Industry InsightA case study by KAESER Compressors Australia

Oil Free Compressed Air

UGL/Synergy: Kwinana Power Station

ENERGY FOR THE PEOPLE“ ”Four specially, made-to-order Kaeser dry-running screw compressors support one of the world’s most efficient simple-cycle gas turbines. GE’s LMS100 aero derivative turbines require only the cleanest of air to operate in; free of all water, oil and dirt contaminants.

Situated 45km south of Perth is the Kwinana Power Station; it covers about 10% of Western Australia’s electricity demand connected to the South West Interconnected System (SWIS). Built in 1970 firstly as an oil burning power station, it was later converted to coal as a result of the 1973 oil crisis initiated by OAPEC’s oil embargo. Due to the generous reserves of gas in Western Australia, and the subsequent reintroduction of oil-burning, Kwinana is unique as it is capable of burning three fuels – coal, natural gas and oil.

In 2012, Synergy commissioned UGL the task of en-gineering, designing, procuring, constructing, in-stalling, testing and commercially operating 2 new dual fuel (diesel/gas) generators to replace two de-commissioned 120MW steam powered generators. UGL sourced two high efficiency GE LMS100 aero derivative gas turbines (HEGTs); each capable of de-livery 100MW each.

Jeff Coyle - Kaeser Australia’s engineering manag-er - recalls, “We had assisted UGL on several other projects previously so they approached us directly again with very specific requests to aid the opera-tion of their new HEGTs. GE had very explicit clean air requirements for their turbines.” Kaeser provid-ed 2 separate compressed air stations next to each of the HEGTs. Each system consists of 2 DSG 220-2 dry-running screw compressors, 2 desiccant dry-ers, a 13,000L capacity air tank, SAM 44 controllers and carbon filters.

Even with Western Australia’s arid climate, these compressors are able to run smoothly at ambient temperatures of 45°C or higher. One compressor in each station is on continuous run, whilst the other provides full standby cover. The machines are rotat-ed regularly to maximise life cycle and efficiency of the station.

Matthew Weston – Synergy Mechanical Technical Officer – explains the importance of the compres-sors. “Their key task is to provide purge air to the turbine bearings. . . during operation and cool-down. We also use low pressure clean air for insulation purposes for the IPBD (insulated phase bus ducts).

Jeff Coyle closes with, “These compressors [main-tained properly] should run forever.” They will con-tinue to ably support the state-of-the-art HEGT’s that generate such an important energy source throughout Western Australia.

These compressors are able to run smoothly at ambient temperatures of 45°C or higher.

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König PilsnerKAESER AND THE KING“

For more than 150 years the Duisburg district of Beeck has been home to ‘König Pilsner’, affec-tionately referred to as the ‘King’ of beers. Master brewer Theodor König first started brewing pilsner in the Northern Rhine community of Beeck in 1858.

Today, the König Brewery, now part of the Bitburger Group, still continues to grow steadily and recently celebrated its 150th anniversary. Its sesquicenten-nial ‘birthday present’ to itself was the commission-ing of its new bottling plant, the largest and most advanced of its kind in the world.

With the introduction of the introduction of the new bottling plant the compressed air system also had to be updated to accommodate for the increased compressed air demand.

As with any brewery, the importance in the sup-ply of clean sterile compressed air is critical to the process. The whole brewing process relies on com-pressed air, from its use as a pumping medium, the aeration of the wort at the beginning of the fermen-tation processes through to the filling of bottles and kegs. In addition, a considerable volume of com-pressed air is also needed for the pneumatic valves and regulators.

For Koning Pilsner, the requirement for clean sterile compressed air was not the only important factor, the supply of reliable, efficient compressed air also weighed equally in the balance for a new system.

With such high bench marks, Kaeser was brought into the picture with their latest range of “Dry Run-ning Rotary Screw Compressors”. With Kaeser’s extensive experience in the field of Compressed Air this led to the design and implementation of a 132Kw frequency controlled compressor – DSG220-SFC with sterile filtration.

The new frequency controlled DSG 220-2 SFC (132KW) forms part of a system that already in-cludes three existing Kaeser Dry- Running Rotary Screw Compressors. With the introduction of the latest Kaeser unit, König Pilsner compressor sta-tion’s idle run time dropped from over 25% to just 2%, resulting in significant energy savings.

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-tially serviced mainly in the brewery’s own pubs and establishments.

An advance dry running rotary screw compressor from Kaeser is used in the production of this distin-guished beer.

Master brewer Theodor König first started brewing Pilsner in the Northern Rhine community of Beeck in 1858. He wanted to brew Pilsner style beer and successfully market it, as we would say to-day, in the undisputed heartland of traditional ale. With a slow and steady start, his brewery the “Bairischen Bierbrauerei” Theodor König, served predominantly in the brewery’s own pubs.

