Siemens Automation Solutions: ABC
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Siemens Automation Solutions: ABC
Aeration is the process by which compressed air is forced through a liquid or substance, normally from the bottom of a tank, in order to reach a certain level of dissolved oxygen concentration. This method is mandatory for all biochemical production processes but also used commonly in wet flue gas desulfurization units. These different production processes have one general requirement in common: the process control is linked to the flow control of the compressor which must respond exactly and stay within small tolerances even at varying compressor inlet conditions. Siemens supplies specialized, highly-efficient and reliable single stage centrifugal compressor packages for your aeration needs, satisfying these demanding requirements.
Siemens has installed more than 6,000 aeration applications worldwide and has saved 675 MW in excessive energy consumption when compared with alternative technologies, resulting in a saving of 2.9 million tons per year of CO2 emissions.
We offer choice!
Siemens is one of few suppliers offering a comprehensive portfolio of integrally-geared, separately-geared and direct-driven turbocompressors combined with application related special solutions. Our product portfolio covers the full range of 1.500 – 120.000 Nm3/hr air flow with differential increase from 0.4 up to 2.5 bar(g).
As each compressor technology has specific advantages and disadvantages, our sales specialists will objectively select the best suitable technology based on total cost of ownership and your project and plant specific requirements.
Fully customized turbocompressor package
Integrally geared STC-GO
Pre-engineered plug & play turbocompressor package
Integrally geared STC-GO(c)
Direct driven STC-DO
Aeration Automation solutions
Master control system (MCP) for controlling multiple compressors
Air Bio Control (ABC) to control & master the aeration distribution system based on dissolved oxygen or ammonium control
Upgrades & revamps
Modernizations & replacements
A dedicated and responsive team of more than 300 specialists within our Aeration Competence Center offers you a wide portfolio of integrally geared and direct driven turbocompressors for your aeration needs. The groups headquarter with R&D, production and execution is located in Helsingør, Denmark with subsidiaries and packaging network around the world (the core of the group is former HV-Turbo A/S).
Sales, engineering and project management teams specialize in developing the right package and solution choice with customers for each project and plant requirement.
With more than 7.000 aeration tubrocompressors installed in more than 2.300 plants around the world, our group is the market leader in high efficient aeration compressors in the waste water treatment (WWT) and flue gas desulphurization (FGD) market.
Together with our customers, we have saved the industry 675 MW in excessive energy consumption when compared with alternative technologies, resulting in a saving of 2.9 million tons per year of CO2 emissions.
The Siemens aeration compressor technology is providing aeration for municipal WWT plants in major cities, cleaning the waste water of some 450 million people. A few major cities utilizing Siemens equipment today:
The high efficiency Siemens Single Stage turbocompressors are customized to the individual requirements of the applications below (API requirements and certifications, xxx).
Special application solutions and the expertise of our large installed reference base are available to our customers to tailor the right solution to the process and plant requirements.
Siemens has decades of experience in turbocompressor technology and aeration know-how, with more than 7,000 units now in operation world-wide.
Siemens provides complete air-supply systems for wastewater-treatment plants, thus ensuring effective integration of the aeration process with the other down-stream processes in the plant. This makes it possible to achieve full end-to-end control, avoiding bottlenecks and boosting efficiency at every stage.
The prime advantages of the system solutions include:
The aeration process consists of three central control loops that – when fully integrated and fine-tuned – ensure smooth, efficient operation of the aeration system.
Increasing demands for quality and tougher legislation on environmental issues create needs for the best possible control of the aeration process. Experience from a large number of wastewater-treatment plants has shown that the right choices for control systems and solutions rapidly give full pay-back in terms of energy savings and ensure full compliance with legal requirements regarding the effluent. With the rapidly accelerating automation of waste water treatment plants, choosing the most appropriate technology is no longer sufficient. It is now increasingly important to identify the overall configuration that provides maximum efficiency, via integrated system design.
Most aeration systems are controlled on the basis of measurements of the dissolved oxygen in the aeration tanks. The settings of the air-flow control valves are based on these measurements. It is possible to achieve considerable additional improvements in control of the aeration system by also including such parameters as ammonium control to determine the oxygen set-point. This results in a lower average air flow and makes it possible to comply with both current and future environmental requirements world-wide.
To minimize power consumption, the header pressure is kept as low as possible by monitoring the control-valve positions. During peak loads, the header pressure is increased in order to provide maximum air flow. Under part-load conditions, it is reduced to keep power consumption to a mini-mum. This enables continuous adjustment of the total delivered air flow to match requirements exactly. An unlimited range of different processes can also be linked to the main air header, thus facilitating control of many additional sub-processes Main-header pressure control. The aeration tanks are supplied with air flow through a main-air header. This is kept at a constant pressure by regulating the compressors between 40–100% capacity.
The Siemens ABC Panel is designed to ensure the efficient, reliable control and monitoring of the complete air supply system – automatically and/or remotely, if required. The ABC system uses a standard Programmable Logic Controller (PLC), running customized, job-specific software, to monitor and control the complete air-supply system for aeration and compressors as one highly efficient, integrated system. A standardized Profibus DP master interface is fitted for communicating with multiple Local Control Panels (LCPs).
Where several aeration cells are auto-mated to provide varying air flow, flow controllers can be added to control each air flow control valve with a fine-tuning sub-loop, enabling set-point adjustment via the dissolved oxygen level. A system that monitors multiple process variables must be designed and implemented to ensure reliable, long-term operation.
Each wastewater treatment plant operates differently, with individual characteristics and requirements that result in widely differing operating cycles.
Prior to any design work, Siemens experts therefore carefully investigate and analyse the overall operating philosophy behind the hourly, weekly and monthly running of the existing plant and aeration efficiency. This enables Siemens to provide the system designs best suited to system requirements, such parameters as flow- control valve- opening times – all items that play a crucial role in ensuring mini-mum downtime and highest efficiency.
When Siemens deals with your air flow requirements – both current and future – you benefit from the total sum of our experience from more than 6,000 single-stage turbocompressors throughout the world. We know that it is essential to focus on the correct dimensioning of the aeration system as a whole in order to avoid in-efficient operation and unnecessary costs.
Siemens is uniquely capable of designing aeration systems that exactly match your present needs, while also taking future requirements into consideration. We spend time with your consultants and plant operators to understand your needs in full and to integrate our know-how with yours in order to find the most effective form of control. The right solution yields considerable savings up front, as well as greater efficiency in all the other processes that inter-face with aeration.
An automated air-supply system assures the lowest system-operating pressure, thereby keeping power consumption to the minimum.
Continuous monitoring of process variables such as dissolved oxygen, ammonium ensures the lowest air flow delivery, optimizing the aeration process and minimizing power consumption. Precise, continuous air-flow control makes it possible to enables maximization of the more complex nitrification/denitrification process, as required in the most modern aeration processes.
Air-supply system automation eliminates the need for direct operator intervention and optimizes process control, ensuring superior effluent quality.