Scheuch: ventilation technology from the market leader goes global

1/2014
emissions
The Scheuch magazine for ventilation and environmental technology
Scheuch: ventilation technology from
the market leader goes global,
4-6
Cement manufacturer AfriSam opts for Scheuch, 8 - 9
Press emissions cleaning: The right system pays off, 11 - 13
Team 7: Decreased energy consumption, increased safety, 16 - 17
CONTENT
10
WOOD BASED PANELS
Press emissions cleaning:
The right system pays off,
11 - 13
Coverstory
Scheuch: Ventilation technology
from the market leader
goes global,
4-6
Improved capacity through
new dedusting and material
conveying system,
14 - 15
ENERGY
Scheuch is expanding: Energy
Industry project team in France,
7
MINERALS
Cement manufacturer AfriSam opts
for Scheuch for EMC dedusting,
8
Clear sign for environmental
protection,
9
Good performance of new
SCR treatment,
10
18 - 19
WOOD
Team 7: Decreased energy
consumption, increased safety,
16 - 17
METALS
New dedusting plant for electric
arc furnace and secondary
metallurgy,
18 - 19
TECHNOLOGY
New compact IMPULS filter,
20
PulseMaster Advanced,
21
THE WORLD OF SCHEUCH
New general manager of the
Industrial Minerals Industry
division at Scheuch,
22
Satisfied customers are our
top priority,
22
FILTRATED OFF
A big anniversary celebration
for staff members and
business partners,
23
Research into the ashes of
exotic fuels,
23
IMPRINT:
Owner, editor and publisher: Scheuch GmbH, Weierfing 68, A-4971 Aurolzmünster, www.scheuch.com
Chief editor: Mag. Christina Hinterleitner
Conceptual design, editorial staff and organisation: ikp Salzburg GmbH, Alpenstraße 48a, 5020 Salzburg, www.ikp.at
Graphic design and layout: Createam, Spittelwiese 5, 4020 Linz, www.createam.at. Creation: Ingeborg Schiller
Photographs: Scheuch GmbH. Print: hs Druck GmbH, www.hs-druck.at. Printing paper: Printed on illustration printing paper
(woodfree, matt) 150 g, typesetting and printing errors reserved. “emissions” is published twice a year.
2
editorial
Alois Scheuch with his son Stefan Scheuch
(right) and Jörg Jeliniewski (left).
Generational handover at Scheuch
Dear business partners,
Last year we celebrated our company's 50th anniversary. We are proud that we can look back on
such successful 50 years and offer our heartfelt thanks to all staff members, customers and
business partners alike. Without you, this success would not have been possible.
We have also made use of this auspicious occasion to set the company on course for a good future.
After 50 years, during which I have shaped and guided the company, it is time to handover to the
next generation: My son Stefan, who has been part of the company since 2008, has taken over as
Managing Director of Scheuch Holding GmbH. Scheuch GmbH, which is responsible for our core
business of air pollution control, will likewise be led by him, together with Jörg Jeliniewski.
With the generational handover and the changes to the basic conditions, we have created a base
from which we, as a strong family-operated company, can make the best possible use of the
opportunities that are opening up all around the world for ventilation technology from Aurolzmünster.
Scheuch is and remains a family-operated company in the best sense: We think in generational
terms and work with passion for our products and technologies. In the future, as now, we will be
a reliable partner for our customers and staff members, with traditional business values. For us,
these are the fundamental requirements for doing sustainable, successful business.
Yours,
Alois Scheuch
Company founder
3
Stefan Scheuch and Jörg Jeliniewski, Managing Directors of Scheuch GmbH,
are increasing their focus on internationalisation and innovations.
Scheuch: ventilation technology
from the market leader goes global
As market leader in the field of ventilation technology, Scheuch
is bringing its technologies to a global market. For this, the
company is expanding its international presence through
new sites. This will also enable Scheuch to support its core
customers, who themselves carry out projects all over the
world. The new company structure, the handover to the next
generation, and the clear commitment of the new supervisory
board have laid the foundations for this growth strategy.
4
Coverstory
"Research and
development is
the nucleus of
our success."
Stefan Scheuch
In the so-called BRICS states, the emerging economies of Brazil, Russia, India, China and South Africa,
attractive expansion opportunities are opening up in
many sectors. These markets are increasingly of interest to Scheuch, too, as specialists in air pollution control and dedusting, since ecological sustainability and
adherence to environmental regulations are gaining importance internationally. "We want to make even better use of these opportunities in future than we have
done to date," says Dipl.-Ing. Stefan Scheuch, Managing Director of Scheuch GmbH, outlining a goal for the
coming years.
Stefan Scheuch is the Managing Director
of Scheuch Holding GmbH.
PERSONAL DETAILS:
Stefan Scheuch (43) studied machine construction
in Vienna and Aachen. While working for Daimler/
Mercedes in Germany and Brazil, he was involved in
the development of the S-Class, among other tasks.
Since 2008, he has been Managing Director for
Technology and Production at Scheuch GmbH.
Strong international presence
Successful family-operated company
As part of the current growth strategy, Scheuch will
establish international sites in all the major regions of
the world. Depending on the size of the new markets,
on-site activities such as sales, project management
and sourcing will be supported by local engineering and
local production facilities.
In the future, Scheuch will continue to be a completely
autonomous, independent family-operated company. "For
us, that means not being dependent on the capital market
and being able to reinvest our profits to ensure that we
continue to develop and grow," explains Stefan Scheuch.
To create a firm foundation for the future, the company –
which celebrated its 50th anniversary in 2013 – has been
reorganized. The role of the Scheuch family is structurally
anchored in the company through Scheuch Holding GmbH,
which is responsible for strategic developments in environmental technology. Scheuch GmbH focuses on global
growth in the existing core business of ventilation technology. "The lean structure ensures rapid decision-making,
short chains of command, flexibility and personal communication," notes Stefan Scheuch. The Group generates
turnover of around 130 million euros per year and employs
around 800 staff members at two production sites and
seven sales offices.
"This strong international presence will put us in a
position to provide our major core customers with detailed professional support on their route to new markets," Dipl.-Ing. Jörg Jeliniewski, Managing Director of
Scheuch GmbH, emphasises. One example of the rapid
and successful implementation of the new strategy is
in France: Scheuch recently opened a new site in Paris
to support the Energy Industry division and the expansion of its activities in this market.
