GEA Generate 5 En

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The inTernaTional magazine of The gea group issue 05 marCh 2008

The wonders of olive oil

healThy demand for

goaTs milk

CreaTing The righTaTmosphere for arT


2/36

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refrigeraTion

air TreaTmenT

meChaniCal separaTion

proCess eqUipmenT

farm sysTems

proCess engineering

emission ConTrol

Thermal engineering

pharma sysTems

One of the biggest challenges

the world faces today is the

need to provide for the energy

supplies of the future in ways

that will minimize the impact

on the environment. We need

more energy than ever before to

fuel both the worlds traditional

powerhouse economies

and the rapidly developingeconomies in countries like

China, India, Brazil and Mexico.

As our feature article in this

issue suggests, the answer is

likely to be found not in one but

in a range of energy sources:

fossil fuels and nuclear power

will continue to be used, but

complemented by an array oftechnologies from wind power

to geothermal. Whatever

the combination of energy

sources, GEAs businesses

will be at the forefront of the

efforts to develop them.

GEA is making a difference

in more than just energy

generation. Were improving

the energy usage of whiskey

distillers and boosting

the productivity of the US

dairy industry through our

technical innovations.

In this issue, we look at the

shipping industrys response

to challenges created by

environmental pressures,

how cultural institutionscan benet from climate

control technology, and the

myriad benets of olive oil.

Of course, staying at the

cutting edge of technology

needs an organization that is

t and strong. GEA enjoyed a

successful year in 2007, has

a full order book and is one

of the technology leaders in90 per cent of the markets

in which it operates. All this

should ensure we remain well

placed to help meet the needs

of our customers worldwide.

Jrg oleas

Chairman of the Executive Board

GEA Group Aktiengesellschaft

wc t t t u generaTe, ub b t gea guaktct.

Dear Readers,


3/36GENERATE MAGAZINE ISSUE 05 1

FEATURE STORY

THE HEAT IS ON WITH THE WORLDDEMANDING MORE POWER, DIVERSITYIS THE KEY TO PROVIDING IT

HOLIDAY ON ICEThe rise o urban ice rinks

HOW TO DO ITStep-by-step guide to pressing olive oil

LIQUID GOLDCholesterol buster, digestion aid,culinary godsend, uel and cosmetic

WHISKEY GALORENew process saves energy

Q&ASea change: Tony Mason tellsus how the shipping industry ishandling environmental challenges

SUPER NANNYGoats milk growing inpopularity

INNOVATION IN DAIRYINDUSTRYUniue valve boosts US milkoutput and cuts dairy costs

CULTURAL REVOLUTIONEnsuring the best environmentor museums and theaters

A DAY IN THE LIFESteen Bersch is GEA`s guyin Dubai

ART IN ENGINEERING THE LAST WORDGlobal news rom GEA


4/3622

IN TODAYS TECHNOLOGY-DRIVEN

WORLD, THERES SOMETHING

WONDERfULLY OLD-fASHIONED

AND ROMANTIC ABOUT OUTDOOR ICE

SKATING. AND WITH URBAN ICE RINKS

BECOMING INCREASINGLY POPULAR,

SKATERS ARE VOTING WITH THEIR fEET

AT RINKS IN fAMOUS CITY SETTINGS

ACROSS THE WORLD.



GEA And icE

GEAs expertise with rerigeration technology goes

back over 45 years, in the shape o Netherlands-based

Grasso and Grenco businesses. Industrial rerigeration

manuacturing specialist Grasso has been supplying

rerigeration equipment or ice rinks in Europe sincethe 1960s, helping to build the worlds third 400-meter

ice skating circuit in Amsterdam in 1961 and the

rst with direct expansion o ammonia in the tubes.

All Grassos ice rink systems use environmentally

riendly rerigerants.

Grenco B.V. is a market-leading developer, designer,

engineer and service provider o rerigerating

installations in the Netherlands and a key supplier

to the countrys temporary and permanent ice rinks.

For example it has recently converted the cooling

system o a 400-meter outdoor skating track in I jsbaan

Kennemerland to liquid carbon dioxide and addeda state-o-the-art skating rink inside the circuit.

Grenco adapted and updated the existing compressors

to create a system that allows the rink and the track

to be at dierent temperatures and even permits

dierent temperatures on the straights and the corners

o the circuit. Grenco has also supplied ice rinks

in Belgium, France, Spain and the UK.

GENERATE MAGAZINE ISSUE 05

ong before it became a leisureactivity, skating was a vital meansof travel and winter trade along

rivers. The pioneers of ice skating

strapped sharpened animal bones totheir footwear to cross Europes frozen

wastes some 4,000 years ago. Todaysmodern ice skates, made of steel, rsttook shape in the Netherlands in the

13th century when sharp edges wereadded to the bottom of the skates,enabling skaters to propel themselves

without needing wooden sticks.

Skaters have taken advantage ofnaturally occurring ice for hundreds

of years. The rst rink with articiallyfrozen ice was the Glaciarium, opened

in London in 1876 at a cost of 20,000for use by noblemen and gentlemen incertain conditions. Since then, ice rinkshave become a far more inclusive leisure

pursuit.

Theres nothing new about the appealof outdoor articial rinks: The famous

Rockefeller Center in New York City hashosted ice skating for over 70 years.That rink rst opened on Christmas Day

in 1936 and is now a popular venue forskaters from October to April every year,with over 250,000 people taking to the ice

each season.

Its in the last decade, though, that outdoorskating on temporary ice rinks has reallytaken off and these days outdoor skating

can be held against the backdrop of someof Europes most stunning buildings andunder the stars. In colder climates, articial

rinks can be made enclosing a level areaof ground, lling it with water, and lettingit freeze. But todays urban ice rinks are

made by building a bed of sand or slab ofconcrete and running pipes across therink which contain frozen uid so water

placed on top will freeze. Nowhere is thismore popular than in Britain. Two fths ofEuropes 90-plus temporary rinks are in

British cities and towns.

One of the most famous is at SomersetHouse in London, just off the Strand. The

elegant eighteenth-century palace is asuperb setting for skaters from Novemberto January. Although not the rst temporary

outdoor rink in Britain, Somerset House hasreally caught the public imagination sinceskating began there in 2000, prompting

other cities to follow suit.

Paris was one of the first continentalEuropean cities to host a temporary ice rink

when it built one in the Hotel de Ville in 1996.It opened an even more spectacular rink in2004 on the rst oor of the Eiffel Tower, 50

meters above ground level. Surely settingsdont get much better than that. Berlin,Hamburg and Cologne are among the German

cities to put up rinks in the winter, the latterconstructing a huge one every year on theHeumarkt. Bruges, Brussels and Bratislava

have all followed the trend. Not to be outdone,Moscow has constructed a temporary rink in

Red Square, overlooked by the onion domesof the Kremlin.

Temporary rinks have been put up evenfurther afield, and in some unlikely

locations. Mexico Citys famous ZocaloSquare was the venue for a 3,000m2 rinkfrom December 2007 to January 2008, with

capacity for 1,200 skaters at any one time.Japan and Dubai also have temporaryrinks and a city center rink in Seoul in

South Korea, opened in 2004, attractsclose to 200,000 visitors from Novemberto February.

It looks as though outdoor skating rinksare here to stay. Temporary sites in

tourist locations with historic buildings

as a backdrop are proving an irresistibledraw. As well as being fun, its a healthyactivity. One hour on the ice can burn

nearly 500 calories unless you rewardyourself with a hot chocolate and whippedcream afterwards.


6/364

Since 1990 global demand or olive oil hasmore than doubled. As a result the majorproducing countries have been under

intense pressure to boost yields in anenergy ecient way while improving uality.This has gone hand-in-hand with thedevelopment o new and better technologyin the shape o high perormanceseparators.

Spain, the top producing country, supplies40 per cent o the worlds olive oil. Morethan 95 per cent o this is etracted usinga two-phase process which produces arst class product and, because it usesless water than other systems, is betteror the environment. This is how it works

4

Pressing olive oil

WASHING & CRUSHING

First the harvested olives are

cleaned of any leaves and twigs,then washed to remove sand andsoil. This is important becauseforeign particles could spoil thepurity and avor of the oil.

Washed olives are fed into ahammer mill where they arecrushed into a paste by high-speed rotating hammers.

ExpErts in oil rEcovEry

GEA company Westalia Separator, one o the world

leaders in providing separators and decanters or a

wide range o applications and industrial sectors,

has been involved in the olive oil recovery business

since the 1950s.

