Issue 1 / 2009 / Inside …donar.messe.de/exhibitor/hannovermesse/2017/G96094/...Inside Hydraulik...
Transcript of Issue 1 / 2009 / Inside …donar.messe.de/exhibitor/hannovermesse/2017/G96094/...Inside Hydraulik...
Inside HydraulikThe Official WATZ Hydraulik Newsletter
Issue 1 / 2009 / www.watzhydraulik.de
When it comes to efficientpower transmission, you can relyon WATZ Hydraulik
Always on the move
Over the past few years, hydraulics
engineering has been increasing in
significance in all areas of drive and
control technology, in particular, the
fields of machine, plant and vehicle
construction. At the same time, client
demands on quality and efficiency of
the systems in use have also increased
greatly. WATZ Hydraulik has been
meeting the challenges of these markets for over 35 years.
Moving in sync with the market and the constantly chang-
ing technical demands, WATZ Hydraulik has never slowed in
offering its clients innovate and industry-spanning hydraulics
products. With hydraulics engineering being, as a rule, an in-
tegral component of an overall system, WATZ constructors
and technicians have been trained to collaborate with mech-
anical engineers and plant constructors in elaborating plans,
schedules and everything else needed to carry out a project
successfully. This is the only way to develop optimum sol-
utions while avoiding later alterations and modifications,
which are always costly and often unnecessary. WATZ Hy-
draulik produces made-to-order constructions and refines
these as specific large-batch or small-batch production
models according to customer requirements. The follow-
ing pages will offer you some insight into the diversity of
WATZ Hydraulik’s range and service spectrum. Countless
industries around the world stay on the move thanks to
hydraulics products produced in Central Hesse – from
materials handling technology and foodstuffs preparation all
the way to the demolition of chemical weapons. Wherever
one requires the efficient transmission of power, you’ll find
WATZ products doing the job.
And if you turn over this newsletter, you’ll be able to
become better acquainted with FAUDI GmbH. At home in
the filtration industry, this long-standing firm entered a busi-
ness partnership with WATZ Hydraulik GmbH in 2006. Both
companies are experts in the field of special purpose machin-
ery manufacture. Using this and many other synergies is the
secret behind the success of our business collaboration. We
hope you’ll find this newsletter informative and inspiring.
Best regards, WATZ Hydraulik GmbH
Horst Watz
2 | 3
Contents
3 Pressure: The most natural thing in the world – for WATZ
4 Where quality saves lives
5 Successful plant engineers rely on WATZ hydraulics technology
6 Perfect porcelain requires perfect technology
7 Precision meets performance
8 Finding solutions where no solutions can be found
9 Why look far ...
Big performance, small space!
10 Moving water in massive amounts
11 Digging for black gold
12 Rings and wheels for the automotive industry
Imprint
WATZ Hydraulik GmbH
Auweg 8 · 35457 Lollar · Germany
Phone +49 (0)64 06 91 02-0 · www.watzhydraulik.de
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Learning from Mother Nature? That’s nothing new. The
lessons of nature have, after all, been behind countless life-
changing inventions. Today, nature continues to serve as
a shining example for process efficiency and state-of-the-
art technology. At WATZ Hydraulik, we too are inspired by
nature when it comes to developing new hydraulics tech-
nology. And it’s no surprise, really, with nature performing
massive force transmission, often on the smallest scale, or
changing momentum at will. Care for an example? Let’s take
the sperm whale, which uses an ingenious system to reach
the oceans’ deepest depths.
A sperm whale’s brain is known to hold some 2,000 kg
of “spermaceti”. This wax-like substance enables the sperm
whale to dive to great depths while also helping to control its
buoyancy. The density of spermaceti changes with the influx
and efflux of water. It makes it possible for the whale to dive
with a minimum exertion of energy. With a decrease in tem-
perature, spermaceti forms brilliant white crystals. This den-
sification leads to an increase in weight, thereby enabling
the sperm whale to sink more easily. When hunting at great
depths, sperm whales use up their oxygen, thus generating
heat and melting the spermaceti. Despite utilising hydrody-
namic force, i.e., by swimming, the sperm whale is never-
theless able to continue its dive. Once it is ready to resurface,
the sperm whale simply expels the sea water from its body
and begins to ascend.
Nature gifted the sperm whale with this natural technol-
ogy. If it hadn’t, WATZ would surely have helped the sperm
whale on its way. Aside from the development and production
of customised hydraulic systems, WATZ also sets itself apart
from its competitors by offering comprehensive customer
service. At WATZ, we support our customers as early as the
planning stage, ensuring that clients receive individual care
and attention, customised to suit their individual demands.
