Pumps & Valves

Overhaul of digester mixing system delivers better biogas yields

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Following an extensive upgrade of its reception tank and digester mixing system, Eco Verde Energy (EVE) has put a once troublesome Anaerobic Digestion (AD)+ plant firmly back on track with encouraging new biogas yields.

At Holton* in Suffolk, England, which receives around 65% of its feedstock from the adjacent Bernard Matthews poultry facility, the AD plant, under a series of different operators, had seen biogas production drop significantly, and eventually to a complete halt for a much-needed overhaul.

Initially, the primary digester (2700m3) was drained down, discovering, as expected, faults with the mixers, but also a broken stanchion. Later, further inspections revealed that there was damage to the roof of the digester, so the decision was taken to postpone operations for a complete maintenance revamp.

“The mixers that were sold in as part of the biogas package were never going to last in the long-term,” said Eco Verde’s Site Manager at Holton, Kris Martin.

“It is hard to understand a design that doesn’t allow equipment to be looked after! The mixers couldn’t be lifted out of the tank for even the most basic of service tasks such as an oil change and cleaning the propellers.”

He added: “At one point, the site was being run remotely, but it has now benefitted from a complete review of operations. When we shut down for the maintenance overhaul, trying to get shipshape became more challenging, due to some suppliers not being able to assist; either unable to provide equipment quick enough for our needs, or did not seem to have a deep understanding of the industry. Either way, the essential assistance we required was not readily available. We couldn’t for example, get anyone to look at the feed-in module (which is a jacketed tank to provide heat) we have between the reception tank and the digesters. The previous chopping pump had failed because of the high temperatures, so again, it wasn’t specified properly. There can be a huge difference in supplying equipment in 304 stainless steel compared to 316. For a biogas process with food waste, compromising is only going to lead to problems.  This has been the classic case of a package plant being sold on price rather than quality.”

Matters took a significant turn for the better though when Kris made contact with Landia, about whom he’d heard good reports.

‘Clearly wanted to try and understand how a solution could be found’

He continued: “They’re a pump and mixer company, and there are plenty of those,” he said, “but unlike some others, they actually listened and clearly wanted to try and understand how a solution could be found. As soon as they first came to the site, there was a good vibe. Linking up the mixing operation from the reception tank, through the feeding module, and then on to the digesters, and finally through to the pasteurisers, wasn’t going to be easy, but rather than just try and sell us equipment, Landia were keen to find a way to help make the Holton plant perform as it should.”

New submersible mixers (5.5kW) from Landia have been installed for the reception tank, which unlike the previous units, can be easily lifted up on a crimped rail system for inspection to remove any plastics and perform standard maintenance such as oil changes.

For the feeding module, which is batch-fed from the reception tank, a Landia Chopper Pump (invented by the company in 1950) has replaced the failed unit. The unique external knife system (combined with the addition of a new shredder propeller) ensures that particles are continuously reduced in size, and that solids cannot enter the pump’s casing.

The primary digester was first upgraded to replace the failed units with Landia mixers. By utilising a pre-existing hatch system that provides easy access, these new 18.5kW mixers were installed with minimal disruption to the biogas process, and can likewise be easily serviced without causing downtime.

The secondary digester is now served with a system that comprises the proven Landia chopper pump, fitted with venturi nozzles to provide truly comprehensive mixing. When the primary digester meets the right level, the feedstock is automatically transferred to the secondary digester. The simple, but highly effective combination of submersible mixers, chopper pumps, and the venturi nozzles work to constantly recirculate the mixture of liquid and gas, even though it only typically has to run in 10-minute intervals, rather than mixers at many plants that run flat-out 24/7.

At the end of the process, in order to meet the legal requirements of a feedstock that contains animal bi-products, there are now two (25m3) Landia pasteuisers, which heat the final effluent to the required temperature of 70 degrees centigrade. The pasteurisers are supplied as complete processing units (tank, chopper pump, and controls), to break down the food waste effluent and any remaining solids. Each tank from Landia is made with a double stainless-steel tank wall that acts as a heating jacket. From here, heat is transferred by circulating hot water, meaning that a heat exchanger is not always required. Post-pasteurisation, with the maximum possible amount of gas extracted, the final digestate from Holton makes a first-class, nutrient-rich fertiliser.