In the 1990s the company harnessed its process

and engineering know-how to develop an

environmentally riendly two-phase separation

process. This eliminated the need to dilute the olive

paste with water, which was later wasted. It also

increased yield and the quality o the product. The

launch o decanters with CETEC technology in 2001

brought a urther increase in yield o one to two

percentage points.

MALAXATION

This process allows the

microscopic droplets of oil toconcentrate so that they can beextracted more easily. The pasteis stirred slowly in a speciallydesigned mixer, called a malaxer,at low temperature. Surprisingly,extra virgin olive oil, usuallylabeled as cold or rst pressing,can actually be warmed up to27C (80F). Lower grades can bewarmed to between 30 and 35C(86-95F).

pUlp

2-stAGE mAlAxEr

olivEs



lonG lifE

Some olive trees can live or thousands o years.

It is believed that a tree rom the olive grove where

Plato established his academy was still standing

in the 1980s, making it more than 2,300 years old.

vAlUABlE Gift

According to Greek mythology Athens was named

ater the goddess Athena when she oered the

city an olive tree. The locals much preerred this

git to Poseidons oering o a salt water spring.

pEAcE siGn

Olive leaves have been symbols o peace since

Biblical times. They are a key eature o the United

Nations emblem and the Great Seal o the United

States.

STORAGE

After processing the olive oilis stored in large containersin cool, dry and dark rooms.Once it has settled, usuallyafter about two months, it isltered, bottled and sold.

SEPARATION

A decanter separates the oil fromthe pomace solids and water bycentrifugal force. The oil is thenpolished with self-cleaning, highperformance separators.

A second decanter stage canrecover some more oil from thepomace. Nothing is wasted as thepomace can then be separated intopits and pulp: olive pits make goodfuel while the pulp may be sold asfertilizer or a high-ber additive foranimal feed.

2-phAsE dEcAntEr

cEntrifUGE

pomAcE

oil


8/36

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9/36

uring the 1990s scientists were keento discover why, despite a rich diet, theFrench were less likely to suffer from

cardio-vascular diseases than their northEuropean neighbors or people in the UnitedStates. The answer pointed to a high intake

of fruits, vegetables, wine and olive oil.

As if to conrm this, Jeanne Calment,

who died in 1997, made history as thelongest-living human since records began.Born in the Provenal city of Arles, shelived for an astonishing 122 years. This

sprightly woman, who took up fencing at80 and was still riding her bike when shewas 100, attributed her amazing longevity

to olive oil which she added to all herfood. She even used it as a moisturizer.

Olive oil is the healthiest vegetable

oil because it is high in antioxidants,which strengthen the immune system,and monounsaturated fats, which help

to regulate cholesterol and ward offcancer and heart disease. It is alsogentle on the stomach, promoting the

healing of ulcers and aiding digestion.

The heart-friendly properties of olive oilwere pinpointed in 2005 by researchers

at the Monell Chemical Senses Center inPhiladelphia, who found that the naturallyoccuring chemical oleocanthal had similar

properties to ibuprofen. However, as youwould need to swallow 500 grams of olive oilto equal one dose of ibruprofen, its unlikely

to take off as a headache cure. Nevertheless,

the research helped to explain further thehealth advantages of the Mediterranean diet.

It is believed that olive trees were rstcultivated on Crete around 3500 BC. Sincethen olive oil has brought great wealth,

power and well-being to Mediterraneancountries. As well as a myriad of culinaryuses for frying, marinades, sauces,

salad dressings and preserving cheese,sh, sausage and vegetables itsalso found in soap and provided fuel

for oil lamps. In fact olive oil was theoriginal fuel for the Olympic torch.

Jeanne Calment was not the rst to

appreciate the cosmetic value of extravirgin olive oil. In Greek and Roman timesathletes used to rub it over their bodies.

Lovers of natural beauty remedies continueto praise its versatility. As well as beingan excellent moisturizer, it can be used

as an eye makeup remover and as ashaving oil, especially for sensitive skin.

When mixed with sea salt it makes a goodnatural body scrub or you can add it to

melted beeswax for an effective lip balm.

There are hundreds of olive varieties,

ranging from the Greek Kalamata to theFrench Picholine. Their color reects the

degree of ripeness. Olives harvested at thebeginning of the season are green, whereasthe black, or fully ripe olives are collected

later. On average, a single olive tree bearsaround 20 kilograms of fruit a year, whichis equivalent to three to four liters of oil.

Like wine the quality of olive oil is

determined by the area of cultivation and

climate. Oils are graded according to thecontent of oleic acid, a simple unsaturated

fatty acid. The lower the content of oleicacid, the ner and fruitier the taste. So, forexample, extra virgin, the top grade, has no

more than 0.8 per cent acidity (0.8 gramsof free fatty acid per 100 grams of oil).

Around ninety-ve per cent of the

worlds 750 million olive trees are in theMediterranean region. Spain is by far the

largest producer, with more than 200million olive trees, followed by Italy, Greeceand Turkey. Olive plantations can also befound in Australia, South America, the

United States, South Africa and the MiddleEast and their numbers are growing.

Today global olive oil consumption is at an

all-time high. According to the InternationalOlive Council 2.9 million tonnes wereconsumed in 2006/7, more than double

that for 1990/91. With people becomingmore aware of the link between whatthey eat and major diseases, olive oils

important contribution to a healthy dietis assured for the foreseeable future.

7GENERATE MAGAZINE ISSUE 05

Acid tEst

Olive oil is graded according to the FFA (ree atty

acid) content.

Ea g comes rom the rst pressing o the

olives and contains no more than 0.8 grams o

FFA per 100 grams o oil.

vg is also cold pressed and acidity must not

exceed two per cent.

oe generally virgin oil blended with lower

grade rened olive oil.

Today global olive oil consumption isat an all-time high. According to theInternational Olive Council 2.9 million

tonnes were consumed in 2006/7.


10/3688


11/36GENERATE MAGAZINE ISSUE 05 99GENERATE MAGAZINE ISSUE 05

THE GOAT IS THE TRENDIEST ANIMAL IN fARMYARDS

ACROSS THE WORLD. NOT SO LONG AGO, PEOPLE WERE

RELUCTANT TO EVEN TRY GOATS MILK. NOT ANY MORE.

INCREASED AWARENESS Of GOATS MILKS POTENTIAL

HEALTH BENEfITS MEANS THAT DEMAND HAS NEVER BEENHIGHER. THE GOATS TIME IN THE SPOTLIGHT HAS ARRIVED.

istorically known as the poor manscow, goats are one o the worlds oldestdomesticated animals. They have been

kept or their milk, meat, hair and skins ormore than 10,000 years. These incrediblyversatile animals eat pretty much anythingand need ar less graing space than cows.In many developing countries, goatsmilk is an important source o protein,

phosphate and calcium as cowsmilk is not always available.

In global terms, more people drink goatsmilk than milk rom any other animal, eventhough goats milk production accountsor approimately two per cent o theaudited world milk market. Asia, Arica,and South America are the populouscontinents where goats milk has alwaysbeen popular. Its taken longer or goatsmilk to crack the markets in the developedcountries; but increasingly health-consciouscustomers and a desire or innovative

new products mean goats milk is theworlds astest growing dairy product.

In Europe, the market is growing by tenper cent every year and this increaseddemand has resulted in bigger herds,the introduction o high-tech milkingeuipment and improvements in milkuality. france, Switerland and Greecehave traditionally been among Europesleading goats milk producers but theNetherlands has become one o Europesbiggest eporters o the product as themarket has developed. More than 75 per

cent o all goats milk in the Netherlands iseported to Germany, france and England.

The Netherlands 375 goat arms, thebiggest o which have around 1,000 animals,produce over 150 million liters o milk,with high-yield goats each producing morethan 950 kilograms o milk per year. But allthis has only been possible thanks to theentrepreneurial spirit o the goat armersand state-o-the-art milking euipmentdeveloped by GEA company WestaliaSurge.Already a global orce in milking cows,WestaliaSurge has adapted to the markets

needs by creating a bespoke rotary parloror goats the AutoRotor Capri 90.

Jan van de Ven and his wie Jean are typicalo progressive Netherlands goat armers.They arm 1,200 Saanen goats in 2,000 suaremeters in Oirschot near Eindhoven. Van deVen says Saanens larger and strongerthan other breeds are more sensitive thancows. They need more care with eedingand husbandry, but on the other handreuire much less space and ood. Moreover

they are cleaner and easier to milk.The goats are milked twice a day by just twopeople. Everything else is ully automatic.Once the barn gate is opened, an automaticdriver herds the goats in the direction othe rotary parlor. Attracted by ood in themilking bo, the animals allow themselvesto be attached to the cluster (the milkingeuipment) and enjoy the ride on thecarousel, which is 14.5 meters in diameter.

