Sector Utilities
Project type Refurbishment
Project location Outside the UK
Products used HST turbocompressors + master control unit
 
 

Overview

Sulzer delivered two HST turbocompressors for aeration of the biological basins as part of the latest upgrade for a major producer of dairy products in Europe. The client has three factories close to each other, with a common industrial wastewater treatment plant (IWWTP), one of the largest in the country. The plant has seen a series of upgrades and extensions in the past, including average flow increases and the addition of a tertiary filtration process. 

Challenge

Because of successive extensions of the dairy production sites the size of the wastewater treatment plant has grown significantly. Initially, a set of roots blowers were providing air to the biological tanks. These roots blowers were later replaced by more efficient screw compressors. The performance of the new machines, however, proved to be rather disappointing and moreover, their maintenance was expensive. When the latest extension of the IWWTP was decided, the client looked for additional compressors, which would not only respond to the technical specifications, but also give complete satisfaction in the long term.

Solution

Sulzer tailored a package of two HST 20-6000-1-190 turbocompressors and one master control unit (MCU) to match the customer’s exact requirements. A complete set of pipework accessories for the new compressor room was also supplied. In addition, Sulzer gave recommendations for the most proper application of the equipment, eg for the ducting of the motor cooling air outlets, which reduces the temperature in the compressor room and is beneficial for the process air. Finally, the optimal design of the installation helped save a lot of energy.

Outcome

The two HST 20-6000 turbocompressors offer an outstanding wire-to-air efficiency. They interface with the upper level control system through the MCU. This MCU selects the most economical compressor combination (one or two running – duty points in the best efficiency zone) to keep the pressure within tight limits whatever air flow is needed.

The two HST 20-6000 are extremely silent, which means a better working environment. The noise level in the compressor room is remarkably low (max 73 dBA).

The HST uses digitally controlled magnetic bearings, which cause no mechanical friction or wear. The maintenance of the machine mainly consists of the regular replacement of inlet filters.

During the past 3 years, the operational costs have been minimal, with low energy consumption, no shutdowns, and very small service and maintenance expenses.

Today, the client is extremely satisfied with the Sulzer equipment and collaboration and is considering further HSTs for the future expansion of the wastewater treatment plant.

Comment

The performances of the HST turbocompressors have exceeded the client’s expectations with significant energy savings, little maintenance, and a low noise level. Furthermore, the top-quality service from Sulzer is greatly appreciated.
– Fabrice Martin, Business Development Manager


Overview

Sulzer delivered two HST turbocompressors for aeration of the biological basins as part of the latest upgrade for a major producer of dairy products in Europe. The client has three factories close to each other, with a common industrial wastewater treatment plant (IWWTP), one of the largest in the country. The plant has seen a series of upgrades and extensions in the past, including average flow increases and the addition of a tertiary filtration process. 

Challenge

Because of successive extensions of the dairy production sites the size of the wastewater treatment plant has grown significantly. Initially, a set of roots blowers were providing air to the biological tanks. These roots blowers were later replaced by more efficient screw compressors. The performance of the new machines, however, proved to be rather disappointing and moreover, their maintenance was expensive. When the latest extension of the IWWTP was decided, the client looked for additional compressors, which would not only respond to the technical specifications, but also give complete satisfaction in the long term.

Solution

Sulzer tailored a package of two HST 20-6000-1-190 turbocompressors and one master control unit (MCU) to match the customer’s exact requirements. A complete set of pipework accessories for the new compressor room was also supplied. In addition, Sulzer gave recommendations for the most proper application of the equipment, eg for the ducting of the motor cooling air outlets, which reduces the temperature in the compressor room and is beneficial for the process air. Finally, the optimal design of the installation helped save a lot of energy.

Outcome

The two HST 20-6000 turbocompressors offer an outstanding wire-to-air efficiency. They interface with the upper level control system through the MCU. This MCU selects the most economical compressor combination (one or two running – duty points in the best efficiency zone) to keep the pressure within tight limits whatever air flow is needed.

The two HST 20-6000 are extremely silent, which means a better working environment. The noise level in the compressor room is remarkably low (max 73 dBA).

The HST uses digitally controlled magnetic bearings, which cause no mechanical friction or wear. The maintenance of the machine mainly consists of the regular replacement of inlet filters.

During the past 3 years, the operational costs have been minimal, with low energy consumption, no shutdowns, and very small service and maintenance expenses.

Today, the client is extremely satisfied with the Sulzer equipment and collaboration and is considering further HSTs for the future expansion of the wastewater treatment plant.

Comment

The performances of the HST turbocompressors have exceeded the client’s expectations with significant energy savings, little maintenance, and a low noise level. Furthermore, the top-quality service from Sulzer is greatly appreciated.
– Fabrice Martin, Business Development Manager


 
 
 
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Sulzer Pumps Wastewater UK Ltd
5th Floor
Astral Towers
Betts Way
Crawley
RH10 9UY
Tel: 0870 608 0123
Fax: 01293 527972
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Optimising wastewater treatment in dairy plants