 

‘Nothing on this site is now off-the-shelf’

 

Kris Martin added: “The more Landia and I worked together, the more we had a focal point. Although they do provide some guide rails and pipework, it’s not their main business, but when looking at how we could transfer everything from the start of the process, right through to the pasteurisers, it made sense for Landia to include it as part of their service, rather than me having to bring in another supplier. They did a top-quality job in putting all the extensive pipework together. It’s very impressive and we’re all proud of it. Nothing on this site is now off-the-shelf. Paul Broadhurst (from Landia) and I have put this all together step-by-step. It’s not been easy, but we’ve worked through it with a very healthy rapport and that all-important common goal of wanting something to work and work well for the long-term. It’s a world away from the daily hassles that we had previously. Paul’s attitude to whatever we ask is ‘we’ll sort it out’, and I know he and Landia will, because they value us as a customer and care about the plant’s success.”

In addition to its primary feed (which is first treated by a DAF -Dissolved Air Flotation) piped in from the Bernard Matthews poultry facility’s treatment plant, EVE’s Holton site also receives effluent from the local Adnams brewery and distillery, plus various fats and oils from nearby food processing plants. This variety of intake then takes very careful managing to maintain a steady feed for the now, much loved biogas plant.

Kris Martin continued: “With the Landia submersible mixers at the front end, we’ve gradually developed a constant, homogenous feed, which provides excellent stability for the remainder of the process and our drive to maximise biogas yields. The consistency we have means happy bugs, because otherwise, too much of one intake at one time can cause foaming. That’s not an issue at this site any more.”

At 1.1MW, the new-look Holton biogas plant (which now has two CHP engines and additional gas storage), can provide most of Bernard Matthews' 1.4MW energy needs, with a grid connection in place for times if/when the poultry facility is on shutdown.

‘Low energy consumption

and maximum biogas yields’

Kris commented: “The investment here safeguards the future, with plans for a lagoon to be built and to have PAS 110. With Landia’s help, it means that we’ll be in good shape with low maintenance costs, low energy consumption and maximum biogas yields, which of course means profit – not to mention the fact that we do something great by making renewable energy from waste.

“Having to shutdown and clean out a couple of digesters creates downtime of almost three weeks; costing in the region of £150,000. We’re pleased of course to have now sorted out all the problems; turning everything around so that instead of having put out fires, we can finally be proactive and concentrate on making gas, rather than having to react to all the problems on site. The initial issues were made all the worse by having equipment that you couldn’t work on without having to shut the plant down! A design that effectively traps mixers inside the tank without access is ridiculous.

“We now have a proper maintenance schedule in place, and unlike in the past, no problems or delays in the availability and delivery of parts. If we order before lunchtime, Landia deliver the next day. During installation, there were also never any problems with the paperwork and permits from Landia; progress emails, and all the necessary RAMS (risk assessment and method statement) and proof of qualification were in place so that the work was seamless, with no delays. This differs significantly from others who simply aim to provide a product, without considering how it integrates into our process.

“Site managers can overcome all sorts of challenges, but aren’t necessarily engineers. You need calculations. You need experts to answer your questions to complete the jigsaw puzzle. No two plants are the same. It is reasonable to expect seamless support from the companies that provide equipment, but often, you find yourself navigating through various departments – from quotations to finance, engineers, and a loosely termed ‘support team.’  Having to repeatedly explain your requirements can be very frustrating and time-consuming. It is always easier to work with those who have been to a biogas plant, and who aren’t worried about getting their hands dirty. It’s been a long journey to get where we are, but we now have peace of mind with a plant that is performing very well and with fine-tuning, will get even better. It shows exactly what can be achieved with the right people, the right equipment, and a belief in our industry.”

24 Carrot solution found by Hayley Group with special Chopper Pump

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For a fast-growing company that makes machines for the post-harvest processing of vegetables, Hayley Group is set to provide two new Landia Chopper Pumps that have special external shredders.

Originally developed to deal with difficult wastewater solids in the fish processing industry, the Landia shredder-propeller design has now proved its capability in handling troublesome stringy material such as carrot tops, that typically cause problems for standard pumps.

Speaking for Hayley Group, the leading nationwide engineering component supplier (who also supply bearing and pneumatic products to the machinery manufacturer), Daniel Moulding, Assistant Manager, said:

“The Landia Chopper Pumps work extremely well for our customers in numerous applications. In this particular challenge, the specialist machinery company asked us for help, because their existing pumps struggled with the fibrous and gritty material that is an inevitable part of the wastewater process with vegetables.