Scheuch is already very active globally, with 75 per cent
of its sales coming from exports. In the last few weeks,
a large order has been completed to provide an EMC filter to AfriSam in South Africa, another example of the
many projects Scheuch carries out around the world.
Trademarks: know-how and experience
Scheuch customers – from tradesmen to industrial en5
Coverstory
"We know our customers‘ production
processes and always look to create
a holistic solution. This provides real
added value to our customers."
low operating costs, increased reliability and
a service relationship lasting for decades.
Innovations from Scheuch
terprises – benefit from the company's knowledge and its 50 years of experience. "Our staff
members in the individual divisions have very
precise knowledge of the respective production processes; as a result, they don't just
focus on the extraction or dedusting but always consider the process as a whole. This
helps us to make use of synergies and exploit
efficiency potentials," says Jörg Jeliniewski.
One example is the patented fibre sifter for
the Wood Based Panels Industry. The good
separation performance leads to better sifting of fibres and hence to improved quality of
the panels produced.
With an in-house technical centre with laboratory, and pilot plants that were created in
collaboration with customers, it is clear that
Scheuch does not just offer state-of-the-art
technologies but, thanks to its innovations
and improvements, is the forerunner for the
entire sector. Scheuch's patented EMC filters
have set global benchmarks in filter technology. The newly developed, energy-saving DeCONOx process enables simultaneous
reduction of nitrogen oxides and organic
carbon compounds. These are just two examples of innovations developed by Scheuch
in Aurolzmünster. "The recipe for our success
is a blend of curiosity and process knowledge.
Being at the cutting edge of technology is, and
remains, the goal we strive for in all sectors“,
explains Stefan Scheuch.
Premium technology with
added value
A passion for
customer-specific solutions
The added benefit of our premium technology
is clear: If you choose Scheuch products, you
will receive the embodiment of 50 years of
success in the construction of several thousand plants in the area of ventilation technology. These are plants that represent energy
efficiency, durability and technical perfection.
It pays dividends. The investment results in
Whether extraction, dedusting, fire protection, pneumatic transport, exhaust or flue
gas cleaning, indoor climate management
or energy efficiency: The more complex the
customer requirements, the more enthusiastically the specialists at Scheuch work to
deliver the perfect solution. Scheuch always
creates a customer-specific package. From
design, through engineering, to production in
the in-house factories, assembly and startup, the projects are looked after at all stages
by the skilled technicians at Scheuch. There is
a benefit to personal contact and traditional
business values, and these are qualities that
will remain trademarks of the company even
as Scheuch develops a global brand. n
Jörg Jeliniewski
PERSONAL DETAILS:
Jörg Jeliniewski (51) studied machine
construction and business administration,
and worked for GEA Group AG in Düsseldorf
for 20 years. He played a significant role
in developing GEA Group into an international corporation. He joined the
Scheuch management board in
September 2013.
6
ENERGY
Scheuch is expanding: energy industry
project team in France
The French market in the area of Energy Industry is becoming
increasingly important for Scheuch. In order to provide the best
customer service, we have now established an office in Paris
and put together a project engineering team.
When it comes to making use of biomass to generate energy, France is currently experiencing the boom that took
place in other European countries ten to fifteen years
ago. Right now, combined heat and power plants using
biomass are being designed and built in many towns and
cities in France. This is a market that is becoming ever
more attractive for the Energy Industry division. Flue gas
cleaning is one of the core competences of Scheuch.
In the past, we have implemented filtration and heat recovery plants with renowned French companies such as
Dalkia, Cofely, Electrawinds and Idex, among others. In
order to expand our presence, it was an obvious move to
set up our own office in France.
Project team in Paris
Scheuch's France team: Franz Söllhinger, Markus Grünseis and
Klaus Emprechtinger (from left), and ...
In September 2013, the new Scheuch office opened in
a modern office building at Charles de Gaulle Airport.
Thomas Le Cointe and François Gallic, both French by
birth and with plenty of experience in project engineering
and plant construction, were appointed as staff members for the office. The two technicians will be on site
at all times, looking after the projects, coordination and
communication with the customers. Service and maintenance of existing plants also falls within their remit.
In addition, the core France team includes Abdel
Berkoune, who has represented Scheuch in this growing
market through his company APitec Sarl for some time
already, and two technical salespeople, Dipl.-Ing. (FH)
Klaus Emprechtinger and Ing. Markus Grünseis, who
will be looking after the French market from the Austrian company headquarters in Aurolzmünster.
A partner for core customers
on their route to France
"Once we started taking on more projects in France, it
quickly became clear to us that it wasn't just about overcoming the language barrier. The French have a different
attitude to project engineering," says Mag. Ing. Franz
Söllhinger MBA, General Manager of Energy Industry,
explaining the decision to set up an operational branch in
… François Gallic, Abdel Berkoune and Thomas Le Cointe
(from left).
Paris. "Now, we are in a good position to provide the best
service to our French customers." The team in France
also has a role in providing assistance to Austrian, German or Swiss companies who have been collaborating
with Scheuch on plants for a long time and who wish
to gain a foothold in the French market. "We want to
support our core customers in their projects by offering
them the chance to collaborate with our French project
engineers," Söllhinger explains. n
7
MINERALS
Scheuch delivered
AfriSam with a turnkey
dedusting system.
Cement Manufacturer Afrisam
opts for Scheuch for EMC Dedusting
AfriSam, the second largest cement manufacturer in South Africa, is
investing to improve its environmental standards. A dedusting system
from Scheuch was recently commissioned at the cement plant in Ulco.
The Ulco contract is not the first cooperation between
Scheuch and the cement concern, who currently operates three plants in South Africa. AfriSam's positive
experience with an EMC filter that was installed in its
grinding facility in Roodeport in 2009 was an excellent reference that gave impetus to the tender for
Ulco. Scheuch was awarded the contract for planning,
delivery and installation of a turnkey dedusting system
that is a part of AfriSam's large-scale environmental
program. An EMC process filter with a bag length of
eight meters was installed.