Work processes are coordinated automatically, thereby guar-
anteeing absolute precision in handling and application. And
that saves both time and money!
Pressure: The most natural thingin the world – for WATZ
Examples of Nature
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Chemical warfare ranks as the most dangerous, the most
deadly and the most feared method of waging war. At the end
of World War II, the use of chemical and biological weapons
was prohibited by the international community. Since then,
aside from the numerous violations that have occurred
despite this decree, mankind has also had to deal with another,
similarly important issue: What to do with the chemical
weapons that already exist? These arsenals of doom harbour a
great potential of danger in more ways than one. Their use on
humanity is of course the primary risk. However, the improper
storage of such weapons is no less dangerous. Environmental
catastrophes of unimaginable scale loom on the horizon.
Large caches of chemical weapons are still in storage across
Eastern Europe and the former Soviet Union. In 2006, several
German companies helped to establish special facilities for
the demolition of chemical weaponry in the Russian cities of
Kambarka and Potchep. Each of these plants prepares up to
1.000 kg/h of reactive matter for incineration. Special technology
provided by WATZ Hydraulik is in operation at both plants. The
Stuttgart-based company Eisenmann AG is known to be the
world’s leading system supplier of surface, environment and
process technology. Their expertise in constructing facilities
for exhaust air and waste water treatment and, in particular,
thermal recycling and disposal of waste materials, is of primary
importance in the disposal of chemical weapons. For these
aforementioned applications, Eisenmann supplies a variety
of technically sophisticated components, including explosion
chambers, state-of-the-art robotics for transporting chemical
warfare agents and special ovens in which nerve gas is safely
incinerated. Many of these plants also feature components
supplied by WATZ Hydraulik. In this field, the smallest error
can lead to great catastrophe. The companies charged with the
demolition of these weapons and the manufacturers of the
machinery in use therefore rely only on those components
suppliers able to guarantee the highest-possible product quality.
That is why Eisenmann relies on hydraulics products made by
Where quality saves livesTechnology developed by WATZ Hydraulik in action against chemical weapons
4 | 5
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Technology developed by WATZ Hydraulik in action against chemical weapons
WATZ Hydraulik. Due to the very special circumstances of the
project, WATZ was integrated in the planning and construction
phases from the very start. Working closely with Eisenmann’s
development department, WATZ was able to develop optimum
solutions for this highly sensitive area of application. WATZ
provided the entire hydraulics station for the shuttle kiln. The
power unit, installed on a special platform, was charged with
opening and closing the shuttle kiln’s lift gates, which weigh
some 18,000 kilograms. Each lift gate is operated by a separate
power unit. To ensure operating safety, the power units are
switched to the alternate lift gate.
The lift gates themselves are raised and lowered by a
special chain hoist. When lowered, the lift gate touches down
on special rollers and is then pulled up to the furnace chamber
by way of additional horizontally installed, unidirectional
cylinders. This towing action must occur under a specifically
predetermined amount of pressure, as the incineration
process can potentially cause an increase in pressure of up
to +300 mbar. Special safety valves prevent excess pressure
inside the chamber. Furthermore, pressure reservoirs have
been integrated to prevent pressure peaks. In the very unlikely
event of hydraulic system failure, full closure of the lift gates
is nevertheless guaranteed. Moreover, the gates are also
protected against sudden collapse caused by an unforeseen
loss of pressure, as it is possible to open only one gate while
the system is in operation.
With all of these measures in place, this WATZ system is
able to guarantee maximum operational safety. Not bad for an
application that is in use on 350 days a year, with three shifts per
day! WATZ technicians were naturally on hand during system
start-up and visit the site regularly for service and maintenance
calls. System documentation was made available to the client
in Russian, English and German language.
Pictures: Eisenmann AG
More than 100 core sand treatment plants is a fact that
speaks for itself: K & W is one of the most successful plant
engineering companies in this field and its reputation has been
built on quality and constant innovation since its beginnings
in 1907. Its product offering ranges from individual casting
machines to complete – fully or semi-automated – casting
plant, including core sand treatment and regeneration.
Casting machine performance ranges from 10 to 330 casts/
hour. In exactly the same way as Watz, K & W always focuses
on meeting its customers‘ requirements. For this reason,
the casting plant is always tailored to the customer‘s special
needs. The average technical availability of K & W is over
98%. High-precision humidity control and weighing equip-
ment together with robust cooling and mixing design
ensures a consistently high level of sand quality. All K & W
products are characterised by innovation, expertise and
experience combined with sound, high-quality design. And
in order to provide its customers with the trusted high quality
in all areas of plant engineering, K & W also relies on hydraulic
systems from WATZ.