“This latest purchase of two new Landia Chopper Pumps follows orders for five units that were successfully introduced at various locations during 2023.

“Landia have been very helpful indeed in working with us to understand our customer’s needs; adapting the shredder-propeller so that there is no longer any downtime on the processing lines, which is a huge benefit.”

Howard Burton, Technical Sales Engineer for Landia, added:

“For certain effluents with difficult solids, the pre-cutting shredder-propeller adds another important chopping stage; continuously reducing particle size and keeping the process running efficiently.”

Daniel Moulding from Hayley Group, continued: “In addition to providing such an effective, reliable solution, Landia also give us fast and efficient back-up whenever we need it.

“When our customer first used the Landia Chopper Pump, they said they’d never go back to the previous type of units. Another eight pumps later, we and they are very happy with the positive outcome, as are the end-users of the equipment.”

www.hayley-group.co.uk

www.landiaworld.com

Retrofit of digester mixers helps Biosciences Institute boost gas yields by 15-25%

Northern Ireland’s Agri-Food and Biosciences Institute (AFBI) has made a significant breakthrough with its research into on-farm biogas production by introducing a new digester mixing system.

At Hillsborough, one of seven AFBI sites that provide scientific research and services to government, non-governmental and commercial organisations, the retrofit of the AD plant’s main digester has improved biogas yields by 15-25%.

At what was the first biogas plant of its type in Northern Ireland, the cow slurry from the site’s 300-strong dairy herd is co-digested with grass silage produced on the research farm, to produce biogas which is combusted in a CHP engine providing heat and electricity for the site.

The new mixing system ensured that fresh feedstock was being better mixed in the main digestion tank and was not discharged too early, as witnessed by higher discharge temperature than that observed from the old mixing system.

Dr Gary Lyons from the Agri-Environment Branch at AFBI, said: “The original mixing system, installed when the plant was built, worked well for a number of years, but eventually a build-up of sludge in the bottom of the primary and secondary digestion tanks meant that we were getting poor digestate mixing. This impacted biogas production and the level of methane in the biogas. We decided that we needed to shut the system down, clear the sludge from the tanks, and retrofit a new mixing system on to the main digestion tank, which would not give us issues with sludge build-up in the future.”

 

 

‘A robust mixing system is critical’

He added: “At AFBI, we understand that busy farmers have more than enough to do, without having to constantly repair and maintain their biogas plant, so we’ve been able to see first-hand that a robust mixing system is critical. One that doesn’t have any wear parts on the inside of the tank will prevent the big headache of downtime.”

The new mixing system in question is a simple, but highly effective one. Externally-mounted, a Chopper Pump (invented by Landia in 1950) with venturi nozzles. No working at height. No working in the gas zone. And no costly downtime for servicing.

“There’s more to it than that of course,” continued Gary. The Landia GasMix provides the dual benefit of both hydraulic and biogas mixing in one system, which was appealing to the AFBI team. We’re not a commercial plant, but our role is to explore all of the possible benefits for farmers. This means not only maximising the amount of clean energy that can be produced, but how to achieve that with the minimum amount of energy that goes in.

‘More gas and also better quality gas’

“When we were just using slurry as a feedstock, the Landia mixers increased our output from 300 cubic metres of biogas per day of dry solids to typically 360, and as high as 400. I’m a sceptic by nature, but the results were there right in front of us with our readings; more gas and also better quality gas, with the Landia GasMix system working away without any problems, continuously reducing the particle size of the feedstock.

“Over time, only two of the 18 lines on the old mixing system hadn’t blocked. We knew we had to look for a lower maintenance alternative.”

Gary and his team’s search saw them consult with the first biogas plant of its type in the Republic of Ireland, where in County Limerick, impressive performance numbers were being reported at the site owned and operated by Greengas.

I spoke with David McDonnell at Greengas,” said Gary. “He told me that his plant was benefiting from having Landia mixers. I also looked hard at the Danish Biogas Association’s advice on the use of venturi nozzles for digester mixing at AD plants. This led to us working with DPS (part of the EPS Group) of Bangor (who supply Landia equipment in Northern Ireland and the Republic of Ireland) to help with their knowledge and experience

“In this situation, throwing more power at the process isn’t the answer. We’ve also understood that dwell times are very important, which takes convincing for some, but through careful fine-tuning, we don’t have to run the Landia mixers flat out to optimise biogas yields; just in 10-minute cycles, so only 30 minutes each hour. We need to experiment more with dwell times to hit the sweet spot of minimal mixing for maximum plant performance.