Goats are notoriously impatient so theclusters need to be attached uickly. Andtheir propensity to chew everything in sight

meant WestaliaSurges engineers had todesign totally bite-resistant euipment.

The AutoRotor Capri 90 holds 72 goatsand all 1,200 at the van de Vens arm canbe milked in just 90 minutes. Prior to itsinstallation, this process took our hours.The arms milk is collected by one o theNetherlands three goats milk co-operatives,beore being urther processed to producecheese, yoghurt and other nished products.

WestaliaSurges latest generation milkingcontrol unit measures the milk yield o

each goat and shares the data with theherd management program. It enables thearmer to assess each goats protability.Operating without state-o-the-arttechnology simply isnt a viable businessoption or large-scale goat armers.

In just 20 years the market or goatsmilk and associated products haschanged beyond recognition. And thehuge demand looks set to continue.

from GoAt to hEro GoAts milk At-A-GlAncE

> The worlds most popular dairy product

> Goats were rst kept as domesticated animals10,000 years ago in Iran

> Revered in Egypt: milk and cheese were placed

in pharaohs burial chambers

> Widely consumed by the Ancient Greeks

and Romans

> Goats milk started to become more available

again in the 1970s

> As well as being a good source o protein, goats

milk is more easily digestible and less allergenic

than cows milk

> The plethora o products available now includes

goats cheese, eta cheese, ice cream, yoghurt,udge, chocolate and skin care products


12/3610



BY 2030, THE INTERNATIONALENERGY AGENCY PREDICTS, THEWORLD WILL NEED 50 PER CENTMORE ENERGY THAN TODAY,WITH MUCH Of THAT INCREASEDDEMAND COMING fROM CHINA,INDIA AND OTHER RAPIDLYDEVELOPING ECONOMIES.

Steve HobSon ExAMINES THECONSIDERABLE CHALLENGESTHE ENERGY INDUSTRY fACESAS IT TRIES TO BALANCE THEWORLDS INSATIABLE ENERGYDEMANDS AND DIMINISHING OILRESERVES WITH THE NEED TOPRESERVE THE ENVIRONMENTfOR fUTURE GENERATIONS.

PHOTOGRAPHY:PETER DAzELEYSTYLING:

SABRINA JARD


14/3612

both processes currently rely largely on

the same fossil fuel sources that wouldhave provided the transport fuel.

Our demands for electricity, heat, and

transport are growing faster than ever.According to US Department of Energygures, global energy demand which rose

by around 42 per cent between 1980 and 2000(from 283 quadrillion British Thermal Units[btu] in 1980 to 400 quadrillion btu in 2000)

will nearly double again in the years to 2030.

Fssil fuls

No one is sounding the death knell for fossil

fuels. The World Energy Council (WEC)points out that there are still extensivereserves of fossil fuel but they are being

depleted faster than ever. For example, theEstimated Ultimate Recovery (useablereserves) of conventional oil was originally

387 billion tonnes. Of this, about 143 billiontonnes had been exploited to the end of2005 and within the next ten years fully half

of the reserves will have been extracted.

More fossil fuel reserves are likely tobe discovered: for example, so-called

unconventional sources such as theimmense oil sands in Canada. The questionof whether these unconventional sources

will be fully exploited is a complex one:some have already been tapped and it istechnically possible to recover most of them.

Chagig dircis

Its not the rst time the energy industryhas needed to make a step change. A recent

example is the switch to using gas as botha direct source of heat and as a clean and

efcient fuel for electricity generation. Theindustry originally depended on thousandsof miles of pipeline transporting the gasfrom the source to the user. That network

is still being extended, but it requireshuge investment. Its also inexible andrestricts the gas market, a very real

concern when three countries Russia,Iran and Qatar hold around 50 per centof the worlds natural gas resources.

Cooling and liquefying the gas, however,allows it to be transported by ship.Overcoming this technical challenge has

been the basis for developing a globalmarket for liqueed natural gas (LNG).Now twelve countries export natural gas

and ten more may become exporters inthe next few years. Whether its pipelinesor LNG plants, GEAs Thermal Engineering

Division takes a leading position in supplyingcooling components for these applications.

Developments like LNG have broadened

the options available for the global energymarket. But the sheer rate of growth indemand and increasing fears over the future

of fossil fuels have sent the energy supply

industry back to the drawing board to lookat how energy is delivered and used.

he need for bodily warmth and for

cooking food was what drove the rsthumans to make use of re, and it has

been a constant of our search for the best

energy sources for thousands of years.

Our energy needs may be more varied nowand electricity was discovered long ago

but heat still forms the basis of many ofour systems. Since much of our electricityproduction has relied on producing steam

to move the turbines that produce power,the energy industry has been focused onnding and exploiting the best heat sources.

And that has generally meant extractingfossil fuels such as coal, oil and gas.

Its not just demand for electricity and

process heat for industry putting pressureon fossil fuel resources. They also providefuel for transport and feedstock for the

chemical and manufacturing industries.And, while electricity and hydrogen have

both been mooted as potential fuels forthe transport industry, this is shifting, not

removing, the burden. Electricity must begenerated and hydrogen produced and



There are nite and renewable energy

resources. The rst are the organically-based resources of coal, oil, gas andtars, along with the uranium and thorium

resources used as nuclear fuel.

Renewable energy sources include solar,photovoltaic, wind, wave, tidal and bio-

energies. There are no reserves to bemined; instead, exploitation is a matterof harvesting them whenever they are

disposable. Perpetually available they may

be, but they cant always be guaranteedto match the place or time of demand.

The answer, then, is diversity: a mix ofrenewable energy sources; robust andextensive energy networks that make the best

of the energy available at any one time; andstorage, either electrical or in the form of anenergy carrier such as hydrogen, or biofuels.

The costs of abating emissions ofcarbon dioxide will drive up the price ofusing fossil fuels, as will the increasing

burden of extracting them.

Carbon capture and storage (CCS) is expectedto be commercially viable by around 2020

and will allow fossil fuels such as gas, oiland coal to be used without contributing tocarbon emissions. CCS involves extracting

carbon from the fuel either pre- or post-combustion before transporting it viapipelines to underground storage on- or

offshore. Its economics are expected to begreatly improved when used in conjunctionwith enhanced oil recovery, where the

liqueed carbon dioxide is used to helpextract more oil from depleted elds.

Coal power stations on the UKs North Seacoast are ideal proving grounds, and theUK government is holding a competition todevelop viable CCS among power station

operators. Bob Taylor, Managing Directorof UK generation at German energy giantEon, says that, as well as contributing to

a reduction in the UKs carbon emissions,it is vital CCS is developed for tmentto India and Chinas rapidly growing

eets of coal-red power stations. TheUK Government wants to see a smallscale demonstration of CCS by 2014 and

applied to 300 to 400MW plant by 2018.

GEothErmAl EnErGy

One o the lesser-known orms o electricity

generation, geothermal energy, is power generatedrom beneath the earths crust. Hot water rom below

the earths surace is extracted and converted into

electric power. Geothermal steam and hot springs

have been used or centuries but geothermal energy

wasnt used to make electricity until 1904 when a

steam eld in Italy powered a small generator to

light our bulbs.

The utilization o geothermal energy has reached

the state o industrial application. The geothermal

power plant Unterhaching in Bavaria, Germany, is

a perect example o cross-divisional collaboration

within the GEA Group: GEA Energietechnik GmbH

and 2H Kunststo GmbH, both rom the Thermal

Engineering Division, have delivered the cooling

towers including the cooling tower lls. GEA Ecofex

GmbH rom the Process Equipment Division supplied

plate heat exchangers.

Unlike many other renewable energy sources,

geothermal energy can produce a constant source

all year round. Geothermal energy currently accounts

or less than one per cent o the worlds energy but a

range o pilot projects are underway around the globe

to explore its potential.

>


16/3614

Rwal rgy

Tapping renewable energy resources hasproved challenging. In some cases, suchas wind power, exploiting the resource

has sent engineers back to re-examinetechnologies that have been used forcenturies and consider how they can be

re-engineered for modern purposes. Inothers, such as solar photovoltaics, therehave been true technological leaps. Their

common thread is the need to step up theseniche technologies to meet a signicantproportion of global energy and power needs.

