Mayor of Zweibruecken Visits TLT-Turbo

On 4th May 2022, Mayor Dr. Marold Wosnitza visited the TLT-Turbo global headquarters. Mrs. Anne Kraft from the “Wirtschaftsförderung Zweibrücken” joined him for the visit and the two were welcomed by TLT-Turbo’s Managing Directors, Xiongfei Zhao and Matthias Adamy.

The visit included a tour of the facility and meeting various members of the TLT-Turbo team. The Mayor was interested in learning more about TLT-Turbo. First of all, the company in general was introduced, including topics such as the global locations of TLT-Turbo and the long-standing cooperation with the parent company PowerChina. The product range and its application areas were also discussed, as well as the activities and
functions of TLT-Turbo’s Zweibrücken site.

Source: City Zweibrücken/jj
Source: City Zweibrücken/jj

The on-site test stands were also presented with an explanation on the types and methods of testing carried out here. To showcase TLT-Turbo’s products, a demonstration of the new MoJet® Fan was staged for the visitors. The on-site test hall was filled with smoke using a fog machine allowing the MoJet® Fan to show its capability in swiftly extracting the smoke. This showcased not only the performance of the fan, but also provided a clear visualization of the air flow lines.

Source: City Zweibrücken/jj
Source: City Zweibrücken/jj

The visit also provided an opportunity for the Mayor to get to know TLT-Turbo’s new leadership team and to discuss the city’s future support for the company. The Mayor, Mrs. Kraft and TLT-Turbo’s management team discussed the environmental conditions of the Zweibrücken site with regard to the availability of qualified employees, an improvement in internet bandwidth and electrical power capacity, and the location of TLT-Turbo GmbH in an area at risk of flooding.

“Mr. Wosnitza and Mrs. Kraft have promised us their support and cooperation on these important issues. It was great to show the Mayor around our facility. I really appreciated the time that he took to learn more about TLT-Turbo, our people and our products. On behalf of everyone at our Zweibruecken Office I would like to thank him for his time and support,” said Mr. Adamy.

“It was impressive to see this demonstration and it is always exciting to see which innovative companies settle and develop at the Zweibrücken location. TLT-Turbo is planning an expansion at our location, which will primarily require new office space. I will work to ensure that TLT-Turbo can invest in the Zweibrücken location as quickly as possible,” said Mayor Dr. Marold Wosnitza during his visit

Source: City Zweibrücken/jj
Source: City Zweibrücken/jj
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TLT-Turbo to exhibit at Anuga FoodTec 2022

Global ventilation fans and systems manufacturer, TLT-Turbo GmbH, has officially announced its participation in Anuga FoodTec 2022, the most prominent international food and beverage industry trade show in the world. This four-day event will be held from 26-29 April, 2022 in Cologne, Germany.

As a leading global trade fair, Anuga FoodTec (AFT) is the most important source of impetus for the international food and beverage industry. As the world’s only supplier fair, it covers all aspects of food production. Industry players are provided the opportunity to present their latest innovations and technological visions – from process technology, filling and packaging technology to food safety, packaging materials, digitalization and intralogistics.

At the event, TLT-Turbo will showcase their extended range of fans for mechanical vapor recompression (MVR). Among other things, this has been specially developed and optimized for food production and processing.

There is a clear upward trend in the demand for energy efficient solutions for the food industry, especially as the energy transition presents the industry with major challenges to reduce operating costs and CO2 emissions. Mario Schmidt, Head of the Vapor Fans Business Segment, says that TLT-Turbo is participating in AFT event for exactly this reason. “We’re attending because we offer high efficiency fans for the food and beverage industry. Our objective at the event is to connect with EPCs as well as with end-use customers requiring this technology.”

TLT-Turbo products, renowned for their energy efficiency capabilities, are a perfect fit for food producers who want to increase their energy efficiency, increase their availability and minimize their maintenance costs. Using this technology can drastically reduce the use of fossil fuels and significantly improve the company’s CO2 footprint.