“We have had no problems with digestate mixing whatsoever since installing the Landia digester mixing system. By increasing the surface area of the feed with truly comprehensive mixing of the tank, the bacteria get to work much quicker. I do like the fact that the system incorporates biogas recirculation, and we do not appear to have solids settlement issues.

“As a scientific research centre, we’ve experienced the good, the bad and the ugly of AD, which should help farmers avoid the downside of those mixing systems that can only be retrieved by having to laboriously drain down the tank and then have to start the whole process from scratch. We won’t be doing that again.

“Following the increase in biogas production and methane content that we saw with mono-digestion of slurry as the feedstock, it will be very interesting in time to collate the data from the co-digestion of slurry and grass silage.”

www.landiaworld.com

Landia Biogas Digester Systems set for Indonesia

For pre-treatment tanks at a wastewater facility in Indonesia, Landia is supplying 12 of its digester mixing systems.

Part of a major Bio Production Plant in Java, the facility converts grass materials into biodegradable bags, with the excess matter utilised to produce biogas in six 4,000m3 rectangular concrete tanks.

To accelerate the installation, Landia is sending the pipework of its externally-mounted systems in self-assembly sets, with an appointed engineer to supervise the set-up. At the heart of the system is the Chopper Pump (invented by Landia in 1950), plus venturi nozzles, which will provide comprehensive mixing of the tanks, so that no crust forms on the surface of the liquid.

Fergus Clark, who heads up the Asia-Pacific region for Landia, said:

"This is a very important new order, which underlines the effectiveness of our digester mixing system and the unrivalled reputation it has for maximising biogas yields.  Operators also like the fact that it is so reliable, and that everything is easily accessible on the outside of the tank - with no working at height. Unlike some systems, there is no downtime or very costly emptying of the tank for servicing or repair."

www.landia.com

 

Chamber success as Borger’s pumps take screws out and send energy costs down

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Burdened with cumbersome maintenance, expensive spare parts and very high energy costs, a wastewater treatment plant has replaced its multi-phase eccentric screw pumps with new Rotary Lobe pumps, made by Börger.

Installed for a chamber filter press, the space-saving Börger pumps have been supplied as a twin-pack unit; two identical Rotary Lobe Pumps, which are operated in series. Each Börger rotary lobe pump has its own frequency converter that allows speeds to be individually regulated.

When feeding the chamber filter press, operators at the wastewater treatment plant now have a choice between two phases - the pre-fill phase and the pressurized phase. During the pre-fill phase, large quantities of sludge are pumped at high speed into the chamber filter press to fill up its chamber.

As the solids in the sludge gather in front of the filter screens, the increasing filling level of the chamber increases the counter pressure in the chamber filter press. Using the frequency converter, the speed of the Börger pumps is then reduced accordingly.

In addition to improving the output and efficiency of the application, the new Rotary Lobe pumps have drastically reduced energy costs, and are also far easier to service with their easy access, Maintenance-In-Place design.

Borger UK

01902 798 977

www.boerger.com

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High fibre in wastewater handled by robust Börger pump

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A rotary lobe pump made by Börger has helped solve a wastewater processing problem at a textile manufacturer.

Taking effluent from the bleaching process into a storage tank, the Börger pump has to contend with significant fibrous material that also contains elements of hydrogen peroxide and caustic soda.

When the defined fill level of the wastewater has been reached in the collection tank, the Börger rotary lobe pump automatically conveys the liquid in measured amounts from the collecting tank into the sewage system.

Made of Duplex stainless steel and equipped with a maintenance-free mechanical seal, the compact Börger rotary lobe pump is very easy to service, requiring only basic tools.

Borger UK

01902 798 977

www.boerger.com

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Riventa make headway in Brazil with superior SAS pump monitoring

Water companies in Brazil are now benefitting from Riventas SAS Software as a Service model 002

 

 

 

 

 

 

 

 

 

 

 

 

Riventa’s expertise in optimising the performance of pumps and blowers has seen it win important new contracts in Brazil through its partner in São Paulo, Toraqua Technologies.

