Our solutions
Atlas Copco Rental
Solutions
Rental Fleet
Atlas Copco Rental
Accessories
Rental Fleet
Oil-free air compressors
Rental Fleet
Oil-free air compressors
Oil-free air compressors
Oil-lubricated air compressors
Rental Fleet
Oil-lubricated air compressors
Oil-lubricated air compressors
Industries served
Compressors
Solutions
Products
Compressors
Industrial condensate treatment solutions range
Products
Industrial condensate treatment solutions range
Industrial condensate treatment solutions range
Industrial condensate treatment solutions range
Process gas and air equipment
Products
Process gas and air equipment
Process gas and air equipment
Process gas and air equipment
Industrial Tools & Solutions
Solutions
Industries Served
Industrial Tools & Solutions
Aerospace
Industries Served
Aerospace
Aerospace
Aerospace
Aerospace
Foundries & Metal Fabrication
Original equipment manufacturer
Industries Served
Original equipment manufacturer
Original equipment manufacturer
Original equipment manufacturer
Original equipment manufacturer
Industries Served
Industries Served
Products
Industrial Tools & Solutions
Air line accessories
Products
Air line accessories
Air line accessories
Air line accessories
Drilling solutions
Material removal tools
Products
Material removal tools
Material removal tools
Material removal tools
Material removal tools
Material removal tools
Material removal tools
Material removal tools
Material removal tools
Material removal tools
Service
Industrial Tools & Solutions
Atlas Copco service solutions
Service
Atlas Copco service solutions
Atlas Copco service solutions
Atlas Copco service solutions

Oil-free centrifugal blowers ZB VSD save Weser-Metall yearly up to 60MEUR

The lead recycling plant of Weser-Metall GmbH in Nordenham, Germany is unusual. Not only does its compressed air control unit use volume flow as the reference variable (rather than pressure) it is also uniquely energy-efficient, saving up to 600,000€ in energy costs.

Afterburning air at Wesermetall GmbH

Weser-Metall specializes in recycling lead, especially from battery scrap and battery paste. The plant purchased six new oil-free centrifugal ZB VSD (variable speed drive) compressors from Atlas Copco, which are flow-controlled, within a range of 1500 to 10,000 Nm3 (standard cubic meters) per hour with up to 1.95 bar excess operating pressure.

“Our requirements are totally different”, explained Timo Tesch, manager of design/process engineering/ancillary operations at Weser-Metall. The lance immersed in the furnace in the liquid slag experiences fluctuating counter pressure at its tip. In order to keep the metallurgic process securely under control, it is absolutely necessary for us that we can securely provide a specific constant volume flow at any time. Also, operating conditions change very quickly, requiring rapid intervention and readjustment.”

customer_wesermetall_ZB VSD

“ The new compressed air installation is now so flexible, powerful, and user friendly, that they have met our, admittedly, high demands. As far as I am aware, this kind of installation is unique worldwide. We save € 500,000 to 600,000 on energy costs per year with our new compressed air station. ”

Timo Tesch , Manager of design/ process engineering/encillary operations at Weser-Metall.

Low pressure air around the clock

Compressor room_Wesermetall GmbH

The air from the turbos is provided 24 hours a day – blown together
with natural gas and oxygen through a lance immersed in the molten mass,
maintaining the metallurgic process in the immersion melting furnace. Parallel
to this, after-burning air is fed into the furnace via the molten bath to ensure
that no reactive components, such as non-combusted natural gas, end up in
the exhaust.

When the Nordenham lead works converted from the coke-fired melting shaft furnace process to the more environmentally-friendly natural gas-fired immersion melting furnace process in 1996, a two-stage turbo compressor (first stage 0.82 bar; second stage 2.8 bar) was installed for processing and after-burning air, but it was always felt this could be more efficient.

Unique ability to regulate flow volume

Weser Metall GmbH

Ultimately, rising energy costs and better compressor technology prompted the purchase of the brand new ZB centrifugal air blowers with VSD direct drive from Atlas Copco. The problem for Weser-Metall, however, was the lack of any references for those kinds of applications. Although ZB turbos were used in wastewater treatment plants, they were always pressure-controlled and not flow-controlled.

Clean water. Swedish reliability Blowers Class 0 Centrifugal oil-free Process industry Oil-free compressors Compressor Technique