This is true for its projects all over the world. In Brazil, for
example, it built a modern casting facility for an automotive
components supplier which has been manufacturing motors
and clutch systems for many well-known car makers in
Curitiba/Paraná Brazil ever since. WATZ supplied the hydraulic
power systems for this project. The equipment supplied
includes hydraulic power units with a tank volume of up to
32,000 litres.
Successful plant engineering com-panies rely on hydraulics from WATZ
Innovative core sand treatment for foundries
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Ceramic production is one of humankind‘s oldest cultural skills.
The combination of time-proven knowledge and the use of
state-of-the-art technologies make it possible to produce the
highest quality ceramics. This is what Eisenmann AG, based
in Böblingen, stands for. Eisenmann is a leading international
system provider in the areas of surface finishing, material
flow automation, ceramics, thermal process engineering and
environmental technology and employs some 2,600 people
in its many locations in USA, Mexico, Brazil, United Kingdom,
France, Spain, Italy, China and Thailand. Eisenmann supplies
complete firing lines for chinaware and sanitary ceramics
Perfect china demands perfect engineering
WATZ hydraulic systems meet royal requirements
6 | 7
with fully automated material flows from the moulding
operation right through to sorting and packing. Well-known
customers such as the Königliche Porzellan-Manufaktur
depend on quality made by Eisenmann. In order to meet the
high demands of its end customers, Eisenmann relies on
components from Watz Hydraulik in its kilns and machinery
such as spray-glazing facilities and driers. For Eisenmann AG,
the name Watz Hydraulik stands for professional know-how,
leading-edge technology and customer-focused service and
guarantees the optimum result for every end customer.
Pictures: Eisenmann AG
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
The highest possible precision is the essential prerequisite
for achieving lasting success in the components supply
industry. Schuler AG, with its headquarters in Göppingen and
18 further locations on three continents, is a technology and
global market leader in forming technology and puts its full
trust in the quality of the products supplied by Watz Hydraulik.
Watz Hydraulik supplies Schuler, for example, with standard
cylinders in all sizes together with the corresponding special
equipment. Special cylinders in Schuler machinery, for example
built in the form of telescopic cylinders, also come from Watz
Hydraulik. A hydraulic drive unit designed to provide power
to a forming machine using cold forming technology was
supplied to the end user AUDI AG. The hydraulic power unit
is built on a walk-on platform (in accordance with accident
prevention safety regulations). The mechanical cutting
and forming machines from Schuler, equipped with parts
supplied by Watz Hydraulik, meet any challenges made on
them such as increasing quantities, complex part geometry
and processing high-strength materials. The pressing forces
exerted by the machines range from 2,000 to 30,000 kN.
Watz Hydraulik and Schuler – a strong partnership for
innovation and the highest quality.
Pictures: Schuler AG
Precisionteams up withperformance
Hydraulics for forming technology
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Providing seemingly impossible solutions
Bending and forming technology
8 | 9
This is the brand
promise of transfluid®
Maschinenbau GmbH.
A promise that the tube
processing specialists from
Schmallenberg have to honour
every single day. Over the last 20 years,
transfluid® has established itself as the
leading manufacturer of pipe bending and end
forming machines in the market. Once a medium-
sized company, the transfluid® brand of today has become
a future-oriented global player. Wherever tubes are bent, cut
formed or cleaned in the world – transfluid® is never far away.
„We are proud to have supported transfluid® in this success
story for more than 20 years“, says Horst Watz, Managing
Director of WATZ Hydraulik GmbH, based in Lollar near
Giessen. The two companies have enjoyed close cooperation
for all of these 20 years. WATZ mainly supplies hydraulic
power units and differential cylinders (in special sizes). The
products have been developed and improved on the basis
of many years of experience. What is special in this is that
WATZ manufactures many of these products especially for
transfluid® in series and thus supplies customised equipment
from series production. Nevertheless, some special power
units and cylinders for tube bending pilot projects are supplied
custom-made. One example is the end customer Deutz. The
specially designed and produced tube bending plant was
assembled directly in the factory.
The power units required were
produced by WATZ in
close cooperation with
transfluid® and in accord-
ance with the end customer‘s
individual specifications. A
further example is MJ Gerüst
GmbH, a well-known German
producer of scaffolding systems. The
plant from transfluid® is installed as stationary
equipment in the factory and performs work in the areas of
clamping, bending and stamping. An appropriate hydraulic
system was designed and supplied by Watz for this. 14
devices (clamping and forming cylinders) are controlled and
supplied with power via a system connection from a central
power unit. The hydraulic power unit is equipped with all the
extras required: reservoirs to reduce pressure peaks and
absorption of fluctuations in pressure and volume flows.