A total so far of five public and private water companies are now benefitting from Riventa’s SAS (Software as a Service) model, where the customer no longer has to concern itself with the maintenance of hardware.

André Vizioli Gomes, General Manager of Toraqua Technologies, commented: “The market here is pleasantly surprised and excited about just how quickly they get instant information about how their pumps and blowers are performing. In addition to the real-time data, management reports showing, for example, where to make energy savings, can be produced. The sensors provided by Riventa are also far more accurate than what has been in use previously.”

Testing and monitoring as a service has been key to Riventa’s worldwide growth, but with Software as a Service (SAS) also now available, water companies in Brazil can identify savings quicker and plan maintenance significantly better from the data that is gathered on measured flow, efficiency, head and power.  

“Everything is faster, yet much simpler for our customers,” added André Vizioli Gomes. “SAS is the way forward for us. It provides an excellent insight that enables the water companies to make quicker yet better decisions – with advice and recommendations on hand as we and Riventa also view the readings from the software to analyse the data as it happens.”

www.riventa.com

Trane Heat Pump Solutions Help Decarbonise Schools in the Fiumicino District in Italy

 

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Trane heat pumps replaced gas-boilers to deliver clean, renewable heat as part of the municipality’s overall project to eliminate the schools’ CO2 emissions.

 

The project has made 31 nurseries, kindergartens, elementary schools, and middle schools buildings in Fiumicino carbon-neutral, sustainable and energy-autonomous.

 

 Trane®, a leading global provider of indoor comfort solutions and services and a brand of Trane Technologies, announced today its heat pump solutions have been instrumental in decarbonising the heating systems of 31 schools in the Italian district of Fiumicino. Replacing gas boilers and electrifying the schools’ heating systems is part of the municipality’s project to convert all schools in Fiumicino into carbon neutral, energetically sustainable and autonomous buildings.

The overall project including the electrification of heating systems, installation of photovoltaic systems, replacement of lamps with new LED lights and creating of a fully automated management system will generate energy savings equivalent of around 650 TOE (Tonnes of Oil Equivalent) of heat and electricity, correspondent to the reduction of atmospheric emissions of almost 1,400 tonnes of CO2 per year.

The new, sustainable heating systems in Fiumicino’s schools are based on a total of 40 Trane Sintesis Advantage CXAF, Conquest CXAX and Cube CXB air-to-water heat pumps, which contribute to the overall emission reduction with an estimated average of up to 390 tonnes of CO2 per year.

“By rethinking how we manage our heating and cooling systems, and moving away from the historic, fossil fuel-driven approach, we can reset our course and radically reduce the emissions of our buildings,” said Louis Rompre, portfolio manager at Trane in Europe, Middle East and Africa. “With gains in the decarbonisation of the electricity grid, the future of how we heat our buildings must surely be electric, contributing to safer buildings and improving the air quality of our cities. Replacing gas boilers that contribute significantly to NOx and CO2 emissions worsening the air quality around schools is particularly important for the wellbeing of children and neighbours. The decarbonisation project in Fiumicino that Trane is proud to be part of, is a great example of how a Municipality can put existing technology to work to become one of the greenest districts in Italy.”

The decarbonisation of the nurseries, kindergartens, elementary and middle schools’ heating systems involved the redevelopment of 31 thermal power plants, removal of old gas boilers and installation of highly efficient Trane heat pumps. Sourcing energy from the ambient air, with zero direct greenhouse gas (GHG) emissions, these air-to-water heat pumps offer a renewable energy solution to traditionally carbon-intensive space heating demands:
 

  • Trane Sintesis™ Advantage CXAF provides best-in-class efficiency levels at Eurovent Class A full load performance. The Sintesis™ Advantage CXAF heat pumps offer market leading operating maps and can deliver 40°C hot water even at -15°C ambient air temperature, enough for conventional low-temperature space comfort heating. For boiler installations coupled with medium temperature radiators in average requiring hot water of 45°C - the Sintesis™ Advantage CXAF can efficiently meet that requirement at -10°C ambient air temperature.
  • Trane Conquest CXAX air-to-water scroll heat pump delivers reversible cooling and heating at wide operating maps reaching down to -15°C ambient air and offers up to 60°C leaving hot water temperature. Trane Conquest CXAX heat pumps combine high performance and reliability in a compact design ensuring lower noise, without reducing efficiency or affecting the footprint.
  • Trane Cube CXB air-to-water heat pumps produce leaving hot water up to 65°C and down to
    -10°C outdoor air temperature. With low ambient air kit, the unit can provide up to 55°C down to -20°C outdoor air temperature.