“TLT-Turbo MVR fans can be used in a wide range of industrial applications, especially in the food and beverage sector. Whether for modernization, expansion or new construction – TLT-Turbo has the optimal solution ready,” explains Schmidt.

Further, Schmidt says events like Anuga FoodTec provide an opportunity to showcase TLT-Turbo’s innovative products and solutions on an international stage. “This is our first time exhibiting at AFT. Currently, we perceive a strong increase in demand of our MVR technology. For applications in this industry, the attention in the world market is mainly focused on our unique designs and innovative technical solutions in this regard. We have received numerous orders for MVR fans from customers in the food and beverage industries over the past year and now it is time to showcase these proven products to a larger and international range of customers.”

TLT-Turbo’s exhibition is located at Stand C-030 in Hall 4.1. All media and press are invited to visit the booth and learn about TLT-Turbo and current trends in plant technology (especially evaporation and crystallization technology). Mario Schmidt and several additional TLT-Turbo representatives will be present to answer all questions.

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TLT-Turbo consolidates its position as an MVR expert in serving the pharmaceutical industry

In October 2021, after TLT-Turbo received a huge new order for 20 MVR fans, another additional order for 4 larger MVR fans was put in by the same customer. This order precedes the delivery of 32 machines to the customer which shows its satisfaction in our products and continued trust in TLT-Turbo.

Four years ago, TLT-Turbo was a newcomer to the MVR industry and completely unknown to potential customers, especially those in the pharmaceutical industry. Within four years we have strived to make considerable ground in the market by supplying numerous high-quality MVR fans of various sizes”, says Mario Schmidt, Head of Business Segment Vapor Fans.

After intensive and positive discussions and a huge effort by our TLT-Turbo team in Beijing, we successfully wrapped up two orders in a row from our main client in the pharmaceutical industry. TLT-Turbo ensures to provide continuous delivery of 3 to 4 fans every 6 weeks up to September 2022. This continued partnership shows the confidence and trust that the customer has in TLT-Turbo. This new order also strengthens TLT-Turbo’s market position as MVR experts serving the pharmaceutical industry which will help grow our customer base further in 2022.

“Our MVR range is ideally suited to facilities in the pharmaceutical industry as witnessed by our continued partnership with our customer who uses our fans in the process of manufacturing Water For Injections (WFI),” says Mario Schmidt, Head of Business Segment Vapor Fans. He further added that, “given the higher efficiency of TLT-Turbo manufactured MVR fans, it makes us more competitive in the small to medium mass flows market where there are many potential clients in different industries such as dairy, food and beverage and pharmaceutical production.

For more information on the TLT-Turbo MVR range, click here.

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TLT-Turbo looks forward to continuing building the bridge from real to digital at the revolutionary Tunnel Digitalization Centre.

In September 2021, TLT-Turbo commissioned one of their jet fans at the TDC, which will be used from now onwards for research projects in a real tunnel environment including the joint development and testing of digital products.

TLT-Turbo became industrial partner of the Swiss Center of Applied Underground Technologies (SCAUT) at the end of 2020 and has since participated in the joint research project of the “Tunnel Digitalization Center”. In October 2019, the Tunnel Digitalization Center (TDC) was officially opened in the Hagerbach Test Gallery in Flums, Switzerland.

For the first time in history, this unique tunnel center allows demonstration and simulation in a realistic environment.  The “Tunnel Digitalization Center” project was initiated by the Swiss Center of Applied Underground Technologies (SCAUT). Through the continued use of new technologies and innovative concepts at the TDC, the center now consists of a BIM Centre, a Control and Training Centre, a Simulation Centre and, a cloud center.

The Swiss Centre of Applied Underground Technologies (SCAUT) is the world’s leading competency center for the use of underground space. SCAUT bundles the accumulated knowledge, competencies, and technologies from underground construction as well as from other industrial sectors to further develop them as the first competency center of its kind worldwide and to make them available for various applications in the underground space.

