Competitor ANDRITZ has equipped its decanter centrifuges with the TurboJet-Weir plate. This reduces the flow resistance of the liquid outlet and can lower energy consumption by 10 to 30 % – depending on the operating conditions. The GentleFeeder system also optimises the feeding of the suspension, which means that less energy is required for the separation.
Flottweg relies on a special grid design for the screw body in its current Xelletor machines, which reduces polymer and energy consumption by up to 15% when dewatering sewage sludge. At the Turku sewage treatment plant, replacing an old rotor with a Xelletor rotor reduced energy consumption and increased the dry matter content of the dewatered sludge.
Energy-efficient compressors – potential savings through heat recovery and maintenance
Compressed air is an indispensable source of energy in industrial production, especially for the pneumatic conveying of bulk materials. It enables the gentle transport of sensitive materials, is used for control tasks in many process steps and is essential for numerous machines. However, the generation of compressed air is very energy-intensive and expensive: compressed air systems account for up to 10% of total industrial energy demand. In addition to selecting an energy-efficient compressor, operational optimisation measures offer great potential for savings. These include waste heat recovery, regular filter and oil changes, as well as optimised control of compressed air networks.
Since a compressor converts almost all of its drive energy into heat, this can be used in a targeted manner – for example, to heat production areas or to support drying processes. Kaeser relies on screw compressors with heat recovery that make up to 96% of the energy used available for heating purposes. Fluid-cooled models release about 76% of their energy via the cooling fluid and a further 15% via the compressed air aftercooler. This reduces heating costs and CO₂ emissions.