The investment at the Warendorf site, the so-called “Technology Center Plastics”, became necessary when an old closed system from Miele with a hybrid evaporative cooler was sent into well-earned retirement after 25 years. The new solution enables the provision of water at a temperature of 30 °C even at high outside temperatures of up to 35 °C.
In the system used by the group until then, the water came into direct contact with the ambient air and led to a high level of dirt entering the treated make-up water. This is because the cooling principle is based on the evaporation effect. Water is continuously lost in the process. In addition, the circulating water must be elaborately filtered and inoculated with water additives. Extensive monitoring due to an increased risk of contamination, for example with legionella and other bacteria, makes this an increasingly important and maintenance-intensive task.
The alternative to open cooling systems are closed free-cooling systems that dissipate heat to the environment via an air-water heat exchanger. They come within about 5 Kelvin of the outside temperature. So if a water supply temperature of 30 °C is required, this conventional technology will work without any problems up to an outside temperature of 25 °C. If it is warmer outside, additional cooling must be added via spraying, the addition of city water or an additional refrigerating machine in order to maintain the 30 °C water supply temperature.
The special feature of the new Reisner solution is its combination with the PAD system, which also enables cooling at high outside temperatures via humidified honeycombs. This not only saves Miele time and money, but also meets the company’s own demand for high-quality solutions. Alexander Wibe, Head of Plant Technology, describes this as follows: “We were looking for an energy-saving solution that also leaves nothing to be desired in terms of technology. The cooling system had to be of high quality and rely on well-known components. Low-maintenance, reliable and efficient, coupled with a 24-hour service in the event of an emergency – that was the overall package required.”
From Warendorf, the company supplies all appliance plants of the Miele Group. The product range includes complex assemblies such as washing machine doors or dryer sieves, multi-component parts and parts with high-gloss surfaces such as hoover housings. According to its own statement, 60% of the plastic parts installed in German Miele appliance plants come from Warendorf. In addition, the plant, which was founded in 1975 and employs around 300 people, oversees plastics production at Miele sites in Uničov (Czech Republic), Dongguan (China) and Ksawerów (Poland).
The decision in favour of Reisner was ultimately an easy one: “From costs to technology to comprehensive service, Reisner offered the best package,” says Wibe. In the uncomplicated and customer-oriented planning phase, the Reisner project team explained which individual solution they would like to use.
Close partnership with individual solution
The special feature is the closed system in which a V-shaped, self-draining free cooler is installed. The honeycomb structure of the PAD system is only moistened with city water when high outside temperatures of around 25 °C and above make this necessary. When the air flows through this structure, it cools down – as is usual with adiabatic cooling. Then the process heat is dissipated to the cooled air by means of a CU/Al heat exchanger (not by evaporation).
“The decisive factor here is that the spraying water does not come into contact with the heat exchanger. The heat is almost completely dissipated via the air, making the system a reliable and cost-effective cooling solution.”
– Günter Sareyko, Head of Sales at Reisner Cooling Solutions GmbH
In total, the new system offers a recooling capacity of up to 500 kW and reliably ensures the desired process temperature at up to 35 °C outside temperature. Reisner has also thought along when it comes to maintenance. Easy replacement of the PADs, which already provide a service life of three to five years depending on use, was just as important as minimised water consumption and the use of durable materials.
“Miele not only saves energy through its special design, the components themselves are also designed to be energy-saving,” says Reisner. The fail-safe dual-pump system with a volume flow of up to 87 m³/h is speed-controlled, as are the 14 fans with EC motors. The humidification itself is also multi-stage. The built-in return filter works completely pressureless and can be changed during operation. Reisner thus reduces the energy required in each process step to a minimum.
After the system has been running since October 2020, Wibe is more than satisfied: “The quick delivery and commissioning during operation without the installation of rental refrigeration were optimal. Reisner always worked cleanly and conscientiously, so our expectations were absolutely met.” This also includes, for example, the control cabinet construction according to Miele specifications or the uncomplicated communication during the entire project.
Wibe is not yet able to precisely quantify the cost and time savings, but is very positive after the first experiences. “The early findings show that energy consumption has dropped significantly. The plant runs very stably and we have managed to completely dispense with the use of chemicals.”
Additional optimisation with full-flow filtration
The group’s high standards are also evidenced by the decision to use an additional filter solution and chemical-free water treatment. Even after a short period of use, the water quality showed a steady improvement due to the water treatment with full-flow filtration in the return flow. The system dissolves lime and corrosion compounds by means of low-frequency electromagnetic alternating fields. These can then be filtered out of the water accordingly. “Miele stands for quality. We are therefore very pleased that we can contribute to this image with our cooling expertise,” Günter Sareyko sums up.
Pump innovations at Nordbau 2021
After the Covid break, many suppliers are returning to the stage now that trade shows can finally take place again. Consistently present in Neumünster: Tsurumi from Düsseldorf. As a novelty, the pump market leader presents the HS3.75SL, henceforth the most powerful model of the series.