Daisy-chained mounting subplates favoured by Watz ensure
that valves can be replaced quickly and easily. transfluid® has
good reason to rely on the quality supplied by Watz Hydraulik.
Once more, long-standing and above all trusting customer
relationships always pay dividends. transfluid® and WATZ
Hydraulik have proven this in many projects – both nationally
and internationally.
Picture: transfluid® Maschinenbau GmbH
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Good partnerships can also often be found on one‘s very
own doorstep. A good example is the firm Howial in
Reiskirchen. The company, a manufacturer of special
machinery for wood processing, is located in the immediate
neighbourhood of WATZ Hydraulik‘s headquarters. It has
been manufacturing finger-jointing machines near the
university town of Giessen for over 30 years. The family-run
company, now in the third generation, plans and develops
a full range of finger-jointing machinery. The Howial name
stands for reliability, high performance, intuitive operation
and robust design. This accords with the demands for
quality that WATZ Hydraulik also places on its product range
Both companies are also owner-managed and have an
Why seekfar afield ...
On the doorstep
Hürner Schweißtechnik – stands for innovation,
performance, customer focus and operational safety with
a widespread network of competent partners around the
world. The company has been in the business of developing,
producing and marketing products for plastic pipe joining
for more than 25 years. The demands for premium quality
that Hürner Schweißtechnik places on itself and on its
services can only be met by incorporating first-class
products in all its equipment and machinery. This is the only
way to ensure the end customer‘s long-term satisfaction.
Hürner Schweißtechnik GmbH is well aware of this and
therefore depends on products from Watz Hydraulik in its
equipment. Special miniature power units from Watz have
High performance in the smallest spaceCustomised lightweights
been incorporated into the portable welding units that are
used by Hürner GmbH. What is important in this is that
all important valve functionality of the pressing and drive
unit is implemented compactly and with no loss of quality
in the control or valve block. And of course, the design
of the units may not exceed a certain format and weight
in order to ensure that the equipment in which they are
used remains mobile and portable. Watz Hydraulik took
up this challenge and has developed a series product
that exactly matches the wishes and requirements of the
customer, Hürner Schweißtechnik. Flexible solutions for
any requirements without compromising reliability and
quality – Watz Hydraulik makes it possible.
international focus. It is therefore not surprising that these
two neighbours have sought out and found each other.
Picture: Howial
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
VAG GmbH moves water – on any scale. The Mannheim
company is a manufacturer of innovative and reliable valves.
Its product range includes state-of-the-art technology in the
treatment of water and waste water together with many
customer-specific solutions. Wherever water is treated,
moved, stored and distributed, VAG gate valves and butterfly
valves, plunger valves and hollow-jet discharge valves, air
release valves, control valves and hydrants play an important
role. Durability and decades of operational reliability matter.
Repairing or replacing valves that often weigh several tonnes,
such as those used in dams, is very costly. The supply and
distribution of water and the treatment of waste water are
very demanding operations. Valves must be able to withstand
high water pressures and extreme temperature and weather
conditions, irrespective of whether they are used in a desert
or tropical climate. WATZ Hydraulik supplies the right solutions
for even these most demanding scenarios. As VAG GmbH‘s
When large quan-tities of waterneed to be moved
Hydroelectric power plants in Asia
10 | 11
partner, the Central Hessian company is supplying hydraulic
units for two projects currently under way in Indonesia and
China. WATZ is supplying a complete hydraulic unit for the
construction of a hydroelectric plant in Indonesia. The hydraulic
power systems are primarily intended to drive and control the
hollow-jet discharge valves installed. The discharge valves are
controlled via the turbine‘s oil hydraulic system. Should the
turbines fail, the valves will open by themselves within four
seconds at the most. This prevents pressure peaks in the
system. The type ZM differential cylinders supplied are capable
of pressures of up to 250 bar and operate synchronously. The
cylinders of course have the necessary corrosion protection.
Reliability and safety are the key requirements in this project
relating to sluice-gate operations for the 150 km Asahan river
in Indonesia.
Pictures: VAG Armaturen GmbH
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
The company ITAG was founded back in 1908 and today
employs some 550 people. The ITAG engineering works are
primarily engaged in the manufacture of equipment for the
for the oil and gas industry such as ball valves, drill string
components and wellhead systems. ITAG products are used
all over the world in the production of oil, gas and geothermal
energy. ITAG also performs drilling and workover services for
its customers. It is in this area in particular that hydraulic
technology made by WATZ Hydraulik is used.
The Central Hessian hydraulics specialist supplies, for
example, complete hydraulic power units for ITAG‘s drilling
rigs. What is special about the equipment is the way in which
the technology is powered. The power units are installed
in easily transportable sound-insulated containers and
comply with the strict ATEX directives governing electrical
and mechanical equipment used in potentially explosive
atmospheres. This is particularly important with regard to the
equipment‘s specific use. When drilling down into the earth,
underground gas-bearing formations may be encountered.