TATURA /Bega CheeseQUALITY DAIRY PRODUCTS FOR OVER 100 YEARS“ ”

Kaeser Compressors have satisfied TMI/Bega Cheese’s stringent internal benchmarks for air quality in its food processing operations. Four Kaes-er dry-running screw compressors provide clean air for one of Australia’s most iconic and trusted dairy brands. Therein lies the enduring standards that the best companies operate by to provide the highest quality products for the Australian consumer.

Nestled in the heartland of the Goulburn Valley lies the historical community of Tatura. This is where you can find the largest Australian owned supplier of infant formula and historic dairy brand; Tatura Milk Industries Ltd. (TATURA). TATURA has been manufacturing dairy products of the highest quality since its humble beginnings in 1907.

In 2007, TATURA formed a strategic alliance with another iconic Australian dairy manufacturer, Bega Cheese Ltd.; to expand their product manufacturing operations. In 2012, TATURA fully merged with Bega Cheese Ltd.

TATURA processes 80,000 tonnes of dairy products annually from milk supplied by 65,000 cows from the best practice dairy farms in an 80kilometre radi-us of Tatura. TATURA manufactures a wide range of quality dairy products that serves the Asian, Europe-an and local markets. TATURA’s production systems are marked by the most rigorous benchmarks and specifications; which Kaeser Compressors’ quality assurance has proven to meet and exceed.

High-quality clean air is a fundamental component of dairy manufacturing. It ensures that the qual-ity raw dairy ingredients remain uncontaminated during processing. TATURA’s factory uses Kaeser dry-running screw compressors for the production of oil-free air at two different sites.

A specially designed compressor station at site 1 includes 2 DSG290-2 8bar dry-running screw com-pressors, 1 DSG290-2 SFC 8bar, a 13700L air re-ceiver, 1 heated DW desiccant dryer, 1 heatless DC desiccant dryer (standby), and Sigma Air Manager system(station controller). Jeff Coyle – Kaeser Aus-tralia’s engineering manager – recalls, “this is an extremely effective compressed air system, with en-ergy efficiency at its core. The SFC compressor [vari-able drive] is utilised during all operations to adsorb the minor fluctuations in air demand. When a surge in air demand occurs; one of the DSG’s [direct drive] kicks in at full load to supply the extra air in a com-plete block.” Direct drive compressors operate most effectively when operating at maximum capacity, so the Sigma Air Manager (SAM) is programmed to run each compressor at its most efficient levels against fluctuating air demands. “Master controllers (SAM) are vital for any multi-compressor station. It is an automatic optimisation of the compressor station to match with altered consumption (adaptive be-haviour) to achieve maximum cost effectiveness for the entire compressor station”

The second compressor station includes 1 DSG290-2 8 bar dry-running screw compressor, a 3800L air receiver, and 1 heated DW desiccant dryer. An im-portant component of both stations is the heated DW1053 desiccant dryers that ensure there is no purge loss. There are two purge air outlets; connect-ed to an insulating, descending collective line; thus leaving the compressor room similar to outdoor ambient temperatures.

These highly advanced machines have garnered a quiet satisfaction amongst TATURA’s managers for their smooth and continuous operation. Kaeser Compressors Australia is proud is continue deliver-ing total product solutions to iconic Australian companies.

KAESER matched TATURA’s stringent and inflexible

benchmarks in air quality.

“” Compressed air system investment

Maintenance Cost

Energy Costs

Potential Energy cost saving

LIFE CYCLE COSTWHAT DO YOU EXPECT FROM A COMPRESSOR SYSTEM

Potential energy cost savings through heat recovery

Energy cost savings through system optimization

As a compressed air user, you expect maximum efficiency and reliability from your air system.That may sound simple, but these advantages are influenced by many different factors: Energy costs, for example, taken over the lifetime of a compressor, add up to a multiple of investment costs. Efficient energy consumption therefore plays a vital role in the production of compressed air, as does reliability of the compressor. In many cases, a reliable compressed air supply is essential to guarantee maximum performance from valuable production systems. Reliability also ensures a supply of constant quality compressed air that optimises efficiency of the air treatment equipment downstream of the compressor.

Do you know how much you compressed air costs your company?

Are you satisfied with the servicing and maintenance of your compressed air system?

Do you know the efficiency of your compressed air system? Is it running optimally?

If you’ve answered NO to any of these questions, you need to participate, in Kaeser’s CompressedAir Challenge

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Kaeser Compressors Australia Pty. Ltd.www.kaeser.com.auEmail: air@kaeser.com.auPhone number: 1800 640 611Fax: 03 9791 5733

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