The HS is for everyone and everything, they said. Tsurumi is positioning it as a universal helper for dirty water. It meets a highly competitive field not only in the construction industry, but also in the trades, industry and municipalities. However, it is competing there with the best prerequisites. The company therefore encourages product comparisons.
Particularly noteworthy is the performance of the small submersible pump: Compared to the previously strongest model of the series, the flow rate has practically doubled, to 580 l/min now. The HS3.75SL can maintain this value at a constant level. Components are responsible for this. For example, the efficient oil distributor, which reliably lubricates the unit in any position. The double internal mechanical seal made of ultra-hard silicon carbide also contributes to the long service life. Electrical damage caused by creeping moisture is rare anyway: The supplier hermetically encapsulates each conductor in potting compound.
The pump is considered safe to run dry and does not require supervision. Users can carry out maintenance themselves if they wish – Tsurumi’s simple modular design is a real system advantage.
By the way, the dimensions have not changed. However, the manufacturer has had to adjust the elbow at the outlet to handle the flow rate. Many other values also remained the same, such as the motor power (0.75 kW). As before, the pumped medium is discharged to the side in a spiral, which is good for sand water and mud. The scales indicate a dry weight of only 19.6 kg, despite the robust housing made of spheroidal cast iron GGG70. The overall unit height is only 45 cm, and the housing diameter is a slim 18 cm. In this respect, almost everything is the same, but much more powerful: Who wouldn’t like that?
At its booth in the outdoor area West-W210, the company will also be showing other universal pumps and providing information on the special design features of the Japanese pumps with interesting technical models.
World Refrigeration Day 2021 sponsored by Refrigeration Solutions
Sustainable cooling solutions for the benefit of future generations
Proper cooling has a great importance for sensitive goods in various application areas. High-quality cooling solutions can therefore create safe and sustainable environments. Viessmann Refrigeration Solutions is supporting World Refrigeration Day for the third year in a row. This time, the event will take place on June 26 and aims to raise awareness of the importance of refrigeration, air conditioning and heat pumps.
Why is refrigeration important?
The global Covid 19 pandemic has shown us how important a safe environment is for people as well as the planet. Refrigeration plays a key role in many ways: whether it’s storing life-saving vaccines or blood transfusions at the right temperature, or maintaining the cold chain in food retail and foodservice to ensure food safety and ultimately reduce food waste. With the sponsorship, the company, as one of the leading manufacturers of refrigeration solutions in Europe, aims to share and contribute its knowledge and experience in this field.
“Our goal is to create a safe environment for sensitive goods and operations. We focus on future-proofing solutions and delivering lifecycle support to redefine our customers’ business and their environmental impact.”
– Frank Winters, CEO of Viessmann Refrigeration Solutions
Focus on the people behind the ‘cool careers’ This year’s World Refrigeration Day looks at careers in the industry and is themed “Cooling Champions: cool careers for a better world.” The aim of the campaign is to inspire students and young professionals in all countries, both women and men, to meet society’s challenges by pursuing careers in this important sector. The Group is participating in the campaign to advocate the importance of refrigeration specialists to the well-being of society.
The company offers young professionals career opportunities in a business that is strongly driven by the goal of creating living spaces for generations to come. The digital event is designed to provide insights into the refrigeration industry and the exciting job opportunities that this sector offers.
Siemens will be demonstrating how the combination of the real and the digital worlds empowers industrial companies to act in a versatile and sustainable manner at the “Achema Pulse” live digital event. Companies in the process industry are facing urgent and rapidly changing challenges. The Covid-19 pandemic in particular has transformed demand patterns and global supply chains virtually overnight. At the same time, industry-specific regulations and standards are creating new framework conditions for production. Digitalization and automation are the levers for mastering these changes. Industrial IoT solutions can exploit the resulting data to secure a competitive advantage since the intelligent analysis, understanding and utilization of the data allows companies to adapt their processes faster to changing requirements. The Digital Enterprise portfolio makes this possible by combining the real world with the digital world, thus enabling solutions for simulation, virtual processes, remote access and connectivity as well as presenting service offerings for digital transformation. Thanks to the corresponding industry-specific know-how, individual sector requirements can be taken into account.
Focus on industry-specific solutions
“Achema Pulse is a great opportunity to providing impulses to our custumers and gaining insights on how we can implement the digital transformation together. There will be a special emphasis on the pharmaceutical and chemical industries, and we look forward to sharing our expertise in these areas.”
– Eckard Eberle, CEO of Siemens Process Automation
For companies in the pharmaceutical industry, winning the race against time is now more important than ever. The company is helping pharmaceutical companies accelerate their production setups with the help of digitalization and automation. One example is the Mainz-based biotechnology company BioNTech SE which has converted an existing facility in Marburg for the production of the Covid-19 vaccine in record time with assistance from the concern. Through collaboration and the team of experts on site in Marburg, the project timeline for converting the existing facility for the production of mRNA-vaccine was cut from around one year down to five months, whereby the implementation of key parts of the new Manufacturing Execution System (MES) was reduced to two and half months.
