Energy consumption cut by more than half

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

1 The dust collectors are cyclically cleaned with compressed air and the material flow is kept running in the entire lime manufacturing plant

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

2 One of the four lime kilns at Regensburg. The lime deposit of supraregional importance at the foot of the Keilberg near Regensburg with its Jurassic limestone of excellent quality, i.e. 97% to 98% of calcium carbonate (CaCO₃), offers sufficient supplies.

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

3 Three energy-efficient screw compressors, type GA, in the new central compressed-air station at Walhalla Kalk: right in front the speed-controlled GA 75 VSD (VSD Variable Speed Drive), behind it two somewhat smaller units, type GA 55+.

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

4 Walter Fuchs (left), responsible for project planning and maintenance, and Erich Winter, workshop master at Walhalla Kalk, permanently control the compressed-air generation by means of the energy saving system ES 130 V.

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

5 “All in all we were able to reduce our energy consumption by more than the half - with the same volume flow”, said Walter Fuchs, responsible for project planning and maintenance at Walhalla Kalk.

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

6 Compressed air drying according to the season: In summer a very efficiently working refrigeration dryer, type FD 750 VSD, is sufficient, in winter an adsorption dryer, type CD 780, with dew point control ensures a pressure dew point of up to -40 °C.

Source/Quelle: Atlas Copco Kompressoren und Drucklufttechnik

Summary: Those who consider all components of compressed-air supply and coordinate them well will be able to generate compressed air in a very energy-efficient way even with strongly varying requirements. Walhalla-Kalk has set up a new central station, which requires less than half the energy previously required for the same amount of compressed air and, consequently, which will pay off quickly. This is due to the modern compressor technology including speed control and superimposed control as well as to the change between refrigeration drying and adsorption drying depending on the season.

1 Using the efficiency potential

Walter Fuchs has scored a hit with his concept of a completely new compressed-air station. The technician for mechanical engineering, who is responsible for project planning and maintenance at the Regensburg-based Walhalla Kalk GmbH & Co. KG, succeeded in reducing the energy consumption and, consequently, the costs as well, for compressed-air generation for the lime manufacturing plant by more than 50%. The plant manager Wolfgang Scheurer is more than satisfied with the result. Previously four stations, spread out over the works area, supplied the compressed...