Depending on the installation site, escaping gas could
enter the container. Moreover, performance loss due to the
distance to the hydraulically-driven devices must be avoided.
The container is equipped with two power units, with one
of the two 210 l/min units in constant operation while the
second is ready to run in standby, this covering any outages.
The complete motor-pump unit is mounted on a carrier plate,
and the unit can be raised with the help of a double-action
cylinder using a manual pump. This makes any future repair
or maintenance work in the container much easier.
ITAG attaches great importance to innovative solutions for
its components, flexible management, highly qualified staff
and of course reliable components suppliers. For this reason
WATZ Hydraulik is justifiably proud of having ITAG among its
customers.
Picture: ITAG GmbH
Where blackgold gushes
Hydraulics for drilling specialists
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
Rolling rings and wheels requires special technical and
technological competence. The roots of the SMS Meer
Group stretch back to the year 1872. Sufficient time in which
to develop above-average competence and appropriate
expertise. The Group is nowadays one of the world‘s
leading plant manufacturers, and the SMS Meer name is
well known in the steel, copper and aluminium industries.
SMS provides a complete range of products and services:
comprehensive expertise is provided from the initial layout
to the completed ring and wheel rolling mills. Hydraulic
engineering from Central Hesse is very much in demand for
Inside Hydraulik – The Official WATZ Hydraulik Newsletter
12
Rings and wheels for the automotive industry
Tradition since 1872
the implementation of individual projects. WATZ Hydraulik
designs and manufactures complete hydraulic power units
with large tank capacities for SMS. The most recent delivery
consisted of a WATZ power packet – a hydraulic power station
comprising power units with 400, 800, 160 and 630 litres
capacity respectively. SMS installed the power station for
one of the world‘s largest automotive components suppliers.
These power units provide the customer, a manufacturer of
components for diesel and petrol injection pumps as well
as gearboxes and engines, with the power to drive pressing
equipment and ejectors reliably. Picture: SMS Meer GmbH
Sollte hier auch was stehen? Sollte hier auch was stehen?
The China National Offshore Oil Corporation (CNOOC) is
China‘s third largest petroleum company. It runs large
cooling systems with sea water in its plant and machinery.
Depending on where the plant is located, this process water
can be contaminated in all sorts of ways, e.g. by algae,
shells or gravel and stones, resulting in unwanted deposits
and blockages in the downstream plant sections, heat
exchangers and pipes. In order to avoid this, CNOOC relies
on continuous-operation filtration systems from FAUDI such
as the fully automated Type 30 backflush filter. The backflush
filter is cleaned without interrupting operations by using part
Clean sea water thanks to automatic backflush filters
FAUDI for CNOOC
Technical Data
Medium: sea water
Flow volume: 760 m3/h
Filtration grade: 100 μm
Design pressure: 13.8 bar
Design temperature: 60 °C
of the flow of the clean flow medium. Each of the installed
filtration elements is flooded one after another in the reverse
flow direction, and the dirt that has been deposited on the
filter surface is removed and rinsed away. The optimum
product characteristics of the Type 30 automatic backflush
filter from FAUDI were the arguments that convinced the
CNOOC to cooperate with FAUDI. This filtration system
represents qualities such as reliability and robust design with
low running costs and no maintenance.
12
Sollte hier auch was stehen?
Andasol 1 to 3 are located in the Spanish province
of Granada, with Andasol 3 still under construction.
They are state-of-the-art solar-thermal power stations that,
following completion, will consist of 510,000 square meters
of collector surface - Europe‘s largest solar power station.
The technically usable potential of solar-thermal electricity
generation exceeds the worldwide demand for electricity
many times over. Solar radiation heats up oil as a heat
carrier to approximately 300 °C, which is then pumped to
circulate through the system and transfer the energy. In this
process, very fine particles develop, which are deposited
on the insides of the piping and which can cause damage.
To prevent this, candle filters with special stainless-steel
backflush filter elements from FAUDI are used in Andasol 1
and 2. The special design of these HTF filter elements means
that, when the backflush valve in the lowest part of the filter
is briefly opened, dirt is washed out of the filter elements
and discharged from the system. This serves to protect the
sensitive machinery from dirt and suspended particles in the
Protected solar powerin Spain
FAUDI for Andasol
Technical Data
Medium: heat carrier oil
Design pressure: 18.5 bar
Design temperature: 400 °C
Flow volume: 150 m3/h
Filtration grade: 20 μm
optimum way. The filters achieve a filtration grade of up to 3
μm. The newly developed gas-assisted backflushing process
and the newly developed filter elements in the FAUDI candle
filters also reduce flushing loss considerably. This protects
the environment through less waste and also allows financial
savings to be made due to lower amounts of expensive oils
being lost. Besides Andasol, FAUDI candle filters are also
used in Spain in the Extresol power stations 1 and 2.