Wind power is probably the fastest growingof the new power sources. The EuropeanWind Energy Association puts the number

of wind turbines in use worldwide at 85,000,providing 94GW of electricity capacity. Thecapital cost of onshore wind is relatively

low, and can be staged as more turbinesare added to an existing wind farm, so itis often the rst choice for new renewable

energy. Major suppliers and volumeproduction had combined to bring downcapital costs, but in recent years the

popularity of wind power has been toohigh for the industry to manage. Turbine

manufacturers have full order books for yearsto come and so have companies providing

installation and commissioning services,especially in the offshore wind sector.

Photovoltaics (PV) is unique in the variety of

potential applications it offers, from largestand-alone panel arrays to thin lms orglasses integrated into buildings. It can

also be installed in stand-alone applicationsfar from the electricity grid to feed directlyinto the building supply. That means the

potential for different types of installation

is enormous. The European PhotovoltaicsIndustry Association estimates that installed

peak capacity could grow by around 35 percent annually, from the around 1000MWinstalled worldwide in 2005. The growth

of the industry has been slowed by threemajor factors: the price and availability ofsilicon, a vital material; the high capital cost

of the panels; and the problems of providingnancial credit for domestic levels of powergeneration. Problems with silicon supply

may ease during the next few years asnew manufacturing facilities come on line.High sales volumes (the industry hopes)

will start to bring down capital costs.

14

WIND POWER IS PROBABLYTHE fASTEST GROWING Of THENEW POWER SOURCES.



As the PV industry grows, a second solar

industry is developing alongside: using thesuns heat. Collecting and concentrating thesuns energy with specially shaped mirrors

can allow it to be used to produce steam fordriving a conventional steam turbine. It is anew way to use a familiar technology that

ts well into our existing energy networks;and it is growing fast in areas which can relyon sunshine, such as California and Spain.

bi-rgis

Biomass and biofuels are, similarly, a newway to fuel familiar technologies. Fossil fuels

are directly replaced with their plant-basedequivalents: wood or other solid biomass forcoal, or vegetable oils for fossil oil. It is an

attractive solution, as it will also t directlyinto our existing energy infrastructure,sometimes in stages. The UK, for example,

will soon require transport fuels to includea mix of up to ve per cent plant-basedequivalents. There are questions over the

costs and environmental impact of reningand transporting the necessary quantities

of bio-energies. But the biggest questionis over their production: they compete forspace with existing crops, not least foodcrops; and there was an outcry when cash

crops such as palm oil were seen to bethe cause of destruction of virgin forest.

Large-scale hydropower is another part of

the renewable energy portfolio. The differenttypes of hydropower include waterwheels,hydroelectricity (dams) which is the most

widely used, and damless hydro (using thekinetic energy of rivers, streams and oceans).They enable low cost energy to be used

at long distances from the water source.Although hydroelectricity doesnt give outharmful emissions and is cheaper than

energy generated from fossil fuels, it may notbe a major option for the future in developedcountries as there is little scope for further

development and the building of new damsmay present environmental problems.

Other technologies, such as ocean-

based devices that abstract energy fromwaves and tides, are at an early stage ofdevelopment but are likely to encounter

the issues of supply-chain development

that have checked the wind industry.Rwals arg

All these energy sources will be needed tomeet our needs, and at ever faster rates ofdeployment. In January 2008, the European

Commission published detailed plans on howits member states would together produce 20per cent of their primary energy supplies from

renewables by 2020. It is a big increase andwill fuel the European market for all thesetechnologies, but it will not allow the EU to

dominate world markets. Demand is growingstill faster in areas such as China and India.

GEAs rolE in thE EnErGy indUstry

As countries and energy companies around the world

explore how to meet uture energy needs, GEAs Thermal

Engineering Division will be with them every step o the

way. Heat transer technology plays a central role in

the worlds power stations, oil reneries, petrochemicalplants, gas pipelines and GTL (gas to l iquid) and

biomass acilities.

cea GEA eeg eg ae:

> Air Cooled Heat Exchangers (also known as Air Fin

Coolers) or direct dry cooling, which are used in any

application where heat needs to be transerred in

large quantities. Air cooling is used at all modern

industrial acilities (rom energy generation to

energy transportation) air is unlimited, ree and

does not require treatment.

> Air Cooled Condensers, or direct condensing, which

are used to condense steam.

> Wet cooling (a two-step method water is cooled ina Wet Cooling Tower and then the cooled water cools

or condenses the fuid or steam).

> Indirect dry cooling by means o Heller cooling

towers (a two-step method water is cooled in a

Dry Cooling Tower and the cooled water cools or

condenses the fuid or steam).

> Special applications (e.g. de-sublimination,

crystallization).

The Thermal Engineering Division has

businesses worldwide.

GEA has invested heavily in China and it is paying

o with a host o contracts to supply Air Cooled

Condensers or the feet o coal-red power plants and

Air Fin Coolers or the petrochemical reneries that

will power the China o the uture. The boost o Indias

economy is great news or its petrochemical industry

and GEA is supplying components there, too. South

Aricas power industry is also developing at a ast rate.GEA is currently heavily involved in the development o

new power stations there, winning one o the largest

orders in the history o its Thermal Engineering Division

in December 2007 or the design, manuacture, supply

and erection o Air Cooled Condensers or Medupi

power station. South Arica is experiencing energy

shortages and GEA is also involved in projects that will

recommission power stations shut down in the 1990s.

The growth o reneries, GTL plants and gas processing

plants in the Middle East has created a new market

or air cooling as water is scarce. Thus, GEA company

Batignolles Technologies Thermiques opened a new

manuacturing site or Air Coolers in Qatar to tap into

this market.

Historically, GEA has been a major player in

the energy sector, building its rst Air Cooled

Condenser in 1939, and the Groups reputation or

knowledge, reliability and engineering excellence

means it is well positioned to benet rom projected

increases in energy consumption.

And its not just GEAs Thermal Engineering Division

that plays a leading role in the energy industry. The

division teams up with dierent GEA businesses to

oer clients integrated engineering solutions to both

energy production and boosting energy eciency.

>


18/36

GrEEn UrBAn dEvElopmEnt

According to urbanists and statisticians, the human

race has just reached the point where more than hal

o the worlds population lives in cities. By 2050, two-

thirds o the global population will call a city home.

Can cities be green, reinvent themselves asexemplars o sustainable development? Theres

a queue o designers, engineers, architects and

politicians who say emphatically yes.

The environmental and political imperatives

surrounding the need to cut greenhouse gas

emissions have already persuaded the UK

Government to lead the world by committing to the

ambitious goal that all new homes will be built to a

zero carbon standard by 2016. The house building

industry has signed up to this. Work is also now

underway to look at equally tough energy eciency

targets or new commercial and industrial buildings.

Ministers also want to see ten so-called eco-townsclimbing o the drawing board by the end o the

decade. Each will be a small new town o at least

5,000 to 20,000 homes and all will have to achieve

zero carbon development. This will be delivered by a

mix o renewable energy projects, domestic micro-

generation systems, and community heating projects

based on combined heat and power systems and

ultra energy-ecient new dwellings.

Meanwhile, internationally, two city-scale projects

are beginning to make waves. Consultants Arup are

working on what is claimed to be the worlds rst

sustainable city at Dongtan in China. The city wil l

get the bulk o its energy rom wind turbines and biouels. The designers envisage a city powered by local,

renewable energy, with super-ecient buildings

clustered in dense, walkable neighborhoods.

At the same time the United Arab Emirates has

announced plans to start building Masdar, a

multi-billion-dollar green city in the desert. This

50,000-inhabitant city will eature narrow streets,

squat buildings with shaded courtyards and no cars.

Solar and wind energy will power the city and its

water desalination plant. The target is denitely zero

carbon with energy supplied by photovoltaics, solar

power, wind, waste to energy and other technologies.

is EnErGy lABEllinG workinG?

Essentially, there are two routes to diminishing

carbon emissions rom electricity use: cutting the

carbon intensity o power generation (reducing

the carbon dioxide emissions per KWh by using

more nuclear or renewable energy, improving theeciency o ossil uel plants etc); or reducing the

energy intensity o consumption (bringing down

the MWh per square meter by improving energy

eciency o buildings or appliances or reducing

energy-hungry activities).

The US Department o Energys Federal Energy

Management Program has called upon Federal

agencies to reduce energy use by 35 per cent by

2010 on 1985 levels; while last year the European

Union set a target o saving 20 per cent o its energy

consumption compared to projections or 2020.