A remarkable celebration
It was the 200th EMC filter installation – proof that
Scheuch's patented technology (which counts as the
Best Available Technology) has conquered the market. It combines the advantages of online and offline
cleaning, and enables the use of bags up to 14 meters
in length. The new EMC filter allows AfriSam to achieve
8
enhanced separation performance. Scheuch guarantees a filter performance of 10 mg/Nm3 clean gas dust
load at this plant.
Assembly went hand-in-hand
"It was important for AfriSam to keep operational
downtimes as short as possible during disassembly of
the old system and assembly of the new dedusting
system", Project Manager Melanie Hosner explains. The
schedule was tight: Work started mid-April and the new
plant was put into operation by mid-September. The
majority of components were pre-installed on site in
parallel with ongoing production. Cement production in Ulco was interrupted for only one month. The
fact that everything went according to schedule
was also due to the good cooperation with AfriSam
and the local workforce. "This is the type of customer
you really wish for. They provided optimal support
in project handling“, Hosner reports. n
MINERALS
Clear sign for
environmental protection
Robbie Jones took charge of the project
in South Africa for AfriSam. In the interview,
he praised the professional handling and
good cooperation with Scheuch.
The new dedusting system was recently put into operation. What has your experience been up to now?
We were used to just taking a short look at the exhaust
stack to establish whether or not the kiln was in operation. This isn't possible any more. We are very pleased
that there are no longer any visible dust emissions from
the stack, and will be carrying out precise dust emission measurements shortly. These are sure to confirm
what is already apparent with the human eye today.
What are the most important improvements that the
new dedusting system has achieved?
Environmental protection is a key issue in our company. The new dedusting system lets us prove that these
are not just empty words. The plant allows us to use
alternative energies and protect our country's national
resources. Improved gas cleaning enables us to utilize
the full capacity of our cement kiln.
How do you rate the cooperation with Scheuch in
this large-scale project?
Scheuch's approach to communication, cooperation
and its overall professionalism were excellent.
AfriSam had checked out the investments of several
providers and systems initially. What were the primary reasons for choosing Scheuch?
We had received a total of eight offers from different
companies. The most important consideration was
clearly that the plant had to reliably achieve the required dedusting performance levels. In a second step,
the long-term operating costs of each system were
compared with the investment costs. Factors such as
guaranteed service life of the filter bags, pressure loss,
energy consumption and corrosion protection were
also evaluated. Easy operation was a further criterion.
We also asked industry partners about their experience
with the companies we had shortlisted.
Project Manager
Robbie Jones emphasized
the efficiency of Scheuch.
How did you experience project handling and
assembly on site?
There were regular reports on the current project status during the planning and manufacturing phases.
This gave us the certainty that our schedule could
be met. The Scheuch team worked together with the
local team to install the dedusting system. We were
surprised that the installation team was so compact.
But the speed and efficiency of their work demonstrated how experienced the team really was. The
accurate manufacturing of all components also contributed to the rapid work progress. Our team in Ulco
was very committed and did everything to support the
project and ensure trouble-free implementation. At
the same time, our employees were able to familiarize
themselves with the filters and obtain training for
future maintenance work.
Why was the investment necessary?
The old electrostatic precipitator had been running since
1984. Limits have become stricter since then and technology has advanced significantly. The investment is
intended not only as a way to meet the new, stricter limits;
it should also ensure that there is enough scope to increase
production and fully utilize the capacity of the kiln.
How do you see scope for improvement in project
handling or assembly?
Of course, it is always possible to make improvements.
In this case, however, there was really hardly anything
to criticize. The one or two problems we did have were
solved very quickly. What really helped us was the fact
that we were able to bring forward the interruption in the
cement kiln operation by several weeks during the bypass
phase. We had thought that the downtime to connect the
large-scale piping would be longer. All bolt-holes matched
perfectly and assembly went very quickly. All-in-all, the
project was handled professionally and efficiently. n
9
MINERALS
Good performance
of new SCR treatment
In April 2012, Lafarge Zementwerke GmbH in Mannersdorf
started up the world's first semi-dust selective catalytic
reduction (SCR) installation for NOx treatment, made by
Scheuch. The conclusion after 16 months of operation:
The SCR installation is producing good results.
With a production rate of 2,500 tpd of cement clinker,
the rotary kiln at the Lafarge cement plant in Mannersdorf am Leithagebirge is the largest in Austria. The kiln
is designed for low operating temperatures of 290 to
340°C and, as a consequence of the low temperature
level, the dust amount in the exhaust gas is around 150
g/m3. This unusually high proportion of dust requires a
brand new approach.
Lafarge Zementwerke GmbH decided, together with
Scheuch, to start up the world's first industrial semidust SCR pilot plant for NO x removal. The SCR project
was part of an EIA (environmental impact assessment) package including plant expansion and extension
of the alternative fuel approval.
Lower OPERATING costs
The exhaust air from the rotary kiln is prededusted in
a high-temperature electrostatic precipitator (300350°C). Afterwards the gas is passed through the SCR
reactor. As a result of the new process, it is possible
to dispense with the SNCR procedure previously used,
leading to a reduction in production costs – in spite of
increased energy consumption.
No deactivation of the catalyst
"The performance data with the new NO x treatment
are consistently good," explains Alois Hermandinger,
General Manager of the Industrial Minerals Industry
division at Scheuch. After 16 months of operation,
there has hardly been a single identifiable deactivation
of the catalyst. The limits for NO x (200 mg/Nm3) and
NH3 (10 mg/Nm3) could be attained from the start. This
means that since April 2012 Lafarge has reduced its
NO x emissions by 60 % and, as a result, has taken on the
role of global leader in the cement industry.
Despite the good NOx removal, there is still potential for
optimisation concerning the performance of the electrostatic precipitator. The complex dust properties, caused
by the burning process, lead to frequent flashovers in
the electrostatic precipitator. As a consequence, the
dust load over the catalyst is higher, which results in a
higher differential pressure.
Adaption of the catalyst elements
Lafarge has reduced its NOx emissions
by 60 per cent since 2012.
