aerzen Chile SPA

Limache 3363 – Bodega 13

CP: 2520642 Viña del Mar

Phone: +56 32 235 8900

Aerzen Andina Perú SAC

Carr. Panamericana Sur Km. 29.5 Almacenes F-08 y F-09 ZI Megacentro – Altura Puente Vidu

 Lurin – Lima

Phone: +51 1 434 3831

AERZEN NORTH AFRICA LLC

Sheraton Housing 35 el moltaka el araby, Nozha elgedida. Appt - 7, 8, 9.

 Cairo

Phone: +20 2 22698855

Fax: +20 2 22696611

Aerzen AIRGAS (PTY) Ltd.

175 Domkrag Street, Robertville Ext. 1

Roodepoort, Johannesburg

Phone: +27 0 11 474 2193

Fax: +27 0 11 474 2321

ANIS AHMED & BROTHERS

4-Jinnah Cooperative Housing Society, Block 7/8, Main Sharea Faisal

75350 Karachi

inddiv@aabros.com.pk

company profile

MANGRINOX S.A.

14, Grevenon Str.

11855 Athens

Phone: +30 210-3423201-3

Fax: +30 210-3459967

Aerzen Adria d.o.o.

Varazdinska ulica, II odvojak 3

42000 Varazdin

Phone: +385 42 370 808

Fax: +385 42 370 018

SHIPSHORE (CYPRUS) LTD

Patraikou 21-23, Flat 101, Palouriotisa TK 1048, P.O. Box 25283

1308 Nicosia

Phone: +357 22441222

Fax: +357 22490641

L.A Engineering & Consulting Ltd

PO Box 2907, 25 Ha‘ela Street

40500 Even Yehuda

Phone: +972 9 8996544

Fax: +972 9 8996547

MEAKOMP OOD

Ul. Archaritza 2A

4006 Plovdiv

Phone: +359 32 966 681

Fax: +359 32 966 702

Aerzen Adria d.o.o.

Varazdinska ulica, II odvojak 3

42000 Varazdin

Phone: +385 42 370 808

Fax: +385 42 370 018

Airgas Compressors (PTY) Nigeria Limited

3, Adebukola Omolabake Street, Off Eric Omobude Street, Ifako Bus Stop, Along Oworonsoki - Ogudu Expressway

 Lagos

Phone: 00234 0 1 843 4234

Aerzen Thailand Co., Ltd

36/60 Village No. 5, Phlu Ta Luang, Subdistrict, Sattahip District

20180 Chonburi

Phone: +66 0 38 020 090

Fax: +66 86 664 1337

AERZEN VIETNAM

Representative office of AERZEN ASIA PTE. LTD Floor 8th, Unit 802A, Dai Minh Convention Tower, 77 Hoang Van Thai, Tan Phu Ward, District 7, Vietnam

 Ho Chi Minh City

Phone: +84 28 3535 2760

Aerzen Turbo Co, Ltd

800 Jeongjung-ri, Osong-eup, Heungdeok-gu, Cheongju-si,

Chungcheongbuk-28220 Korea

Phone: +82-43-238-6500

Fax: +82 70 4170 4567

local partner: DEWA Projekt OÜ

Väike-Ameerika 15

10129 Tallinn

Phone: +372 50 39239

AERZEN FINLAND OY AB

Teollisuustie 15

FI-02880 Veikkola

Phone: +358 9 8194720

Aerzen Australia - New Zealand Office

Unit 17a Hobill Avenue Wiri

2104 Auckland

Aerzen Australia Pty Ltd

57-59 Rodeo Drive

3175 Dandenong

Phone: +61 3 97067702

Fax: +61 3 9706 8584

AERZEN MACHINES LTD.

Unit 6a, Castlecomer Business Park, Kilkenny Rd, Ballyhimmin

R95 Castlecomer, Co. Kilkenny

Phone: + 353 567807085

Aerzen Korea Ltd

Hyundai Terrace Tower, E-dong #608, 7, Yeonmujang 5ga-gil, Seongdong-gu,

04782 Seoul

Phone: +82 44 277 6500

Fax: +82 2 6463 0064

Aerzen Turbo Co, Ltd

800 Jeongjung-ri, Osong-eup, Heungdeok-gu, Cheongju-si,

Chungcheongbuk-28220 Korea

Phone: +82-43-238-6500

Fax: +82 70 4170 4567

Aerzen Arabia Ltd.

Abed Al-Mis’hal Tower 9th Floor, office 907, Building 3958, District 35514 Al Jubail, Kingdom of Saudi Arabia

 

Phone: +966 13 362 8826

Service Centre - Aerzen Arabia Ltd.

Rezayat Group Dammam Port Area, Dammam Kingdom of Saudi Arabia

 

Contact us