In 1985, the EU introduced an energy rating scheme

covering white goods and light bulbs. Appliancesare rated rom A (the best) to G (the worst) based

on energy and water eciency. In 2004, two new

categories or rerigerators and reezers were added,

where A+ indicates appliances that consume 30-42

per cent o standard energy consumption and A++

those consuming under 30 per cent.

With sales o A-rated white goods rising rom 20

per cent to 60 per cent in the rst three years, the

scheme was a success but any gains were more than

wiped out by modern consumers insatiable demand

or electronic gadgets.

Incandescent light bulbs, which waste 95 per cent

o electricity consumption, have been speciallytargeted. Many governments are proposing to

phase out incandescent lighting and replace it

with more ecient technologies such as compact

fuorescent lamps (CFLs) and light emitting diodes

(LEDs). To encourage the use o energy-ecient

lighting in homes, the European Commission set

up the European Design Competition Lights o the

Future. This years awards will be presented at the

Light+Building event to be held as part o a giant

trade air in Frankurt in April 2008.

16


19/36

th rgy ulk

World energy prices are likely to continuerising because of the combination offalling supplies of fossil fuels and rising

demand from emerging economies. Pastexperience shows that when oil prices inparticular rise too high, demand in the

developed economies especially in theUS falls, correcting prices downwards.

But the picture has changed. While the

developed world still accounts for most

of the world energy consumption, thedeveloping economies especially in

Asia are increasing consumption fast(see table). No country has ever managed

to increase its gross domestic productwithout increasing its energy consumptionand this will certainly hold true for China

and Indias surging economies. In 1990 thedeveloped world used more than doublethe non-industrialized nations. By 2025, the

developing world will be consuming only veper cent less than the industrialized nations.

Those emerging economies expected to see

the largest increases in wealth and henceenergy demand are the BRICS Brazil,Russia, India, China and South Africa.

China and India are currently seeing grossdomestic product growth running at almostten per cent a year and energy consumption

is outpacing this growth as domestic andindustrial electricity demand rockets.

The International Energy Agency (IEA) calls

the consequences of Chinas and Indias risein energy demand alarming, and warns in its2007 World Energy Outlook: If governments

around the world stick with current policies

the worlds energy needs would be more than

50 per cent higher in 2030 than today. China

and India together account for 45 per cent ofthe increase in demand in this scenario.

It forecasts that world energy demand will

hit 17.7 billion tonnes of oil equivalent (toe)by 2030, up from 11.4 billion toe in 2005.Worryingly for the climate, fossil fuels will

account for 84 per cent of this increasein demand, with oil consumption rising37 per cent to 116 million barrels per day

(Mbbl/d) in 2030, while coal demand will

leap 73 per cent. Most of this increasein coal use will be in China and India.

China is both the worlds largest producerand consumer of coal, currently exportingaround 50 million tonnes of its massive

2.3 billion tonnes annual production. Coalanalysts McCloskeys expects Chinas coalconsumption to rise rapidly to 3.3 bnt by

2011, partly fuelled by coal-red generatingcapacity rising at 90 gigawatts (GW) a year.After 2009, however, rising output and

stabilizing demand are expected to morethan cover this domestic increase and China

will have a rising surplus for export.

The global energy industry knows theworld can no longer rely predominantlyon fossil fuels and that renewable forms

of energy must become an increasingpart of the energy supplies of the futureif greenhouse gas emissions are to be

reduced. And the steep increase in demandfor energy as more and more people in thedeveloping economies aspire to own cars

and have electricity means looking longand hard at options to power the worldseconomies. Our future depends on it.

ReGIon

1990 2001 2010 2025

INDUSTRIALIZEDNATIONS* 182.8 > 211.5 > 236.3 > 281.4

EASTERN EUROPE/FORMER SOVIET UNION 76.3> 53.3> 59.0> 75.6

DEVELOPING NATIONS

ASIA 52.5 > 85.0 > 110.6 > 173.4

MIDDLE EAST 13.1 > 20.8 > 25.0 > 34.1

AfRICA 9.3 > 12.4 > 14.6 > 21.5

CENTRAL & STH. AMERICA 14.4 > 20.9 > 25.4 > 36.9

TOTAL DEVELOPING NATIONS 89.3 > 139.1 > 175.6 > 265.9

TOTALWORLD 348.4> 403.9> 470.8> 622.9

Source: Energy Information Administration*US, Western Europe and Australia

eneRGY ConSUMPtIon(qUADRILLION BTU)



20/3618

IN SCOTLAND THEY PREfER IT STRAIGHT OR

WITH A LITTLE WATER. IN MADRID SERVED

WITH ICE AND COLA. PEOPLE IN SHANGHAI

MIx IT WITH GREEN TEA AND IN NEW YORK

ITS THE BASE fOR A VARIETY Of COCKTAILS.

SCOTCH WHISKY IS UNDOUBTEDLY A

POPULAR DRINK ENJOYED BY MILLIONS

AROUND THE WORLD.


21/3619GENERATE MAGAZINE ISSUE 05

hen the clock strikes midnight onDecember 31 millions o peopleacross the English-speaking world

join hands and welcome the New Year witha rousing chorus o Auld Lang Syne.

Written by the amous Scottish poet RobertBurns (the title means times gone by), thesong has become an anthem to goodwill andthe soundtrack to the traditional ScottishNew Year estival o Hogmanay. This involvesa ritual called rst ooting whereby the rstperson to enter the house ater midnightdetermines your luck or the rest o theyear. Ideally, the rst ooter should be atall, dark and handsome man air hair isassociated with Viking invaders bringingcoal or the re, cakes, a coin and whisky.

Famus xpr

Scottish emigrants may have taken thespirit o Hogmanay to other parts o theworld with Auld Lang Syne but nothinghas uite captured the imagination, orthe palate, as that other amous eport,Scotch whisky. O course many countries,such as the US, Canada, Ireland andIndia, produce their own versions o thespirit, spelled whiskey, but just aboutevery bar in the world will have Scotch.

The whisky industry contributes EUR 4 billiona year to the Scottish economy and provides41,000 jobs or its citiens. Annual overseassales are a staggering EUR 3.3 billion. The

top ve markets are france, Spain, SouthKorea and Veneuela, topped by the US whichspends a whopping EUR 535 million a year.

And demand is soaring in growingmarkets such as Brail, China, India,Meico and Russia. In China alone, annualconsumption has risen rom 700,000 to5.7 million liters over the past ten years.

The projected demand in these marketsis the reason why leading drinks companyDiageo is investing EUR 133.8 millionon epanding its whisky production inScotland. This investment is one o thelargest ever in the industry and will createaround 200 jobs over the net ew years.

Ocial records show that the Scots havebeen distilling whisky since 1494 and,over the centuries, theyve developed itinto a ne art. Since the 19th century, itsbeen produced under strict license idone incorrectly, distilled spirits can bepoisonous. Today Scotch whisky is protectedby international law. This means that it hasto be distilled in Scotland and aged or atleast three years to be called Scotch. Thereare ve whisky-producing regions: Speyside,Highland, Lowland, Campbeltown and Islay.

Malig ad disillig

Whisky is made by rst baking barley toconvert it into malt. This is then groundand mied with water to produce a mash.Its the water, combined with the peat usedto uel the malting ovens, that gives thedierent whiskies their uniue avor.

Ater the mash has been ermented,it is distilled and then aged or up tothree years or blended whisky and eightyears or single malts. A single malt is,as the name suggests, the product oone distillery, whereas blended can be

a miture rom several distilleries.Distillation is based on the dierent boilingpoints o water 100C (212f) and alcohol78.5C (173f). The ermented mash is edinto the top o the still, a cylindrical towerlled with perorated plates, and steampumped into the bottom. Water vapor romthe ermented liuid condenses onto theplates and is held there by the pressure rom

the steam, separating it rom the alcohol.

The process reuires a large amounto energy to create the steam. How toreduce this has been a concern o amily-owned whisky distillers William Grant& Sons. The company turned to GEAWiegand or help. And a team headed byDr Daniel Bethge and Paul Hildenbrandwas only too happy to oblige.

Our rst idea was to use an open heatpump but this would have destroyed thetaste o the whisky, says Dr Bethge.

Instead they adapted the mechanical vaporrecompression technology that GEA Wiegandhas used successully or other applications.When the vapor rom the steamed solutioncondenses, the steam is pressuried, causingits temperature to increase even higher.The heat rom the condensed vapors can

then be re-used or the evaporation process.

It is a closed loop cycle, eplainsDr Bethge. The energy reuired is lower andless water is needed during the distillation.