10
Working in close collaboration, Scheuch and Lafarge
Zementwerke GmbH will utilise the winter revision of
the plant to carry out further modifications. "We are
going to use catalyst elements with a larger crosssectional area," Hermandinger says about one of the
planned measures. "This optimisation means we can
further improve the performance of the first semidust SCR installation and achieve the best result in the
process as a whole." n
WOOD BASED PANELS
PRESS EMISSIONS CLEANING:
THE RIGHT SySTEM PAyS OFF
The better the extraction of press emissions, the better it is for the
production process and the air quality in the production hall. This is
just one aspect that is worth considering when choosing a system for
cleaning press emissions. A brief overview for decision-makers.
"Before making an investment decision, it is
essential to really become familiar with the
advantages and disadvantages of the different systems under genuine production conditions," advises Andreas köck, General Manager
of the Wood Based Panels Industry division.
"We advise our customers in the selection
of the most suitable press scrubber system
for their needs, and develop customised
solutions." The modular design of the press
scrubber systems helps to meet the unique
requirements of the customer.
Capturing, transporting and cleaning press
emissions is one of Scheuch's key areas of
expertise. Scheuch is able to offer a wide
range of systems for extracting emissions
and cleanly removing the dust, formaldehyde
and other organic compounds. years of experience, technical expertise and precise series
of measurements mean that Scheuch has
very accurate knowledge of the strengths and
limits of each system. This knowledge is the
basis for perfect reduction efficiency, safety,
system availability and an optimum cost-benefit ratio.
Press
Production
hall air quality
Dust
Formaldehyde
Optimum extraction
100
100
Formaldehyde removal in %
10 mg/Nm3
20 mg/Nm3
SAP
Biosystem
Wet system
Wet electrostatic precipitator
ESAP
Oxidation
SAP incl.
Venturi
20 mg/Nm3
Absorption/Desorption
SAP
Wet system with Venturi
0
Wet system
Dust removal in %
10 mg/Nm3
Therm
SAP+
OxiSAP/
OxiSAP+
BioSAP/
SAP+SABA
0
Optimum extraction of press emissions and removal performance of different press scrubber systems.
11
WOOD BASED PANELS
"By using different extraction
technologies we can achieve the best
result whatever the requirement is."
sions, perfect separation of chips, fibres and
strands, and a clean system in general.
Andreas Köck
SAP (Scheuch press scrubber):
effective emissions capture
The starting point is the SAP press scrubber.
The best result is achieved by starting with
selective and reliable collection of the press
emissions. The more effectively the emissions
are captured, the less dust and formaldehyde
remain in the production hall. This is the only
way to prevent disruptions to the production
run. Efficient extraction of the emissions
also has a positive effect on the overall
air quality in the hall. This is of particular
relevance now, when workplace safety is
gaining in importance.
"Effective collection of emissions leads to
an increase in the pollutant load and thus in
the concentration of pollutants," explains
Köck. "It is therefore important to pay close
attention to the exhaust air cleaning plant
and cleaning of process water." The press
scrubber from Scheuch cleans the process
water through a screen and a clarifier to remove solid particles, ensuring trouble-free
operation of the system. SAP is synonymous
with effective collection of the press emis-
Press scrubbers may be used for precleaning if the emissions are subsequently treated
or burned in central plants. If stand-alone
solutions are required, the system can be enhanced with a range of different modules for
emissions control in order to meet stipulated
emissions limits. While modules such as the
wet electrostatic precipitator stage ESAP
are suitable for dust reduction, oxidative and
biological systems may be a good choice for
reduction of formaldehyde.
Venturi stage removes
marginally more dust
Using a Venturi scrubbing stage can improve
dust removal. However, the high proportion
of aerosols that are insoluble in water (blue
haze) limits the performance of such a system. "You really need to look closely to determine whether there is a good ratio of outlay to
result," Köck advises: “The Venturi stage uses
more energy, but there are only a few cases
where it enables dust limit values to be met
permanently.”
Optimum dust reduction with wet
electrostatic precipitator (ESAP)
The dust and mist collector in the SAP system
can also be replaced with a wet electrostatic precipitator module. "This is particularly
worthwhile if there is no final cleaning sys-
■ Maintenance costs
500.000
■ Waste water costs
Operating costs (euro/year)
■ Steam costs
■ Additives
400.000
■ Power costs
300.000
200.000
100.000
0
System removal
performance
formaldehyde
SAP
<10 %
ThermSAP+
50 %
OxiSAP
50 %
OxiSAP+
70 %
BioSAP
50 %
SAP + SABA
> 70 %
Operating cost comparison of different press scrubber systems for formaldehyde reduction
based on extraction output of 90,000 Am3/h.
12
WOOD BASED PANELS
tem, or if ducting from the press to this system would be uneconomical," explains Köck.
An ESAP procedure guarantees the best possible dust and blue haze removal and is suitable as a final cleaning system. A wet electrostatic precipitator is the safest and most
reliable option for dust removal.
OxiSAP: less formaldehyde through
oxidative water treatment
Formaldehyde can be efficiently reduced by
oxidation agents. The formaldehyde from
the emissions that has been absorbed by the
process water is oxidised directly in the water. The scrubber water retains its ability to
separate and absorb formaldehyde from the
emissions. Without this treatment, the water
would soon be saturated with formaldehyde
and separation would no longer be ensured.
"This system is very simple, and is perfectly
suited to retrofitting in existing plants," Köck
explains. It achieves formaldehyde reduction
of 50 %, and up to 70 % and more can be at-
tained using a technically enhanced version
(OxiSAP+).
ThermSAP: thermal water treatment reduces formaldehyde
In this system, a partial flow of the process
water that is loaded with formaldehyde is
cleaned by stripping in a desorption column.
To do this, the water must be heated with a
heat exchanger – for the most part through
external energy. The exhaust air from the
desorber, which is enriched with formaldehyde – around one tenth of the original air
quantity – must be further treated. One possible option is to burn this polluted air. The
treated water, with a lower concentration of
formaldehyde, is returned to the circuit and
can once more absorb pollutants. "Owing to
the temperature-dependent equilibrium of
formaldehyde in direct exchange with water
and air, there are limits on this system," Köck
points out. Formaldehyde reduction of up to
50 % is possible with reasonable expenditure.