10 | 11
Depending on requirements and the process used,
hydrocarbons from the feedstock products are cracked
and further treated in a reactor with a catalyst bed. If impurities
such as coke particles, rust or other metals are deposited in
the reactor, the whole process could be impacted. Influence
on the speed of the reaction, an increase in the differential
pressure, poor liquid distribution in the catalyser and, above
all, long downtimes for the expensive catalyst plant are
only some of the possible consequences. It is therefore
important to avoid these negative and costly effects. A high-
performance filtration system from FAUDI is the solution. And
there is a good reason for this: as a leading filter manufacturer,
FAUDI can look back on 70 years of company history that
includes many technical innovations and patents. Many oil
refinery operators therefore rely on FAUDI filter technology.
Sophisticated catalyser protection
FAUDI for BPCL
Technical Data
Medium: vacuum gas oil
Flow volume: 318 m3/h
Filtration grade: 20 μm
Design pressure: 25 bar
Design temperature: 340 °C
Bharat Petroleum Corporation Limited (BPCL), one of India‘s
highest-turnover companies, puts it faith in modular filters
from Stadtallendorf. This range of modular filters is a system
designed to filter hydrocarbons and runs automatically,
almost maintenance-free and above all with no filter material
consumption. Cleaning is effected automatically, with the
candles in the filter being flushed in the reverse direction of
flow – without interruption to the filtration process. Thanks
to its modular design, large flow volumes can be handled.
It is also possible to extend the filter systems in a variable
way. This ensures that a customer-specific extension can be
added to the plant while keeping costs under control. BPCL
trusts the filters made by FAUDI and secures competitive
advantage for itself by reliably protecting the catalyst beds
from contamination and improving cycle times.
Inside Filtration – The Official FAUDI Newsletter
The fascinating inner-lifeof an ocean giant
FAUDI for Shell GmbH
Sollte hier auch was stehen?
Tankers fascinate people due to their huge size. It is not
apparent at first sight that in the interior of the giant ship
finely tuned and elaborate mechanisms must operate in
order for loading and unloading to be performed smoothly.
For example, in the final stage of unloading, large quantities
of air are fed through the pipes. This must be separated out
of the liquid flow before it passes the measuring devices.
Here, everything depends on the highest possible precision
and reliability of the technologies used. In its tankers, Shell
GmbH uses gas separators from FAUDI, which, in addition
to having approval by the weights and measures authorities,
guarantee the performance of the gas separation and also
require no maintenance. By constantly measuring the fill
level, the system prevents the level of liquid from sinking
to a critical point, and pressure blows can be intercepted.
Besides helping in the unloading of tankers, FAUDI gas
separators are used in many systems for transferring aviation
fuels, petrol and other hydrocarbons.
Technical Data
Design pressure: 25 bar
Design temperature: 50 °C
Flow volume: 450 m3/h
Air throughput: max. 2,200 m3/h
8 | 9
How can the exacting demands of a global player with 75
years of history be met - one which also happens to be
number one worldwide in the independent servicing of civil
aviation engines? MTU Aero Engines is one such company. It
develops, manufactures, services and repairs jet engines for
the civilian and military markets and has achieved a leading
position in this field of engineering. In addition to several
locations in Germany and a number of global partnerships,
MTU has had a manufacturing facility in Rzeszów in Poland
since the beginning of 2009. Two FAUDI vacuum filters are
used for the required processing of the cutting fluids for
two processing lines used to machine nickel-based alloys,
high-alloy steels and titanium. The floor-based systems
Global playerswelcome
FAUDI for MTU Aero Engines
Technical Data
Filter surface: 7.5 m2
Filtration grade: 30–50 μm
Feed quantity: 2100 l/min and 2200 l/min
Design pressure: 12 bar an WZM
Operating temperature of coolant: 22 °C
Container (steel): approx. 19,000 l
serve as the central units for supplying groups of machines
comprising six and four grinding machines respectively.
Filtration is effected using non-woven fleece in order to
achieve the required filtration grade of 30 μm. A control
system programmed by FAUDI ensures that all elements
and power units interact reliably with each other. In order to
guarantee the assured availability of its plant over the long
term, MTU puts its trust in the many years of experience
in planning, design and manufacturing that FAUDI can look
back on. The expertise and product quality of FAUDI GmbH
provides MTU Aero Engines with the basis for a successful
and dependable partnership.