Pad prcss

The process reduces the amount o energyor alcohol production by a double-digitpercentage and will cut operating costsby thousands o euros. GEA Wiegand ispatenting the process, which oers hugepotential, and is currently in negotiationswith William Grant & Sons and Diageo.

This ground-breaking innovation wonDr Bethge and his team the GEA ProductInnovation Award, a worldwide competitionto bring out the best in GEAs top talents.

Mechanical vapor recompression can alsobe applied to bio-ethanol production. Apartrom the enormous cost-saving, epectedto be several million euros, it will make amajor contribution to climate protection.

tEchnicAl innovAtion

GEA Wiegand designs, manuactures and supplies

plants or the chemical, pharmaceutical and ood

industries as well as or environmental applications.

The company oers complete alcohol processing

lines. Its engineers design systems or the treatment

o raw material, ermentation and distillation, all

o which are manuactured in GEA Wiegands own

workshops under stringent quality controls.

In addition the company has its own research and

development center in Germany or testing the latest

technology in the elds o distillation and evaporation.


22/36

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20


24/36

Q. The International Maritime Organization(IMO), which is responsible for global

regulation of the shipping industry, iscurrently focusing particular attention onenvironmental issues. How is the merchant

shipping industry responding to these issues?

A.Successful and concerted progress hasundoubtedly been made by governments

and industry with regard to reducing oil

pollution, eliminating harmful air emissionsand tackling issues relating to environmental

damage that may be caused by the movementof ballast water or by ships hull coatings.But concern about ships air emissions and

the separate issue of global warming and theneed to reduce carbon dioxide emissions arenow at the top of politicians environmental

agenda.

The reduction of ships emissions occupiescenter stage in the regulatory debate, with

potentially major implications for bothshipping economics and the image of the

shipping industry.Shipping, being a global transport industry,requires uniform international rules in orderto operate efciently. But the shipping industry

also has to respond to more general concernsabout climate change with the desire forambitious targets for the reduction of carbon

dioxide emissions emerging as a mainstreampolitical issue in many countries.

Q.What are the key environmental challenges

the industry faces?

A.The immediate challenge is the IMOs

review of its Convention for the Prevention ofPollution by Ships (MARPOL) and the expectedintroduction of more stringent controls,especially with regard to sulphur emissions

and the sulphur content of fuel.

But whilst the shipping industry appreciatesthe political impetus to the debate, it has

been important to remind governments thatthe agreed terms of reference for the currentround of IMO discussions have been to focus

on the technical and objective scienticarguments relevant to a variety of solutions.

The IMO is about to consider the latest

proposals on the approach that might be

taken. Possible options include reducing thecurrent sulphur cap in Sulphur EmissionControl Areas (SECAs), such as the Baltic Sea,

from 1.5 per cent to 1.0 per cent. It has alsobeen suggested that such a cap should applyeverywhere, and be achieved by a mandatory

switch to the use of distillate fuels by 2010.

Q. What does the industry feel about theseproposed measures?

A.ICS, which represents the industry, hasproposed a new goal-based approach toemissions reduction and has called for a

holistic consideration of emission reductionmeasures. It has drawn attention to theneed to take account of the environmental

justication for the proposed improvements,and to consider fully the relationship betweenmeasures to reduce local air pollution, such

as sulphur, and the subsequent implicationsfor CO2 /greenhouse gas emissions.In particular, we have argued that there

should be choice with regard to compliance

measures.The prevailing view of the shipping industry is

that IMO should focus on the environmentaloutcome required, but should encouragedifferent ways of achieving the agreed

emission reduction goals. Technical innovationcertainly needs to be stimulated but, whereregulation requires technical solutions, it

should be established whether proven androbust technology does in fact already exist.

Above all, any new regulations should

be aimed at delivering an overall netenvironmental benet. The shipping industry

does not wish to solve one problem by creatinganother. Methods for reducing sulphuremissions should not inadvertently lead to anincrease in greenhouse gas emissions, for

example by generating additional CO2 fromoil reneries.

It might be the case that CO2 emissions

from shipping, as opposed to shore-basedreneries, would not be increased byswitching to distillate. But the responsible

and honest approach is to suggest that theregulators consider the wider implications oftheir decisions and that the issues of sulphur

and CO2 are linked.

hE intErnAtionAl chAmBEr of shippinG

he International Chamber o Shipping (ICS) is the

rincipal international trade association or the shipping

ndustry. The aim o the ICS is to act as an advocate

or the industry on issues o maritime aairs, shipping

olicy, legal and technical matters, including ship

onstruction, operation, saety and management, and to

evelop best practice in the industry.

22


25/36

Q.So the shipping industry does not have afundamental objection to the proposal for a

switch to distillate fuel?

A.In principle, despite the considerableeconomic costs, many sections of the industry

have no objection to a switch to distillate fuelfor those shipowners who see this as themost practical solution. But, depending on

who pays the bills, it is far less attractive to

some shipping sectors than others, and thereare also big questions about the ability of the

oil industry to deliver the quantities neededif the whole world eet was required to burndistillate everywhere. The environmental

benet of using low sulphur fuels far fromland in the middle of the ocean also needscareful examination.

The majority view amongst ICS members isthat other compliance options such as theextension of SECAs and the development of

exhaust scrubbing technology should alsobe fully explored before the industry settles

for one single solution, the implications ofwhich have not been properly evaluated.

Q. What is the industry doing to reducecarbon emissions?

A.Shipowners are under pressure to reducecarbon dioxide emissions to mitigate theimpact on climate change although, at a

time when fuel prices are expected to remainhigh, cutting CO2 should be a matter ofenlightened self-interest.

A number of recent media reports haveincorrectly suggested that shippings total

carbon dioxide emissions are greater thanthose of aircraft. There is actually a lackof denitive data, but most expert sourcesestimate that shippings total carbon

emissions are considerably less than those ofaviation. But in any case such reports are notcomparing like with like. Maritime transport

is responsible for the transport of 90 per centof all world trade, including almost everythingthat we buy in the shops.

More to the point, in terms of carbon producedby every tonne of cargo transported one mile,shipping is at least two or three times cleaner

than road or rail transport and around 20

times more environmentally efcient thanair transport. With regard to concern aboutreducing carbon dioxide emissions, transport

by sea is actually part of the solution ratherthan the problem.

However, this is not to say that shipping does

not have a part to play in reducing carbondioxide emissions, and ICS is taking an activerole to achieve this, not least by stressing the

need for the IMO to address CO2 in parallelwith the review of MARPOL proposals on airpollution.

Addressing carbon dioxide emissions isindeed a major challenge, especially asmaritime trade is expected to continue

increasing steadily. The future, of course, isuncertain, but the volume of world trade hasincreased by 50 per cent in the last 15 years

and is predicted to continue expanding.

The IMOs authority for discussions aboutreducing CO2 emitted by ships is derived

from the Kyoto Treaty. Progress at the

IMO has been complicated by maritimeadministrations in some emerging economies,

which have argued that under the currentKyoto framework they should be excludedfrom any new global rules on maritime

CO2 emissions.

Work is continuing on the measurement ofgreenhouse gas emissions from ships, the

establishment of some sort of carbon indexingsystem, and the development of more fuelefcient engine technologies.

An important issue will be how shipping can

respond to the European Unions declarationin March 2007 that it intends to cut across

the board its total carbon dioxide emissionsby between 20 per cent and 30 per cent by2030, and persuade the rest of the world

to do likewise.

Discussions about reducing carbon dioxideemissions in shipping have probably not yet

really begun in earnest, but as the politicaldemand for action increases and the KyotoTreaty comes up for review before expiry in

2012, the shipping industry will need to beready to respond.

GEA And thE shippinG indUstry

GEA company Westalia Separator has an award-winning range o high perormance engine room products and

systems that help ships o all sizes protect the marine environment. Using centriugal orce, the products separate

solids and water rom uel and lube oils to ensure that discharges into the sea stay well within environmental

guidelines. The engine room products, marketed by Westalias Mineraloil Systems Business Unit, treat uel oil , lube

oil and hydraulic oil. Products or processing bilgewater and sludgewater at sea are grouped together as SeaProtect

Solutions and consistently achieve an oil content o less than 5ppm on some o the worlds biggest ships. Since being

launched in 2005, SeaProtect Solutions has quickly established an enviable position in the marketplace and in 2006

won the environmental protection category o the much-coveted Seatrade Dubai International Maritime Awards.