BioSAP: biological cleaning
of the process water
1
Cumulative investment and operating costs (euros)
3.000.000
Th
2.500.000
er
A
mS
P+
Ox
0
(5
iS
%)
+
AP
(7
)
0%
2.000.000
S
1.500.000
SAB
A P+
Bio S
A P (5
1.000.000
S A P (<
A (>
0 %)
10 %)
500.000
0
1
2
3
4
5
)
70 %
The process water can also be cleaned of
formaldehyde and other organic pollutants
biologically. This biological system is characterised by very low operating costs, with
formaldehyde reduction of around 50 %.
Moreover, they are simple to operate.
in-line Bioscrubber (SABA)
A biological final cleaning stage minimises
emissions of formaldehyde and other organic
compounds. It also reduces odour nuisance.
Next to thermal post-combustion, biological
scrubbers achieve the highest degree of
formaldehyde reduction of 70 – 90 %. "However, during operation, biological scrubbers
cost a fraction of the amount of thermal systems," emphasises Köck. n
Time (years)
Total cost comparison of currently available press scrubber systems
for formaldehyde reduction.
Investment costs without the following services: electrics, assembly and start-up;
values in brackets refer to formaldehyde reduction.
1
incl. 50 m stainless steel conduits to the boiler house/burner
13
WOOD BASED PANELS
Improved capacity through
new dedusting and material
conveying system
For Classen – a leading manufacturer of laminate
flooring – Scheuch recently implemented an overall
plan for dedusting of the production plants and
explosion protection. The added value for the operator:
The site became more productive.
Inner filtration courtyard of factory 1 and 2 with the two high pressure conveying pipelines.
14
WOOD BASED PANELS
The Classen Group's major production site is in Baruth,
near Berlin. Around 70 million square metres of laminate flooring currently leaves the factory every year.
Since the demand for Classen flooring is increasing
worldwide, the industrial enterprise decided to expand
its production line. This increase in capacity necessitated additional filtration plants. At the same time the
existing extraction system, with nine filtration plants
for factories 1 and 2, was getting rather outdated and
needed improvement. The material conveying system
had reached the end of its service life. Blockages and
contaminations were constantly causing breakdowns.
The conveying systems required a lot of energy and no
longer complied with the current regulations on explosion protection.
Conversion and new construction
without production standstill
In searching for a suitable partner for an overall plan
for dedusting, Classen opted for the specialists from
Aurolzmünster. Ultimately, they were looking for a proposal to resolve the inadequate existing system and the
associated plant problems, as well as for expanding production. Scheuch was able to provide many references
in the area of wood-based panels; together with their
high level of expertise in consultancy and planning, their
high standard of quality and their adherence to deadlines, this led to Classen choosing them for the project.
"We were impressed by the overall package," emphasises Egon Teubner, who was responsible for the project
on behalf of Classen Industries GmbH. Scheuch was
commissioned with overall site management, from the
disassembly through conversion to the assembly of the
new plants. One important goal: The entire conversion
and new construction should take place without standstill of the existing extraction plants, if possible. "The
boss would not have been happy if we had had to deal
with production standstills," explains Teubner. His positive summation: "We hardly noticed the conversion
taking place alongside normal operation. Implementation on site worked out well."
Overall plan for dedusting
The technical solution is complex: For the purpose of
dedusting the production plants, three additional row
filters were newly constructed in the inner filtration
courtyard of factories 1 and 2, as well as four round
filters. The row filters have an extraction output of
64,400 m3/h, 41,500 m3/h and 30,000 m3/h, respectively.
Then there are four round filters, each with an output of
4,500 m3/h, which are used in place of the previous bunker top filters owing to their optimised intake geometry.
The nine existing filtration plants were reconditioned
and optimised in terms of their function and performance. For example, the discharge system of the exist-
Egon Teubner (maintenance, Classen Industries,
left), Albert Riegler (Senior Sales Manager, Wood
Based Panels Industry, right) and site assembly
manager Mario Könighaus (in the background).
ing filtration plants was improved in order to increase
the availability of the plants.
New high pressure plant
The entire material conveying system was also replaced. The original six low pressure conveying plants
were replaced by one high pressure plant. Dust and
chips from the twelve loading stations are gathered into
one pipe conduit and transported to the silo. So that,
in an emergency, a second high pressure plant – running on standby – can take over the material transport,
changeover points have been incorporated. A third high
pressure plant, more than 500 metres long, transports
extracted material from factory 3 to the inner filtration
courtyard.
The collaboration between Classen and Scheuch on this
project has led to further cooperation. Three dedusting plants are currently being installed in factory 3 in
Baruth, and there is also a follow-up project within the
Group. "The existing old filters are being brought back up
to date by Scheuch," explains Teubner. n
15
WOOD
The filtration plants
were relocated from the
inner courtyard of the
production halls. This
ensures greater safety.
Team 7: Decreased energy
consumption, increased safety
Team 7 Natürlich Wohnen GmbH, based in Ried, Upper Austria,
has had a close partnership with ventilation and environmental
technology specialist Scheuch, based in Aurolzmünster,
for decades. In the last few months they have installed
an energy-saving SEPAS-Plus extraction system.
"We inspire people by bringing real wood and top
quality design into their lives": This is the vision
of Team 7, manufacturer of furniture from
natural wood. Based in Upper Austria, Team 7 has
an export rate of 84 per cent and is represented
on all five continents. For the premium brand
Team 7, market leader for ecological designer
furniture, sustainability is of utmost importance. Company owner Dr. Georg Emprechtinger is delighted: "The new SEPAS-Plus plant
from Scheuch, our long-standing partner, has
enabled us to achieve a significant improvement
for our staff and for the environment."
About a year ago, as part of its energy management programme, Team 7 put power guzzlers
in their sights; the existing extraction system
in the production area was quickly identified as
an issue. The extraction plant, which had grown
over the years and had four intermediate filters
and 23 extraction groups, was no longer state of
16
the art. "Improved energy efficiency, increased
fire and explosion protection, higher capacity
and greater flexibility were what we wanted
from a new plant," explains Stefan Weilbold,
Project Manager at Team 7. To extract the
chips produced during processing, the company
decided on the energy-saving SEPAS-Plus
extraction system from Scheuch. They also
decided to invest in a new plant to deliver
material to the silo, in an innovative exhaust and
recirculating air system for the production hall,
and in safety for the surrounding area with new,
innovative explosion protection concepts for
both the filtration plant and the existing silo.