Picture: MTU Aero Engines
Inside Filtration – The Official FAUDI Newsletter
Germany‘s second largest tyre manufacturer,
Continental AG, sees great potential in the South
East Asian region. As a result, the company decided to
set up a new production facility in Thailand. It has been
producing components for diesel fuel injection systems
there since the beginning of 2009. Continental ordered
two central coolant processing systems in order to set up
the new production operations. The „soft“ production area
is supplied by a FAUDI FUF 22 vacuum filter unit (main
filtration) and an AS 18 pre-coat filter unit (bypass filtration)
while the „hard“ production area is supplied by FAUDI
Type AS 34 twofold pre-coat filters (that can be extended
up to fourfold).
Parts made from cast metal are processed on the soft
milling machines. A FAUDI vacuum filter with relatively
high-quality filter fleece was chosen as the filtration
solution for the machining oil, which is required in filter
quality NAS 12. This ensures that high filtration quality and
Quality for any demandFAUDI for Continental, South-East Asia
Sollte hier auch was stehen?
a filtration grade of approx. 30 μm are achieved even with
new fleece, i.e. without filter cake. The pre-coat filter in the
bypass also prevents very fine particles from collecting in
the machining oil.
In hard machining, i.e. steel grinding, a low-viscosity
grinding oil with a very high filtration of contamination
class NAS 6 is required as coolant. The ideal solution here
is a pre-coat filter system made by FAUDI – the candle
filter allows deep-bed filtration and thus a high filtration
grade. The filter elements are also protected from lasting
contamination through the fact that a deposit layer
develops on the filter candles that is then cleanly removed
thanks to a specific difference in pressure. The dirt is then
finally discharged from the system in a so-called sludge
treatment process. Continental sees FAUDI GmbH as a
competent and reliable partner for whatever demands that
have to be met.
6 | 7
Eastern Europe is growing very rapidly as an automotive
region. Continental AG opened a new production facility
in Zvolen in the Slovak Republic in 2005 in order to keep
pace with this development and to retain its international
competitive edge. It is intending to expand the new factory
in Zloven to become one of the largest facilities for the
manufacturing and assembling of brake callipers. FAUDI
equipment is increasingly being used in the location‘s
16,000 square metre production area, e.g. a coolant cleaning
and supply plant with sediment tank and backflush filters.
This supplies 11 cutting machines with a total capacity of
8,000 l/min. The required filtration grade is 60 μm. In order
Clean performancefor a clean emulsion
FAUDI for Continental, Eastern Europe
to achieve this, the feed emulsion is first pre-cleaned in a
sediment tank and subsequently pumped through three self-
cleaning backflush filters. These are equipped with split-pipe
filter elements made from stainless steel and are backflushed
by the pressure in the system using clean emulsion. The
backflush liquid is then cleaned once more with a vacuum
filter. This combination of various filter systems ensures safe
supplies of clean emulsion to the machining equipment.
Continental AG has great expectations of its location in Zvolen
and puts its complete trust in products made by FAUDI.
Inside Filtration – The Official FAUDI Newsletter
The Austrian company Berndorf Band GmbH has been
manufacturing endless steel bands since the beginning of
the 20th century. A subsidiary of Berndorf AG, the company
takes stainless steel, carbon steel and titanium and turns
them into high-precision processing and conveyor belts.
This Austrian company has built up a reputation around the
world in the development and manufacture of endless steel
belts. The products developed and produced by Berndorf
Band GmbH can be found around the world, with exports
accounting for over 90 % of production.
Berndorf attaches great importance to the highest
precision in all areas of its work. Innovative and sustainable
solutions are also required when it comes to recycling
and disposing of the waste products that result from the
production process such as grinding slurry and swarf.
FAUDI provides Berndorf with such a solution in the form
Endless belts for projectsall over the world
Berndorf Band GmbH
Sollte hier auch was stehen?
Technical Data
Component: stainless steel belts
Processing: grinding, rolling
Coolant: emulsion
Type of swarf/slurry: broken swarf mats
Operational: 12 months/year22 working days/month24 hours/working day
Project volume: 355 kg/h
Residual content of coolant sludge:
approx. 55 % after pre-demoisturising extrusion230 kg/h
Residual content of coolant sludge:
approx. 30 %
Residual content of coolant briquette:
approx. 6 %
Briquette properties: Ø = 95 mmL = approx. 80 mmDensity = approx. 5.1 kg/dm3
of a hydraulic briquetting press. Waste materials that
contaminate the coolant during the grinding and rolling
stages are separated from the actual coolant using a
briquetting press and an extruder allowing the liquid to be
fed back into the coolant process.