The electrification of school heating project in Fiumicino initiated in 2021 is now completed with the Trane system fully operational.

Trane’s extensive network organization includes teams of highly trained professionals available 24/7 to provide technical assistance, advice, and support. Trane customers receive prompt and effective assistance whenever they need it and can benefit from the company’s commitment to delivering energy-efficient and sustainable solutions that help reduce carbon footprint and achieve sustainability goals.

Providing sustainable cooling and heating solutions is part of Trane’s and Trane Technologies’ overall approach to reducing carbon emissions in the industries and markets they serve. It helps advance the 2030 Sustainability Commitments, including the Gigaton Challenge to reduce customer greenhouse gas emissions by 1 billion metric tons.

For more details of on the complete Trane portfolio of solutions, please visit www.Trane.eu

Trane heat pumps replaced gas-boilers to deliver clean, renewable heat as part of the municipality’s overall project to eliminate the schools’ CO2 emissions.

 

The project has made 31 nurseries, kindergartens, elementary schools, and middle schools buildings in Fiumicino carbon-neutral, sustainable and energy-autonomous.

 

Brussels, Belgium, July 6, 2023 - Trane®, a leading global provider of indoor comfort solutions and services and a brand of Trane Technologies, announced today its heat pump solutions have been instrumental in decarbonising the heating systems of 31 schools in the Italian district of Fiumicino. Replacing gas boilers and electrifying the schools’ heating systems is part of the municipality’s project to convert all schools in Fiumicino into carbon neutral, energetically sustainable and autonomous buildings.

The overall project including the electrification of heating systems, installation of photovoltaic systems, replacement of lamps with new LED lights and creating of a fully automated management system will generate energy savings equivalent of around 650 TOE (Tonnes of Oil Equivalent) of heat and electricity, correspondent to the reduction of atmospheric emissions of almost 1,400 tonnes of CO2 per year.

The new, sustainable heating systems in Fiumicino’s schools are based on a total of 40 Trane Sintesis Advantage CXAF, Conquest CXAX and Cube CXB air-to-water heat pumps, which contribute to the overall emission reduction with an estimated average of up to 390 tonnes of CO2 per year.

“By rethinking how we manage our heating and cooling systems, and moving away from the historic, fossil fuel-driven approach, we can reset our course and radically reduce the emissions of our buildings,” said Louis Rompre, portfolio manager at Trane in Europe, Middle East and Africa. “With gains in the decarbonisation of the electricity grid, the future of how we heat our buildings must surely be electric, contributing to safer buildings and improving the air quality of our cities. Replacing gas boilers that contribute significantly to NOx and CO2 emissions worsening the air quality around schools is particularly important for the wellbeing of children and neighbours. The decarbonisation project in Fiumicino that Trane is proud to be part of, is a great example of how a Municipality can put existing technology to work to become one of the greenest districts in Italy.”

The decarbonisation of the nurseries, kindergartens, elementary and middle schools’ heating systems involved the redevelopment of 31 thermal power plants, removal of old gas boilers and installation of highly efficient Trane heat pumps. Sourcing energy from the ambient air, with zero direct greenhouse gas (GHG) emissions, these air-to-water heat pumps offer a renewable energy solution to traditionally carbon-intensive space heating demands:
 

  • Trane Sintesis™ Advantage CXAF provides best-in-class efficiency levels at Eurovent Class A full load performance. The Sintesis™ Advantage CXAF heat pumps offer market leading operating maps and can deliver 40°C hot water even at -15°C ambient air temperature, enough for conventional low-temperature space comfort heating. For boiler installations coupled with medium temperature radiators in average requiring hot water of 45°C - the Sintesis™ Advantage CXAF can efficiently meet that requirement at -10°C ambient air temperature.
  • Trane Conquest CXAX air-to-water scroll heat pump delivers reversible cooling and heating at wide operating maps reaching down to -15°C ambient air and offers up to 60°C leaving hot water temperature. Trane Conquest CXAX heat pumps combine high performance and reliability in a compact design ensuring lower noise, without reducing efficiency or affecting the footprint.
  • Trane Cube CXB air-to-water heat pumps produce leaving hot water up to 65°C and down to
    -10°C outdoor air temperature. With low ambient air kit, the unit can provide up to 55°C down to -20°C outdoor air temperature.