Alongside TLT-Turbo, the SCAUT consortium consists of other leaders within the industry namely Amberg Engineering Ltd, Siemens Ltd, Elkuch Group Ltd and HBI Haerter Ltd. First and foremost, TLT-Turbo GmbH was chosen as they are a leading global expert in the production of fans for a range of industries. Amberg Engineering Ltd are used for infrastructure construction alongside Amberg Technologies Ltd for surveying and scanning, Siemens AG for automation, Elkuch Group Ltd for door systems, and lastly HBI Haerter Ltd for tunnel ventilation simulations.

In the future, most people will live in urban areas. The use of the third dimension, not only upwards but also underground, will be an essential part of urban development. Its goal is to use the surface space as open space and living space for people and social interaction, and to include the underground as part of the usable space. The tunnel Digitalization Center (TDC) offers the unique opportunity to experience the interaction and transformation from real to digital directly in the tunnel.

New technologies and innovative concepts can be demonstrated on a scale 1:1, which leads to a better understanding of complex processes and procedures as well as a high level of cost-efficiency.

“We at TLT-Turbo aim to continue improving specific areas of application in the future within the framework of the TDC, particularly by working on the digital twins in the context of BIM (Building Information Modelling) and how to improve the condition monitoring of fans” says Adrian Wolf, our Global Functional Manager for Product Management.

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TLT-Turbo Donates to Klinikum Bad Hersfeld

TLT-Turbo Looks Out for Nursing Staff Wellbeing in Bad Hersfeld

TLT-Turbo GmbH today announced that their Bad Hersfeld site have donated 1.500€ for the nursing staff at the Klinikum Hersfeld Hospital’s Covid-19 intensive care unit. The intention behind the donation is to show support to these nurses who have worked tirelessly to see the local community through the Covid-19 pandemic and to provide the funds needed to ensure that they take some time out for themselves.

The funds were donated by TLT-Turbo Bad Hersfeld and were handed over by Site Manager, Christian Kosack, on 15th December 2021 at Klinikum Hersfeld.

“As part of our annual budget, we allocate a certain amount to giving back to this community that surrounds our operation. Today’s donation amounts to half of our annual budget which we specifically allocated to those who have been on the frontline of fighting the pandemic. It was important to us that these funds directly to the nursing staff instead of the hospital. We believe that the ICU nursing staff deserve not only the funds handed over, but also to be recognised by businesses in the community for all that they have done,” said Kosack.

The funds were handed over to Frank Heenes, Ward Manager of the Intensive Care Unit 1 of the Klinikum Bad Hersfeld and will be used to host a special summer event for the intensive care unit staff. “Our intention was that the staff benefit directly from the donation and that the funds be used to somehow honour them. This is our way of thanking them for their valuable and exhausting work and to be able to give something directly back to them,” Kosack explains.

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Modular Design

Modular Design Redefines Mine Ventilation Efficiency and Availability

TLT-Turbo have released a modular mining ventilation fan concept that simplifies the planning of ventilation systems for customers while still providing the benefits that are synonymous with TLT-Turbo products including increased efficiency and lower power consumption. The Modular Mining Fan concept offers a range of modular solutions that cater to almost every ventilation requirement and aims to set a new standard for mine ventilation innovation.

The range offers a modular design that results in a well-engineered and efficient ventilation system at lower operational and maintenance costs. Customers have the flexibility to order required units and build on the system as their requirements grow – resulting in lower initial expenditure with more economical options for system expansion.

German engineering and extensive R&D have resulted in the highest product quality. This, paired with TLT-Turbo’s field-proven technology, provides a high-end pre-existing solution which means that mines will not incur the design and engineering costs that are usually associated with bespoke ventilation installations.

The modular concept makes it extremely convenient for customers in the mining industry to plan, design and optimize their ventilation systems to optimally benefit their operations. The modular approach eliminates guess work and ensures that the entire system can be planned to deliver predictable and accurate performance.

The modular design offers seven base fan sizes combined with six different hub sizes to ensure the right fit for all requirements. Numerous customizable and adaptable parts offer flexibility for specific customer needs. Add-ons have been developed for all seven base sizes allowing for modular pre-existing upgrades to meet individual requirements.

