External compressed air emergency supply for a briquette factory

No shut down

External compressed air emergency supply for a briquette factory

Quelle/Source: Aerzen

1 Die drei Adsorptionstrockner arbeiten mit einem Drucktaupunkt von -80 °C • The three adsorption dryers work with a pressure dew point of -80 °C

Quelle/Source: Aerzen

2 Die sechs Aerzener Schraubenverdichter der externen Druckluft-Notversorgung sowie die Notstromaggregate und Dieseltanks (am oberen rechten Bildrand) wurden auf dem gepflasterten Hofplatz vor der zentralen Druckluft-Station installiert • The six Aerzen screw compressors of the external compressed air emergency supply as well as the emergency power generators and diesel tanks (at the upper right edge of the image) were installed on the paved courtyard in front of the central compressed air station

Quelle/Source: Aerzen

3 Blick auf die Dieselaggregate (rote Gehäuse) und die Behälter für den Dieselkraftstoff • View onto the diesel packages (red housings) and the reservoirs for diesel fuel

Quelle/Source: Aerzen

4 Aufstellungsplan • General arrangement drawing

Quelle/Source: Aerzen

5 Die Druckluft-Leitungen wurden überwiegend mit flexiblen Schläuchen realisiert • The compressed air pipings were mainly realised by means of flexible hoses

Quelle/Source: Aerzen

6 Anschluss der flexiblen Druckluft-Leitungen an die zentrale Sammelleitung • Connection of the flexible compressed air pipes to the central manifold

Quelle/Source: Aerzen

7 Drei eingehauste, drehzahlgeregelte Aerzener Schraubenverdichter (Baujahr 1986) mit einer Gesamtleistung von 94 m³/min • Three enclosed, speed-controlled Aerzen screw compressors (year of construction 1986) with a total power of 94 m³/min

Quelle/Source: Aerzen

8 Dipl.-Ing. Christoph Zura, Betriebsingenieur im Bereich Kraftwerkstechnik in der Brikettfabrik Wachtberg in Frechen • Dipl.-Ing. Christoph Zura, production engineer in the field of sewage works technology at briquette factory Wachtberg in Frechen

Quelle/Source: Aerzen

Blick in die zentrale Druckluft-Station der Brikettfabrik Wachtberg (rechts drei eingehauste Aerzener Schraubenverdichter, links drei Adsorptionstrockner) • View into the central compressed air station of briquette factory Wachtberg (on the right three enclosed Aerzen screw compressors, on the left three adsorption dryers)

Summary: This job bordered on achieving the impossible. In the central compressed air station of briquette factory Wachtberg in Frechen, near Cologne, part of RWE Power AG, repairs were to be performed. Temporarily, the compressed air station and the corresponding electrical distribution station had to be completely shut down. Nevertheless the compressed air supply should not be interrupted – particularly when you have a total delivery volume of 282 m³/min. But there was a solution: the temporary supply of the entire factory by an external rental station from Aerzen International Rental B.V. in Duiven (Netherlands), a subsidiary company of AERZEN near Hamelin. This rental station not only comprised six oil-free compressing screw compressors, but with five additional diesel driven generators also generated the necessary electrical energy for their operation.

At the Frechen site RWE Power AG process every year in a production around the clock 5.15 million tons of crude lignite into about 900 000 tons of pulverised lignite and 1.1 million tons of briquettes. In a second operational area the company’s own power plant produces 0.983 terawatt hours of electrical energy every year using briquetting carbon (B-carbon). For the 24-hour-production of both areas an uninterrupted compressed air supply is a must. The compressed air for the entire site is generated in a central station assigned to the power station by three oilfree compressing, speed-controlled...