240,000 m3/h total extraction output
The new SEPAS-Plus extraction system has
two filtration plants and twelve fans, and is designed for an extraction output of up to 240,000
m3 per hour. The air extracted by the individu-
Stefan Weilbold (Team 7, left) and Franz Erler (Scheuch, Senior Sales Manager, Wood
Processing Industry) worked together closely on the implementation of the project.
al machines, together with the dust and chips, is transported to the filtration plant on the roof via a central conduit with patented activation system. There is, in effect, a
continuously working compressed air conveyor belt in the
central pipeline conduit. The single-pipe system is easy to
adapt in the event of modifications to or expansion of the
machinery. The high-performance Scheuch LIGNO IMPULS filters with efficient continuous cleaning ensure a
residual dust content of less than 0.1 mg/m3. In conjunction with the Scheuch residual dust monitoring system,
Scheuch LIGNO IMPULS filters carry the H3 certification mark of the German accident insurance association.
Flexible single-pipe system
"Because of the single-pipe system with patented activation, the extraction air volume is exactly matched to
the actual machine capacity. This ensures high energy
efficiency, close to the theoretical minimum," Ing. Alois
Burgstaller, General Manager of the Wood Processing Industry division at Scheuch, says of the flexible system.
Both the energy consumption and the CO2 emissions are
reducing thanks to the new extraction plant. There is a
saving of around 300 tonnes of CO2 per year compared to
the old plant.
fire and explosion protection
Team 7 places particular importance on fire and explosion
protection. In order to protect the filtration plants and
the silo, as a preventive protection measure a spark extinguisher has been integrated into the central extraction
pipe and into the conveyor pipe. It was possible to relocate
the filtration plants, which previously stood in the company's inner courtyard, to the roof of the production hall.
Should an incident occur, the design includes special pressure relief flaps on the filters to reduce the flame profile,
which would usually be 30 to 40 metres, to just four to five
metres. This is particularly important since the company is
close to a busy road and a school. In the case of the silo,
too, the extent of the flames can be reduced from 60 m
to just 15 m by means of low-turbulence, unpressurised
filling via a rotary valve.
optimising energy efficiency
In order to analyse which extraction system would
be most energy efficient with regard to Team 7's requirements, use was made of an energy index calculation tool,
'SEkT' (Scheuch Energiekennzahl-Berechnungs-Tool), de­­veloped by Scheuch together with faculty Rosenheim.
This tool provides important data about operating
states, savings in energy consumption and CO2, and additional indi­cators, to allow further optimisation during
operation.
heat recovery saves energy
An innovative exhaust and recirculating air system ensures the climate in the production hall is pleasant, with
few draughts. In the summer the cleaned air can be
blown outside by means of a changeover flap, while in
the colder months it can be directed back into the production hall by means of a recirculating air duct. This heat
recovery system with automatic temperature-controlled
changeover saves on additional energy used for heating.
In view of the cramped spatial conditions and the tight
timescale, the project was full of challenges. However,
the plant was ready to be put into operation punctually at
the end of Team 7's annual factory shutdown. "The new
extraction plant means we are well placed for the coming years," Weilbold says , expressing his satisfaction with
the experience. n
17
metall
Dedusting plant for EAF and SMC
Deutsche Edelstahlwerke GmbH in D-58452 Witten.
New dedusting plant for electric arc
furnace and secondary metallurgy
Two dedusting plants from Scheuch have recently been
put into operation in the Deutsche Edelstahlwerke
Witten (DEW) steel mill. With this installation, Scheuch
has set new benchmarks in terms of energy efficiency and
air pollution control in secondary metallurgy. It was one of
the largest orders in the company's 50-year history.
It was a project with many challenges: As part of a comprehensive investment programme to modernise the Witten
site, DEW was also replacing the entire dedusting plant for
the steel mill. At the Witten site, scrap is smelted into crude
steel, which is processed into high-quality stainless steels.
Scheuch received the order for the planning, supply, assembly
and start-up of two complete dedusting plants. "It was our
biggest order in the steel industry to date. The numerous
challenges were resolved successfully owing to the close
collaboration between all involved," explains Dipl.-Ing.
Manfred Lixl, General Manager Metals Industry division.
Perfect collaboration
Scheuch was able to complete the final phase of construction in the secondary metallurgy centre (SMC)
18
in Witten in the summer. Since then, the plants have
been producing top results in terms of dedusting and
are running very satisfactorily. "It couldn't have gone
better. The collaboration with Scheuch was fantastic,
from planning right through to completion," recalls
Dipl.-Ing. (FH) Gregor Ebbers, Project Manager at
DEW. The basic conditions were anything but simple:
The existing steel mill operation had to keep running
during assembly of the filtration plants. The cramped
spatial conditions and the structural engineering of the
building represented major challenges for construction
site logistics. As well as the emissions limit values that
were to be adhered to, DEW placed great importance
on the energy efficiency of the plant. It would have
to be possible to adapt and optimise the air quantities
in line with the capacity of the factory. A prerequisite
METALS
our energy consumption considerably," explains Ebbers,
adding: "Moreover, we were able to improve the climate
in the hall, too, so providing a more pleasant working
environment for our employees."
Challenging assembly
The new dedusting plants
deliver very good results.
was that the annual emissions total must remain the
same, despite the significantly higher overall exhaust
air quantity resulting from the new plant. Moreover,
the dust they were confronted with was of a complicated nature: The dust that arises during the smelting
of scrap has very special properties and is very difficult
to transport.
Two EMC filtration plants
After a lengthy design phase, a customer-specific
dedusting solution was developed with DEW for the
existing 100 MVA electric arc furnace (EAF) and the
SMC, with two EMC filtration plants. The existing
electrostatic precipitator was replaced with a stateof-the-art filtration plant from Scheuch, and the existing gas conditioning tower was reintegrated. Scheuch
had previously constructed a new silo system for the
accumulating dust in order to make space for the new
plants. The first EMC filter was installed in the summer
of 2012. "After one year of operation, we are achieving
clean gas dust values less then 1 mg/Nm3. The result is
impressive from an environmental perspective," says a
delighted Ebbers.