The modular components are designed to slot together, and no additional engineering is needed to ensure that different modules fit together to suit a specific operating environment. The advanced design ensures total fan efficiency of up to 90%, lowering the operating costs while maintaining full performanceThis entire offering is available at lower initial costs with short lead times for supply.

All the modular components can be manufactured simultaneously and are commissioned and installed once completed. Expansion of an existing TLT-Turbo Modular Mining Fan system is a simple process as new components are slotted into the existing system with minimal effort. Typically, ventilation systems need to grow or be upgraded as production demands increase. Where a major overhaul would usually be required, TLT-Turbo’s modular installation can be expanded by installing additional components to the existing system to scale up ventilation capacity or replace existing modules with higher specifications to optimise or upgrade the system.

With the modules being manufactured at state-of-the-art TLT-Turbo manufacturing facilities, customers can be assured of the highest quality end product. Continual monitoring, testing and quality checks are conducted at every stage of the manufacturing process. Well considered opportunities for varied combinations ensure shorter manufacturing and delivery lead times at lower costs to get your project running faster and smoother.

Contact TLT-Turbo to find out how the Modular Mining Fan range can benefit your operation, or visit https://www.tlt-turbo.com/en/product-and-services/mining-fans/modular-mining-fans/ to find out more.

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Corrosion in Power Plants

 

Energy technology is undergoing global transformation. Rapidly expanding renewable energy and other, more volatile power generation plants require significantly higher flexibility of conventional plants. This has resulted in a number of new challenges for ventilation equipment, including:

  • An increased number of start and stop operations
  • Fewer full-load hours
  • Increased partial load operation
  • Lower exhaust gas temperatures due to residual heat utilization
  • Smaller gap to acid dew point  

These factors cause an increased load on the systems which carries increased risk of corrosion during operation. This favors dew point corrosion, which can lead to total failure of fans and system components.

TLT-Turbo offers you a tailor-made solution for your plant by implementing effective corrosion protection measures to maintain uptime of your fans.

Efficient Protection against Corrosion

TLT-Turbo Corrosion Protection for fans includes two key actions: Preventing corrosion where possible and protecting components where corrosion cannot be prevented.

Avoiding corrosive conditions:
  • Preventing or reducing leakage of sealing air
  • Heating of fan components
  • Optimization of insulation
Use of corrosion resistant materials:
  • Weather resistant steel
  • Polymers and polymeric coatings
  • Stainless steel
  • Ni-based coatings or base materials

In order to select the measures suitable to preventing and addressing corrosion on fans operating at your facility, TLT-Turbo conducts an individual corrosion risk assessment. This assessment is based on your operational and environmental conditions.

TLT-Turbo provides further support by conducting an analysis of your specific operating conditions, e.g. on a dew point measurement based on a plant inspection.

Contact TLT-Turbo to discuss your corrosion protection needs and to find the right service package to suit your on-going requirements.

Optimal Protection against Corrosion for Existing Plants

TLT-Turbo conducts corrosion risk assessments and implements suitable preventative measures when designing and manufacturing new fans. These measures can also be carried out when retrofitting existing plants or as part of preventative maintenance during a scheduled shutdown.

Contact your service representative or the TLT-Turbo Service Department for more information on conducting a tailored risk assessment at your facility.

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TLT-Turbo Optimizes Air Flow at European Power Plant Based on CFD

In TLT-Turbo’s 145-year long history of developing centrifugal and axial fans, every fan has always been carefully evaluated through extensive testing before being deemed fit for application. These tests were greatly enhanced when computational testing became available. More recently, Computational Fluid Dynamics (CFD) simulation has greatly enhanced not only TLT-Turbo’s ability to conduct thorough product testing but has also created opportunities for developing new and improved fan types.

According to Sabine Groh, Product Manager for industry fans at TLT-Turbo in Bad Hersfeld, Germany, every TLT-Turbo fan type once was carefully evaluated and aerodynamically measured in aerodynamic test stands before being released for application in the customer’s operating environment. “The arrival of stronger computer performance has allowed us to utilize CFD simulation which has had a massive effect on our ability to develop new products and to improve existing fan types.”