In the future, the digital twin can be increasingly used in vaccine development. Global healthcare company GlaxoSmithKline (GSK) is collaborating with digitalization expert and digital transformation leader Atos to digitalize its vaccine development and production process using the digital twin. As the first application for testing, GSK, Siemens and Atos have developed a proof-of-concept digital twin specifically for the development and manufacturing of adjuvant technologies. Using mechanical models and artificial intelligence (AI), the partners developed a hybrid model to simulate and monitor the process. As such, the digital twin links the process parameters to the quality of the adjuvant, with the sensors and process analytical technology (PAT) feeding the twin with the information needed to predict the quality of the product. Any deviation from the optimal quality is anticipated and causes the twin to act on the process parameters and rectify them to satisfy the target specifications. In the next step, GSK wants to work with the company to support its vision to establish and introduce new digital twins for the entire vaccine development process for new vaccines. Thus, the digital twins of product, production and performance will be linked together.
In the chemical industry, the biggest challenges lie in the fact that plants must run reliably and safely. The “Digital Worker” is a concept that allows operating personnel to digitize and automate work in the field using state-of-the-art technologies such as augmented reality (AR) and virtual reality (VR). This approach supports the user in the digitization of workflows in process plants and in paperless processing, promoting remote access thanks to electronic documentation, access information and guidance by intelligent devices. Against this backdrop, specialty chemicals company Lanxess continues to drive forward digitalization in its production plants. Over the next three years, the specialty chemicals company will introduce mobile operations and maintenance. In a first step, around 400,000 paper-based operations and maintenance checklists used every year will be replaced by digital equivalents, then filled out on tablets. Lanxess is supported by Siemens to digitize its checklists. For this, the Moby.Check software will be used, which runs on tablets and can be controlled using either the keyboard or voice commands. Moby.Check has a flexible operating concept allowing users to create production, servicing and maintenance checklists on their PC – without any programming work or training in advance. In addition to more efficient processing, the error rate of manual transmission can be reduced, and documentation simplified. The Digital Worker supports the transformation from analog to digital workflows and can also exploit the potential of the digital twin in the field. Applications based on AI contribute to higher plant availability through the early detection of anomalies. And predictive maintenance planning means that outages and routine maintenance work are avoided.
As a specific offering for the chemical and oil & gas industries, Siemens offers not only the explosion-proof motors of the Simotics XP series, but also motors of the Simotics SD series for environments without explosion hazard in the Chemstar version. They are equipped with pre-configured chemical-specific options. Both motor series, available with options, operate reliably and energy-efficiently even under extreme conditions and offer all relevant certificates.
Modularization as the key to meeting new requirements with ease
To meet the demands of short innovation cycles and adaptations to new product portfolios, systems must be quick and easy to expand. The prerequisite for this are standardized, cross-vendor interfaces for the efficient configuration, communication and integration of modular plants. An interface of this type is defined in the MTP (Module Type Package). This protocol defines the information technology aspect of process models or plant sections in such a way that they can easily be integrated into a comprehensive automation solution, for example the Simatic PCS neo web-based process control system. The modules are assembled to form an overall process, facilitating their monitoring and control. At Achema Pulse, the example of the cooperation between Siemens and Merck will demonstrate how a modular production plant based on MTP minimizes engineering effort and permits fast and versatile process adaptations.
New IIoT solutions for faster data transmission and reliable data acquisition
“As part of the digital transformation, new trends are emerging in the process industry, which we are driving with our solutions and innovations,” explains Eberle. “We regard 5G as one of the most important technologies in the industrial IoT context. It means we can transfer data quickly and reliably over powerful communication networks to exactly where it is needed. This makes production plants more flexible, autonomous and efficient.” Scalance MUM856-1 is the first industrial 5G router from Siemens.
With its wireless connectivity, the robust Sitrans MS200 Multisensor forms the hardware basis for the collection of vibration and temperature data in mechanical system components. Via a Bluetooth connection, the data is sent to the Sitrans CC220 industrial gateway where it is encrypted before being transmitted from there to the cloud. Sitrans SCM IQ has an anomaly detection feature which is based on machine learning. It constantly monitors and analyzes all sensor values and swiftly detects any deviations from the intended operating state. Via the app, anomalies in plant behavior can be documented for immediate distribution to alert a predefined group of users. The Sitrans SCM IQ system comprises multisensors, gateway and app, and can be used in all industrial plants with mechanical or rotating system components. Scheduled to be available from summer 2021, it allows previously unused data from field devices to be used for the preemptive identification and prevention of imminent device failures in advance, thus reducing maintenance costs and avoiding unplanned downtimes.
Sustainability as a guiding principle
As Eberle emphasizes: “Our offer not only meets the requirements of our customers, it also constitutes a contribution to sustainability.” Accordingly, Achema Pulse will also be offering sessions on the topics of chemical recycling and sustainability.