The electrification of school heating project in Fiumicino initiated in 2021 is now completed with the Trane system fully operational.

Trane’s extensive network organization includes teams of highly trained professionals available 24/7 to provide technical assistance, advice, and support. Trane customers receive prompt and effective assistance whenever they need it and can benefit from the company’s commitment to delivering energy-efficient and sustainable solutions that help reduce carbon footprint and achieve sustainability goals.

Providing sustainable cooling and heating solutions is part of Trane’s and Trane Technologies’ overall approach to reducing carbon emissions in the industries and markets they serve. It helps advance the 2030 Sustainability Commitments, including the Gigaton Challenge to reduce customer greenhouse gas emissions by 1 billion metric tons.

For more details of on the complete Trane portfolio of solutions, please visit www.Trane.eu

Water Treatment Plant installs new Borger pumps for Membrane Filtration

Fourteen Rotary Lobe Pumps made by Borger have been installed for a membrane filtration application at a water treatment plant.

Achieving a total output of up to 10,000 m³/h, the Borger pumps extract water so that it can be purified through the membranes.

In addition to being extremely stable and practically wear-resistant, the pumps were chosen to suit the cleaning of the membranes by back-flushing with filtered water. This made it essential for the operator of the plant to have pumps that could be operated in reverse. The rotary lobe pumps from Borger also have a high suction capacity that allows the treatment plant to vary the quantity of water during the back-flushing phase.

Regulated by a frequency converter, the Borger Rotary Lobe Pumps (which have a rated capacity of 450 - 720 m³/h),

are designed with maintenance-in-place for easy servicing, requiring only basic tools to keep downtime and costs to a minimum.

 

Borger UK

01902 798 977

www.boerger.com

This email address is being protected from spambots. You need JavaScript enabled to view it.

Powerline help further prolong lifetime of proven Landia pumps

Banbury-based Powerline Electric Motors has completed the refurbishment of its latest batch of Landia slurry pumps, including one unit that has been in operation for almost 25 years.

With its ongoing investment in new equipment and growing number of apprentices, Powerline has seen a significant increase in demand for its repair services, which not only help prolong the lifetime of pumps, but also improve efficiencies.

Landia’s Paul Davies, commented:” Although we have our own nationwide service team, Powerline’s skill in overhauling pumps is first-class. We are pleased to see our equipment continue to provide excellent, long-term service.”

Richard Thompson of Powerline added: “We’re not in the habit of disappointing our customers. Landia make very robust pumps and they always have a good stock of spares on hand for us, so that we can offer the best possible turnaround.”

Landia and Powerline also both work closely with Shipston-on-Stour-based Midland Slurry Systems, who specialise in the supply and maintenance of industrial and agricultural wastewater treatment installations and animal slurry management.

Giles Russell for Midland Slurry Systems, said: “We have total confidence in the Landia pumps and mixers that we’ve used for many years. In slurry pits, equipment has to be tough, but it must be maintained properly too. After our pumps have been in for service with Powerline, they’re like new!”

In addition to the farming sector, Powerline also provides high-quality repairs, rewinding and refurbishment of electric motors, pumps, fans, and gearboxes to a wide variety of industries, such as manufacturers of foods, plastics, and automotive, as well as servicing customers working in chemicals, utilities, healthcare, construction, and Oxfordshire-based F1.

www.landiaworld.com

www.PowerlineElectricMotors.co.uk

www.midlandslurrysystems.co.uk

this article can also be found in the latest issue of  EMS

 

Identifying poor assets and inefficient pumps.

Despite the soaring prices brought on by an energy crisis that shows no signs of diminishing, ask pump and blower operators about the efficiency of their equipment, and the truth is that most don’t know – according to a leading monitoring technology provider.

The pumps, for example, might often be described as ‘working fine’ and ‘doing their job’, but is that, now more than ever, a strategy? How about saving money now, and in the future?

“The opportunity to truly maintain, protect and optimise assets is here and now, with a Return on Investment (ROI) that is shorter than ever”, says Julian Lowe from Riventa. “The cost of solving asset management challenges is on a much smaller scale than most companies imagine”.

So, just how can you make hidden costs more visible?