The dedusting plant in the SMC has been operational
since the summer of 2013. "The two dedusting plants
each have an air output of 630,000 m3/h," notes Ebbers.
Despite the very cramped spatial conditions, it was
possible to accommodate the entire electrical engineering plant in the existing bulk goods hall.
High energy efficiency
High energy efficiency is ensured by, among other
things, the pipe system in which the emissions (from
the ladle furnace, rinsing station, skimming station,
alloying plant, hall extraction system) are passed, via
separate pipe conduits, to the collection duct for the
EMC filtration plant. The pipe conduits are connected to, or disconnected from, the individual units via
shut-off flaps, depending on the air output requirement. "It only extracts as much as is necessary, where
it is necessary," Lixl says of the system designed by
Scheuch. The use of electrostatic precipitators (dedusting plant for the EAF) means steam is no longer
needed for gas conditioning. "We were able to reduce
The order was very complex and demanding for the assembly team. "The fact that everything went so well
is also down to the great performance of our assembly partner, SGS INDUSTRIAL SERVICES," says Lixl.
Ebbers praised the team, too: "We were constantly
ahead of schedule. It went as well as we expected."
Assembling the piping and filtration plants on top of
the steel mill halls was a challenge. Space was very
limited and the structural engineering of the hall was
complicated. For example, a rotating tower crane was
required in order to rotate the piping components at a
height of 50 m to clear the top of the existing chimney.
There were a total of around 300 truck deliveries to the
Witten site. The parts for the plants had a combined
weight of around 1,300 tonnes. "It was important to us
that our supplier was manufacturing a large proportion
of the parts in-house, so that there were no problems
during assembly," says Ebbers. "This really paid off. In
view of the complex situation, everything went like
clockwork." His conclusion: "Scheuch was an excellent
partner for us!" n
Dedusting in secondary metallurgy
The increased requirements of materials technology (steels with a high degree of purity) necessitate an intensified use of secondary metallurgy
plants for the precise implementation of alloying
specifications and carbon and gas contents in the
steels. These plants, which are situated between
the steel mill machinery (oxygen or electric steel
mill) and the casting machinery, are often retrofitted into existing production lines in cramped conditions. Secondary metallurgy also reduces the
load on the primary units, as certain processing
steps can be transferred to secondary metallurgy
– with associated increase in production.
“Scheuch is following this trend with space-saving, customer-specific plants for energy efficient
extraction and dedusting technology. Through
selective, needs-based control of the extraction
points, it is already possible to achieve a solution
that is beneficial both in terms of investment and
operating costs with one single dedusting plant.
By creating this dedusting solution for DEW,
Scheuch has implemented a flagship project in
secondary metallurgy," explains Lixl. n
19
TECHNOLOGY
New compact IMPULS filter
Powerful, efficient, flexible, space-saving and
quick to assemble: With this new IMPULS filter,
Scheuch is launching a pioneering system for a
wide range of industrial applications.
In the past, when it came to high-performance cleaning, round bag filters were technically highly superior to
the flat bag filters previously available on the market.
With the new IMPULS filter, Scheuch has developed an
innovative system which combines space-saving filter
geometry with the tried and tested Scheuch IMPULS
cleaning system and provides equivalent filtration performance to the highly efficient Scheuch round bag filters. This compact filter is part of a modular production
series system that makes it ideally suited for mediumscale volumetric flows of 6,000 to 200,000 Am3/h and
many industrial applications.
amount of research effort went into developing a new,
already patented injector nozzle and bag seal. This optimised injector system ensures the best possible regeneration of the filter elements, contributing to low
differential pressure and to the operational safety of
the filter.
Convenient maintenance
Another advantage of the patented support cage injector system is that the injector, the support cages
and the filter bags can be fitted and replaced simply,
without tools.
Space-saving and efficient
Short assembly time
In particular if there are awkwardly shaped spaces,
cramped footprints or low installation heights, the
new IMPULS filter comes into its own. Where there
is filter surface loading, differential pressures or the
use of compressed air, this is on a par with the reliable
Scheuch IMPULS filters with round bag geometry. The
inflow into the filter and the flow speeds in the filter
casing are optimised by means of CFD simulations and
trials in the in-house technical centre. This ensures
good pre-separation and very low differential pressure
in the filter.
Patented injector system
The tried and tested injector system has been further
developed for the compact IMPULS filter. A large
Type
fi m14/07_29
fi m14/10_29
fi m14/10_29
20
A fundamental advantage of the new filter is the
rapid assembly since isolated components, such as
the filter casing, the filter head, the trough or hopper
and the crude and clean gas ducts, are prefabricated
and need only be assembled on-site. This reduces the
assembly time by up to 70 % compared to other systems.
Outstanding results
Extensive application testing in the first reference
plants – for example in the Metals, Energy and
Minerals Industry – have shown that the new
compact IMPULS filter is very reliable and endures
long lifetimes. n
Filter surface
[m2]
Unit
[Quantity]
Width
[mm]
Length
[mm]
Volumetric flow
[Am3/h]
135 - 388
1-2
2,070 - 2,810
1,400 - 2,600
6,000 - 40,000
405 - 675
3-5
2,070 - 2,810
3,800 - 6,200
18,000 - 69,500
776 - 970
4-7
2,070 - 2,810
5,000 - 8,600
34,500 - 100,000
1,080 - 1,350
6 - 10
2,070 - 2,810
7,400 - 12,200
48,000 - 139,000
1,358 - 1,970
7 - 10
2,810
8,600 - 12,200
60,500 - 200,000
TECHNOLOGy
PULSEMASTER ADvANCED
With the PulseMaster Advanced control
unit, Scheuch is launching a new era of
filter management. The new generation
device is powerful and user-friendly.
Control units are a key component in the efficient filtration plants from Scheuch. They are used in anything
from simple extraction units to complex process dedusting systems. In recent months, Scheuch has developed a new control unit in connection with the new
compact IMPULS filter – the PulseMaster Advanced.
SimPle OPeratiOn
The new generation device is fitted with a powerful
processor and touchscreen with full graphic display,
and comes with a user-friendly menu navigation. In order to avoid errors of comprehension in a global workplace, there is a strong reliance on the use of representative symbols and images. The texts can be
implemented in different languages on the request of
the customer.