The advantages can be seen in the distinct savings
in new coolant and also in the possibility of recycling the
filtered residues such as swarf, which are sold to waste
disposal companies. In addition to these advantages, the
high quality of FAUDI products and the volume reduction
result in a lower handling overhead.
The press, working 24 hours a day throughout the year
generally pays for itself within 18 months. It is therefore not
surprising that Berndorf relies on products made by FAUDI.
Picture: Berndorf Band GmbH
4 | 5
One of the world‘s largest oil companies, Brazil‘s Petrobas
S.A., uses filter units from FAUDI in its REVAP refinery.
The fully-automatic and maintenance-free FAUDI modular
pump units are used in refineries to filter hydrocarbons.
Low-molecular hydrocarbons, rust and metal residues are
produced during the cracking processes that take place
in the refineries; these can damage the catalyst units. In
order to prevent this, a cleaning process using modular filter
systems must take place. However, this results in medium
being lost through flushing as it has to be used for flushing,
or an external medium has to be used. By using gas-assisted
backflushing, a maximum amount of filtrate can be obtained
Maximum performance – minimum filtration loss
FAUDI for Petrobas
without losing the medium itself through flushing. It is
this technique that is used in FAUDI‘s modular filter units.
During cleaning, the individual modules are first flushed with
medium or external medium and a gas buffer is then fed into
the module. Medium flushing loss is reduced to a minimum
since the modules no longer need to be fully flushed with
medium or external medium. The inert gas used in the
backflushing process is separated from the medium using a
gas separator. Petrobas is a technological leader in offshore
production and puts its complete trust in FAUDI‘s high level
of technical expertise in order to maintain this position.
Inside Filtration – The Official FAUDI Newsletter
Sollte hier auch was stehen?
Contents
3 Using instinct and entrepreneurial thinking to become “Local Hero - Mutmacher der Nation”
4 Endless belts for projects all over the world
5 Maximum performance – minimum filtration loss
6 Quality for any demand
7 Clean performance for a clean emulsion
8 The fascinating inner-life of an ocean giant
9 Global players welcome
10 Protected solar power in Spain
11 Sophisticated catalyser protection
12 Clean sea water thanks to automatic backflush filter
2 | 3
Imprint
FAUDI GmbH
Scharnhorststrasse 7
35260 Stadtallendorf
Telefon +49 (0)64 28 702-0
Telefax +49 (0)64 28 702-188
www.faudi.de
Germany needs role models - people with optimism and
ideas that inspire. For this reason a top-class jury with
Lower Saxony‘s Premier, Christian Wulff, as patron awards
an annual prize to „Local Heroes - Mutmacher der Nation“.
The prize recognises entrepreneurs from small and medium-
sized companies who have shown exceptional and exemplary
entrepreneurial spirit and determination.
In 2008 Horst Watz, Managing Director of both WATZ
Hydraulik and FAUDI GmbH received the prize for an
outstanding entrepreneurial decision. In May 2006, Horst
Watz bought the insolvent FAUDI GmbH in Stadtallendorf.
The company, numbering 80 employees, was founded in 1938
and is one of Germany‘s traditional companies, operating in
the field of filtration technology. However, the once number
one address in the field of coolants and process engineering
got into great difficulties as a result of mismanagement and
the changing economic situation. Following the instigation
of insolvency proceedings, the company faced being sold
off and broken up. Competitors were already expressing
interest in the company‘s patent rights. Horst Watz decided
Inside Filtration – The Official FAUDI Newsletter
Using instinct and entrepreneurial thinking to become “Local Hero – Mutmacher der Nation”
Courage and gut feeling – a good combination
to purchase the company just 24 hours before the bidding
deadline expired. Through this decision – as he himself calls
it, a gut decision – he saved 80 jobs and a medium-sized
company with a long tradition. The purchase price of 1 million
euros was financed by his own company, WATZ Hydraulik
GmbH, with start-up financing of a further 3.5 million euros
being secured by private guarantees.
Horst Watz has not regretted his courage and his (gut)
decision. On the contrary: „At the end of the day it was a
question of a traditional German company and its people,“
relates the businessman. He continues, „Some people say
that such a decision requires courage. That may be. But I
just knew what the potential of the company and above
all of its people was.“ Insolvency is no longer an issue for
FAUDI. Turnover in 2007 amounted to eleven million euros
and increased significantly in 2008 to 14.5 million euros. The
number of employees has now grown to 85, including 12
vocational trainees who will all complete their training with
flying colours.
Far left: Horst Watz, “Local Hero – Mutmacher der Nation 2008”
The Official FAUDI Newsletter
Issue 1 / 2009 / www.faudi.de
Inside Filtration
Clean filtrationtechnology