As the amount o cargo transported grows in uture years, Westalia Separator Mineraloil Systems wil l be working

closely with ship manuacturers and ship owners to protect the worlds oceans.

fUtUrE oUtlook

The shipping industrys status as the single most

cost-eective method o transporting goods over long

distance is likely to remain unchallenged. Over the last

40 years total seaborne trade estimates have increased

rom six thousand billion tonne-miles to 27 thousand

billion tonne-miles. And some experts are predicting

that shipping trade could triple as world commerce

continues to expand. The ships o the uture are going

to be bigger, aster and more environmentally riendly.

They wont come cheap a new tanker can cost around$120 million and their sheer size will necessitate the

building o new ports across the world. South Koreas

rst tanker was built at Hyundais Ulsan shipyard in the

1970s and since then the countrys shipbuilders track

record o on-time delivery, productivity and quality has

enabled it to dominate the construction o cargo and

bulk carriers. Europes shipbuilders primarily ocus on

the rapidly growing cruise ship industry.

worlds BiGGEst ship

Big is certainly beautiul in the world o container ships

and the Emma Maerskis the biggest o them all. Owned

by the Danish conglomerate AP Moller-Maersk Group,

her maiden voyage was in September 2006. At a quarter

o a mile long and 61 meters high, its the longest

ship ever built and its powered by the worlds biggest

diesel engine and can carry 11,000 containers, 1,400

more than its closest rival. She travels at more than 25

knots/47km/h. All with a regular crew o 13. The ships

route rom China to Europe and back again refects the

development o China as a manuacturing and exporting

powerhouse. How long Emma Maerskretains top

container ship spot remains to be seen.



26/362424

WHERE WOULD WE BE WITHOUT MILK AND,

MORE TO THE POINT, WITHOUT BEING ABLE

TO DRINK IT SAfELY?



permit its use in US dairy plants. PMO

regulations stated that a Mixproof valvecould not be cleaned until all milk had

been removed from it. Therefore, US dairyplants were required to shut down for two

to three hours a day in order to clean thepipework. During this cleaning period,the plant could not sustain production.

In April 2007, in a landmark decision,

the FDA lifted the restriction on Mixproofvalves for the rst time in US dairy plantdesign but only for the new generation

of valves designed by GEA companyTuchenhagen Flow Components. Thisrevolutionary new valve has been specially

designed so that one half of it can becleaned, while the other is in operation.

This is a huge breakthrough for

the dairy industry, which will allowsignicant productivity increases andcost reductions for dairy facilities all over

the US, says David Medlar, Presidentof Tuchenhagen Flow Components.

Around 1,000 of the new valves have already

been installed in multiple dairy plants acrossthe US. Practically overnight these plantshave gained up to 30 per cent additional

production time and, in turn, substantialincreases in operating prot. The US dairyindustry is now poised for a major change

and, with the unique valve, Tuchenhagen

Flow Components is leading the revolutionin the worlds biggest milk market.

With milk consumption showing no let-upthe two key parts of the US dairy industry collecting the milk and processing it can

now work together round the clock.


During the process the milk is fed through

heated pipes, raising the temperature of themilk to 71.7C (161F) for 15-20 seconds,

enough to kill the harmful bacteria.

In the US, pasteurization has been hailed as

one of the all-time public health successes,as milk now accounts for just one per cent

of disease from contaminated food or water,compared to 25 per cent in 1938. The Food

and Drug Administrations (FDA) Directorof Dairy and Egg Safety said in 2006 thatdrinking raw (unpasteurized) milk was like

playing Russian roulette with your health.

But even though selling untreated milk isillegal in 25 states and Washington, D.C.,many choose to play the game. There has

been a backlash against pasteurizationfrom some health-conscious consumers

who believe that the process harms themilk. Sadly, since 1998, 800 people inthe US have been taken ill as a result of

drinking raw milk or eating cheese madefrom unpasteurized milk. Thankfully, thisis a tiny minority of consumers. In 2005,

each person in the US consumed, onaverage, 32 pounds of cheese, 8.6 poundsof yogurt, 27 pounds of fat-free milk, 81

pounds of reduced fat milk, 57 pounds ofwhole milk and 26 pounds of ice cream.

Meeting this demand requires production

on an industrial scale. A combination of

vast herds some farms have as manyas 20,000 cows and modern milking

technology have made milking a 24/7operation. You would expect that processingthe milk would require the same intensity.

Processing milk on a 24/7 basis in a typicaldairy plant requires the use of Mixproofvalve technology. This enables the plant

to be cleaned in sections while productioncontinues in other parts of the plant.Although this technology has been on the

market for some time and is widely usedoutside the US, the FDAs Pasteurized

Milk Ordinance (PMO) regulations didnt

dAiry BrEAkthroUGh

Tuchenhagen Flow Components' new

generation o valves, which enable dairy

plants to continue operations while the

other hal o the plant is being cleaned,

is taking the US dairy market by storm.

hakespeare coined the phrase,the milk o human kindness,to describe compassion or others.

It seems appropriate that an actual glasso milk should be at the heart o a verytouching eample o compassion involvinga distinguished American physician.

Dr Howard Kelly (1858-1943), who was

to become one o the ounders o JohnsHopkins, the rst medical researchuniversity in the US, was on a walkingtrip in Pennsylvania when he calledat a armhouse or a glass o water.But the little girl who answered thedoor brought him milk instead.

Years later the girl went to him orsurgery. The operation was a successand she was discharged, along withher bill on which Dr Kelly had written:Paid in ull with one glass o milk.

This story helps to highlight the value

placed on milk. for centuries people havebeen consuming milk and associateddairy products. Being ull o essentialnutrients particularly protein, vitaminsand minerals, such as calcium milk iswidely regarded as natures miracle ood.

Unortunately, during the milking process,it can be inected by potentially deadlybacteria, such as Salmonella, E.coli andListeria. Which is why pasteuriation invented by and named ater the frenchscientist Louis Pasteur in 1864 hasbecome such a vital part o the milk

production process around the world.


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paint can crack and ake off as the frame

and the canvas move. The result could beirreparable damage to masterpieces.

The answer is to closely monitor andcontrol the environment where paintings

are stored or displayed. In winter, anacceptable level would be a temperature of

18-21C (65-70F) and a relative humidityof 40-45 per cent, while in summer thegures would rise to 21-24C (70-75F)

and 45-55 per cent. Naturally, paintingsneed to be kept away from additional heatsources such as furnace vents, or from

excessive humidity which can cause moldgrowth a common problem in basements.

Historic buildings and museum collections

also require stable environmental conditions.

Organic objects, for instance, containrelatively high proportions of water. When

the air is dry, they give off water whichcould make them shrink, crack or becomebrittle. In damp air, conversely, they absorb

water, with the chance of swelling, warpingor other deformation. Composite objectsmay expand and contract at different

rates. Temperature and humidity controlthrough carefully designed units is vital.

A igh a h har

Theaters and similar spaces have theirown requirements. Air conditioning isessential in many locations; but there is

also a need for quiet running so as notto interfere with the performance.

The recently refurbished Admiralspalast

entertainment center in the heart of Berlin

isit an art gallery, a museum, a national

library or a theater, and what takesyour eye will obviously be the display

or the performance you came to see. But

often, what goes on behind the scenes maybe just as important and may make allhe difference to that buildings future.

Take an art gallery, for example. Excessivelyhigh light levels can cause oil paintingso fade or darken, so its normal for them

o be displayed away from direct sunlight.Equally important though are temperatureand humidity levels. Extremes in those

variables can cause both wooden framesand canvases to swell and shrink. Woodand canvas are relatively resilient, but

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Today, the heating, ventilation and air

conditioning system at the theaterguarantees comfort for up to 1,700theatergoers, by providing up to 37,000m3/h

of conditioned and temperature-controlledair. Indeed, cooling without drafts ispossible up to a temperature of 27C

(80F). Other facilities in the complexwill also be served by the system: these

include the theater foyer, the fourth levelswimming pool, the Grand Caf, theKeller Club and the conference room.

The frequency converters and free-running

fans allow continuously variable controlof the air output, as required. This featureboosts energy economy, since one half

of the air output needs only one eighth ofthe full-output electric power for the fans.Both the air-handling units make use of

adiabatic cooling: this is an environmentally-friendly system whereby air owing in from

outdoors is cooled by evaporative heat lossof exhaust air, requiring no electric energy.

Last but not least, the quietness of any

theater ventilation system is vital. Here againthe GEA air-handling units score heavily:their low air speed effectively eliminates

any noise problem. The maximum noise isjust 30 dB(A) one meter from the air outlets.At this level, even when the actors only

whisper on the stage, they will easily make

any sound from the ventilation inaudible.

is a testament to what can be achieved.