The new PulseMaster Advanced control
unit is very easy to maintain.
new ranGe Of COntrOl unitS
“Following the successful introduction of the PulseMaster Premium and the current launch of the PulseMaster Advanced, in the medium term there will be
only three control units for our filtration plants, which
will cover the entire product range and all requirements. The need for employee training, spare parts
management, and susceptibility to errors will thus
be reduced to a minimum,” notes Ing. Michael Auer,
Development and Production of Control Units. n
Scheuch developed the new control unit in connection with
the new compact IMPULS filter (in the picture).
mOdular StruCture
The control unit has a modular structure. In principle,
it can cover up to four filter units. Up to 15 power modules can additionally be connected via a serial bus system (CAN bus), corresponding to a further 60 units. The
filter control unit can be integrated into the customer's
preferred bus environment by means of an optional
fieldbus interface.
SimPle maintenanCe
Great value is placed on simple maintenance of the
control unit. So, for example, a backup copy of the
settings can be saved to a USB stick, and restored
if necessary. Passwords prevent unauthorised access
to the settings. Potential problems can be solved
quickly by remote maintenance. In many cases, this
eliminates the need for a service technician to travel to
the site.
OPtiOnal SenSOr mOduleS
The new control unit can optionally be enhanced with
sensor modules. This makes it possible to gather all
plant-specific data for measurement and control engineering in the environment of the control unit.
21
THE WORLD OF SCHEUCH
New general manager of
industrial minerals
Alois Hermandinger (40) has taken on the leadership of
the Industrial Minerals Industry division at Scheuch. A
native of Upper Austria, Hermandinger has worked at
Scheuch since 1989 and has a significant amount of international experience. He is highly skilled at providing
advice in the field of dedusting and filtration. As Senior
Sales Manager for the Industrial Minerals division, he
was responsible for Central and South America, the
Near and Middle East as well as for Switzerland and
the CEE/SEE states, among other tasks. "Together with
my team, I will push forward the internationalisation of
the company in the area of Industrial Minerals," states
Hermandinger. He also believes it is important to expand
the role of Scheuch as a technological front runner,
through innovations such as the new DeCONOx process
for the combined cleaning of nitrogen oxides and orga-
Alois Hermandinger
has been leading
the Industrial
Minerals Industry
division at Scheuch
since March 2013.
nic compounds, and to address customers on an equal
footing when discussing the best solution for their
situation: "We know the production processes inside out
and are a reliable partner, supporting our customers for
the entire plant lifecycle." n
Satisfied customers are
our top priority
Customer satisfaction is made up of many elements. Scheuch
is aiming to further improve adherence to deadlines and
reliability with the new CPM project management system.
For an order to be concluded to everyone's satisfaction
and for all deadlines to be met, dozens of processes need
to run perfectly in the background. The more complex
the solutions being provided to the customer, the better
the processes need to be coordinated and mesh with one
another. This requires a lot of communication and documentation.
for industrial enterprises, where several departments and
teams within Scheuch work together, it is necessary for all
involved to be informed about the precise requirements,
their responsibilities and timescales on a daily basis. The
new project management system also facilitates the increasingly important process of providing ongoing reports
to the customer as to the current status of the order.
Optimum adherence to
deadlines, utmost quality
Continuous process of improvement
For this reason, Scheuch has recently implemented a
standardised project management system in order to
improve the coordination of internal processes even further, right from the initial customer request through to
the end of the guarantee period. Internal communication
and responsibilities are clearly set out. The intention is to
increase Scheuch's reliability even further when it comes
to the scheduling and quality of order processing. Particularly in the case of highly complex specialised solutions
22
This standardisation of customer project management
is just one example of how important customer satisfaction is to Scheuch. This extends right from providing
well-grounded advice in advance of a project, through production and assembly, to post-project support. The fact
that Scheuch is responsible for production and assembly
is an additional advantage in ensuring high-quality project
engineering. In terms of ensuring project outcomes, the
project closure meeting is a very important part of the
company's continuous process of improvement. n
FILTRATED OFF
Dr. Josef Pühringer,
Governor of Upper Austria,
taking a tour of the
production facilities in
Aurolzmünster with
Alois and Stefan Scheuch.
A big anniversary celebration for
staff members and business partners
Everything that Scheuch has achieved in the last 50
years could not have been accomplished without the
help of engaged, reliable and competent staff members.
In order to appropriately recognise this tremendous
service, the celebrations to commemorate Scheuch's
50th anniversary were devoted first and foremost to the
company's staff. Around 1000 employees, business
partners and guests of honour from politics and business accepted the invitation to an evening celebration in
the company's headquarters in Aurolzmünster. In the
course of the elegant celebration, company founder
Alois Scheuch received the Silver Decoration from the
state of Upper Austria. The 50th anniversary medal was
presented to the company by Kommerzialrat Dr. Rudolf
Trauner of the Upper Austrian Chamber of Commerce.
The anniversary celebrations were rounded off with an
open day attended by around 3500 people from all over
the region. n
Research into the ashes
of exotic fuels
Different countries, different biomass fuels: While biomass combined heat and power plants in Central and
Eastern Europe mainly burn wood and waste wood, in
Southern Europe, Asia and South America it is common
to use straw, coconut shells, rice husks, sunflower seed
husks and olive stones as raw materials for generating
energy and heat.
The ashes from these fuels have different properties:
The melting point may be substantially lower than that
of wood ash, or the dust resistance may be considerably
higher. The danger here is that this may lead to partial
melting in the separation plants. Dust resistance must
also be known in advance, as it is an important influencing variable on electrostatic precipitator design.
In order to learn more about the properties of ash from these biogenic fuels,
Scheuch sponsored a thesis on the subject.
Michael Adlmannseder, a student on the undergraduate degree course "Bio and Environmental Technology"
at the University of Applied Sciences Upper Austria, spent
his student placement at Scheuch where, for his final year
project, he carried out a chemical analysis and evaluation
of ash samples from a range of exotic fuels. The title of
the thesis is "Determining the dust resistance of biomass
ashes and the correlation to their constituent materials".
The results form the basis for future improvements in the
dimensioning accuracy and technical safety of flue gas
cleaning systems for combined heat and power plants in
which such exotic fuels are used. n
23
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