At minimum, put some testing in place. By obtaining accurate, quality data, this first proactive step will give you a snapshot of performance, as well as health and efficiency. Even this entry-level testing will help identify poor assets and inefficient pumps.

Riventa’s Julian Lowe added: “All we hear about at the moment, understandably, is the giant hike in energy prices, so best test your pumps (and/or blowers and turbines) to reduce energy consumption and maximise savings. This will almost immediately help identify actions to improve performance. In addition to pump efficiency, measuring key parameters such as flow rate, head and electrical power - current pump performance characteristics can be compared to ‘as new’ and ‘post-refurbishment’ conditions. This provides the same accuracy as a pump manufacturer’s test facility – but with the distinct advantage of real operating conditions”.

Across numerous industries, where for some, running pumps ‘til destruction is the modus operandi, Lowe has a point. He claims that for larger pumps, blowers and turbines, the ROI can be as little as 18 months.

A level up from pump testing is to look at an Optimisation Service, utilising secure on-site pump monitoring equipment to provide real-time data. This enables you to start seeing what’s happening across your system by capturing data over 14-days or longer. This doesn’t have to involve tons of ‘spaghetti’. Systems can now be cable-free; up and running in around 1 hour per pump, at low risk and with minimal disruption to existing operations.

‘Realistic payback calculations’

Dr Tom Clifford from Riventa, continued: “Once in place, real-time data for each asset can be evaluated, with information-driven insights highlighting performance issues and supporting decisions. This can establish best practice recommendations, realistic payback calculations and a business case for moving forward – all backed by precision measurement and innovative analytics”.

Clifford explained how Riventa had recently worked with a food manufacturer; testing the company’s cooling system, which is split into two pumping sub-systems: factory pumps 1-5 for sending chilled water from heat-exchangers to the factory; and evaporator pumps that send chilled water from the factory to refrigeration heat exchangers.

“To test the pumps, we used the thermodynamic measurement technique (with our specialist software) to measure suction and discharge pressures either side of the pump, differential temperature, and motor input power. These measurements enabled us to calculate differential head across the pump, hydraulic efficiency and volumetric flow. Pumps were altered gradually. After each change, a test point was taken, while allowing enough time to obtain the best statistical average. Tests also involved a routine of testing performance at an incumbent set point, followed by throttling the pump to reduce its flow rate. The latter action allowed other pumps running in parallel to increase in speed to compensate, with a final test point taken at this moment”.

He continued: “Throttling meant we could observe the maximum possible flow through each pump under test, without altering the overall flow to the plant. At times this was challenging, because conditions downstream in production would change, altering the cooling load and in-turn the flow set point. Nevertheless, good quality performance information was obtained.

‘Strong case for robust savings’

“We found that all pumps were showing signs of wear. Moreover, manufacturer performance levels were not being achieved. None of the pumps we tested reached the manufacturer’s BEP (81%). In fact, the maximum pump efficiency possible was found to be 75% (achieved by pumps 1 & 2 only). Our findings enabled us to put pumps into a descending order of repair: 1, 2, 3, 4 & 5. While pumps 1-3 achieved a good relationship between power and flow, pumps 4 & 5 were not performing when at lower flows. This indicated a high likelihood of internal recirculation – from high to low pressure parts of the impeller – being caused by high wear. We were able build a strong case for robust savings through the pump refurbishment. Broadly, two options were made available:

  • Basic Refurbishment: Internal coating plus replacement of wear-rings, bearings and seals.
  • Comprehensive Refurbishment: As per the Basic Refurbishment, plus a new tailored impeller.

“We calculated that pump refurbishment would bring potential

savings of £19,200 per year, with possibilities to refurbish 2, 3

or 5 pumps”.

This is just one example of what Riventa say they are helping companies achieve across industries that also include water, power, mining, petrochemical, to name but a few.

Advanced pump monitoring and optimisation are available too, continuously focusing efforts by evaluating and understanding performance gains across priority pumps and sites. And for some organisations, full optimisation of networks is available.

‘Change in Mindset’

“Nobody wanted an energy crisis”, concluded Clifford, “but as prices soar, we are beginning to see a change in mindset about just how important it is to know how your assets such as pumps, blowers and turbines are really performing.  Initially, some basic testing might reveal some not altogether pleasing facts (!), but you can soon put yourself on a very positive course to make some seriously good, ongoing savings”.

www.riventa.com

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