The present building was constructed in1911 and converted to a theater in the1930s. It was closed in 1997 and remained

empty and unused until August 2006. It isnow once again a home of art and culture,entertainment and social gatherings;

and the century-old building boasts astate-of-the-art ventilation system.

The project managers faced a challenging

task since the renovation plans stipulatedextensive preservation of the building shelland the indoor facilities. They also needed

to replace the entire existing ventilationsystem because the old facilities either nolonger functioned or did not meet current

regulations. Nevertheless, using two compactbut advanced air-handling units from GEAsAir Treatment Division, the managers

were able to meet the specications.


30/362828



WHENSteFFen beRSCHMOVED TO DUBAI TO

HEAD UP GEA COMPANY WESTFALIA SEPARATORS

MIDDLE EAST OPERATIONS HE NOT ONLY HAD

TO GET USED TO A CHANGE OF CLIMATE BUTALSO DIFFERENT WORKING HOURS AND WAYS

OF DOING BUSINESS. AND, AS GeneRAte

DISCOVERED, HES ENJOYING EVERY MINUTE.

pharmaceuticals, food and industrialproducts, says Bersch. Environmentaltechnology is also a growth area that is

providing major opportunities for us.

Traveling accounts for around 40 per centof his time, otherwise his working dayrevolves around the Dubai ofce where

he heads a team of ten sales engineers,service engineers and administrative staff.He is also responsible for a network of 20

agents representing the company in thedifferent countries across the region. Inaddition to selling the companys products,

Bersch and his team look after theservicing and repair of existing machines.

It is very different from working at our

headquarters in Germany where there

is an organization with someone to solveevery problem, whereas here you haveto be master of everything, he says.

There is a lot of administration workbecause Dubai is such an internationalcity that almost everyone you hire needs

to have a visa and work permit.

And that includes Bersch himself. Hemoved to this boomtown from Bochum,

Germany, with his wife and two childrenin August 2007. As well as acclimatizinghimself to the searing summer heat

50C (122F) during the day and 37C(98F) at night Bersch has had to getused to a different way of working.

Friday is the Muslim holy day so theworking week generally runs from Sundayto Thursday and some companies operate

Saturday to Wednesday. It took me someweeks to get used to the different times,Bersch recalls. Because I can only get

in touch with headquarters for four daysof the week, I have had to organize mytime accordingly. But during those four

days we can be sure of fantastic supportfrom our colleagues in Germany.

Another difference is the way negotiations

with customers are conducted in Dubai.Typically there is a lead partner whocan make a decision at the end, whereas

in Europe for example, you have to deal

with procurement groups which meansyou have to convince more people.

Bersch and his family have embracedthe international lifestyle of Dubai.The two children are happily settled

in an American school which includespupils from 70 countries.

The climate means that he can indulge his

love of cycling all year round. When I wasin Germany it was not possible to cycle inthe winter, he says. Now I train twice

a week with a group of cyclists in Dubaiand my kids are also taking part.

IT IS VERY DIFFERENTFROM WORKING AT OURHEADQUARTERS INGERMANY WHERE THEREIS AN ORGANIZATION WITHSOMEONE TO SOLVE EVERYPROBLEM, WHEREASHERE YOU HAVE TO BEMASTER OF EVERYTHING

espite a 4.30am start, a six-houright delay, late meetings andhaving to t in talks with Jordanian

customers the following day, SteffenBersch is remarkably cheerful.

Im in a very good mood, he laughs. Butthen talking to customers and winning new

business is what Bersch enjoys most abouthis job as General Manager for WestfaliaSeparators Dubai ofce. Also this particular

trip, to the Jordanian capital of Amman,meant leaving behind the heavy rain whichhad earlier ooded parts of Dubai.

Bersch is responsible for all WestfaliaSeparators activities across the MiddleEast region. The visit to Amman was to

discuss supplying his companys productsfor energy and service projects in theregion. A lot of business in the region

is run through partner and contractingcompanies based in Amman, he explains.

Due to the high power demand, the

energy sector is currently by far thebiggest market in the region for WestfaliaSeparators centrifuges, which are an

essential part of the oil treatment process.

Other important areas are growing asthe Middle East countries recognize the

need to create their own added value to

products by investing in, for example,


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Designer dress fabric? A shoal of metallicsh? In fact this striking picture showsa disk stack in a separator bowl. Itsplits the product to be separated intoa large number of thin layers, therebyincreasing the clarication area andshortening the sedimentation distance

that the separated particle has to cover.

30

Centrifugal separation technology is akey process used in a broad spectrum ofapplications: dairy technology, beveragetechnology, edible oil processing, oils andfats recovery, starch technology, chemistry,pharmaceuticals, biotechnology, marine,oil eld technology, energy as well as

industrial and environmental technology.


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BAvAriAs finEst GoEs Alcohol-frEE

One o Bavarias most amous wheat beers is soon

oing to be available alcohol-ree as a result o a

nique process developed by GEA Wiegand. The new

eer de-alcoholization plant at amily brewer Private

Weissbierbrauerei G. Schneider & Sohns Kelheim

ite will use a process rst developed by Wiegand

n the 1980s. Based on the alling lm evaporator

rinciple, its the only known process o its type without

ecirculation or redilution. Tuchenhagen, one o GEAs

rewery specialist companies, is working with Wiegand

n the new plant.he result is a natural product, able to satisy the most

emanding palettes and preserving the reputation o

his proud brewery.

www.gea-wiegand.com

nEw phArmA procEssinG linE in thE nEthErlAnds

GEA Pharma Systems (GPS) has developed a complete

rocessing line or one o Europes most successul

manuacturers o generic medicines.

ynthon BV, based in the Netherlands, manuactures

range o products or worldwide distribution through

ts marketing partners. It required new equipment or aartner manuacturing plant to up-scale production o

ne o its products, and chose the GPS Nica system ater

n exhaustive evaluation process.

he project includes the supply and integration o

ranulation technology with GEA pelletizing systems,

oating technology and fuid bed drying.

www.niropharmasystems.com

risE of thE roBots

The acquisition o the global license or the T!TAN

robotic milking system rom PUNCH Technix nv

o Vijhuizen in the Netherlands has boosted GEA

WestaliaSurges leading position in the worlds dairy

equipment business.

T!TAN is currently the only system that enables the

use o robotic milking on virtually all arms, regardless

o their size, and is seen as the perect complement to

WestaliaSurges existing range.

The robotic milking equipment will continue to

be manuactured at PUNCH Technixs plant orWestaliaSurge. WestaliaSurge will also take over

all PUNCHs existing robotic milking contracts, with

sections o the PUNCH Sales and Service Team being

integrated into the organization.

The unique T!TAN system oers the nancial

economies o scale necessary to cope with herd growth

and increases the number o potential new customers

or WestaliaSurge.

www.westalia.com

wiEGAnd rEcEivEs tEchnoloGy lEAdErship AwArd

GEA Wiegands work in the bioethanol market hasbeen recognized with a European award or technology

leadership. The 2007 Frost & Sullivan Award is given or

technological excellence, superb customer support and

timely delivery o technology.

Wiegands bioethanol technology is the most advanced

on the market. It can help cut operating and energy

costs, reducing plants carbon ootprint in the process.

In addition, it oers a host o plant support services,

rom training and maintenance to operation and

upgrading.

The company also has superior uel ethanol drying

technology. Wiegand has pioneered key technology

developments in this challenging area, including

molecular sieves and complex membranes. No

other company has such a deep understanding o

rectication, evaporation and separation techniques.

www.gea-wiegand.com

GEA powErs AhEAd in soUth AfricA

GEAs Thermal Engineering Div ision has won a turnkey

order or a brand new ossil-uelled power station in

South Arica. GEA Aircooled Systems will be designing,

manuacturing, supplying and erecting the air-cooled

condensers or the Medupi Power Station in Limpopo

Province.

The end customer is Eskom, South Aricas leading

power producer. The Medupi Power Station is an integral

part o the countrys policy to increase installed power

capacity. The major portion o the equipment and

services or Medupi will be put in place between 2008and 2013, and will result in signicant work or GEAs

Johannesburg-based operation.

GEA Aircooled Systems has extensive experience in the

eld o air-cooled power plants in South Arica, having

previously supplied Eskom with air-cooled condensers

or both the Matimba and Majuba Power Stations.

www.gea-energytechnology.com


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