Groh explains that CFD has numerous advantages, all of which have become integral to TLT-Turbo’s product development. One of the greatest advantages is that CFD has enhanced the understanding of flow phenomena more efficiently than empirical testing. By using CFD it is possible to zoom in and out of any area within the simulated geometry to determine most advantageous or disadvantageous parts or geometries. With examination options such as vectorplot, a detailed analysis of the direction within the flow is possible. Similarly, using streamlineplot or velocityplot provides a detailed view of irregularities or aerodynamic phenomena.

“This analysis helps us understand the parts or geometries that cause flow separations and turbulence which allows us to address these in our product design. We can use the CFD simulations for the development or improvement of different fan types, blade geometries or spiral casing for centrifugal fans,” says Groh.

Additionally, TLT-Turbo uses CFD to understand problems in the flow of a given customer application that might result in a loss of pressure, efficiency or untypical wear of parts exposed to the flow. This equips TLT-Turbo with the knowledge needed to carry out retrofitting and product enhancements to ensure improved future performance (see flow optimization use case below).

Flow Optimization Case Study

At a European power plant, a centrifugal fan was controlled by an inlet vane control. During operation, the blades of the vane were rattling after a while and needed repair. After replacement, the same blades were showing the same failure after some operation time. Figure 1 below shows the blade of the inlet vane control dismounted of the socket.

Figure 1: blade shaft of inlet vane control with too much clearance in the socket

It was assumed that the flow was not homogeneous before it reached the inlet vane control blade, and the use of air guiding plates was considered to correct the flow. Through the use of CFD, this pattern could be more deeply investigated resulting in a superior solution.   

Groh unpacks the process and explains how a better solution was found using CFD: “Each CFD requires four process steps. The first step is the creation of the 3D model of the geometry to be analyzed. The second step is discretization. This involves creating a three dimensional computational mesh in the model for the volume in which the medium flows. The third step is defining the boundary conditions for the simulation and as the fourth step, the simulation of the flow can be performed.”

In this specific instance, the ductwork ahead of the malfunctioning inlet vane control, the blades of the closure unit itself and the suction box behind the closure unit were all rendered in 3D models. Figure 2 below shows the geometry that was analyzed in detail in the computer model. The ductwork upstream and downstream was included to ensure the stability of the calculation in the simulation.

Figure 2: Scope of detailed simulation in the plant

After meshing of the 3D model, a simulation was performed to determine the direction of the stream in the ducting ahead the inlet vane control in more detail. Figure 3 below shows the result of the simulation.

Figure 3: direction of the stream in the ductwork ahead of the inlet vane control

The simulation showed that a separation of the stream led to turbulence in the flow ahead of the closure unit. With the validated conclusions of the simulation, TLT-Turbo was able to investigate different proposed solutions to remedy the problem. Figure 4 below shows the streamline plots of these different solutions.

Figure 4: Comparison of different countermeasures against the turbulence

The conclusion was that a combination of two countermeasures in the ducting would be the most advantageous solution. So ahead of the closure unit, TLT-Turbo installed a suction nozzle that helped guide the incoming flow into the duct (see blue colored suction nozzle in Figure 5 below).

Behind the closure unit, TLT-Turbo also welded a split plate (blue colored plate in Figure 5) into the suction box to help guide the stream further into the inlet vane control ahead of the centrifugal fan.

Figure 5: implemented solution to solve the problem with the inlet vane control

In Conclusion

The use of CFD has become an essential tool to TLT-Turbo for the development of new and more efficient fan types and blades. Instead of building numerous test models for each proposed blade or impeller type with subsequent aerodynamic model testing, different geometries can be compared in the CFD simulation directly. However, the value of CFD doesn´t end there. Increasingly, TLT-Turbo is also using CFD for aerodynamic optimization of flow in customer operating environments.  That includes solving aerodynamic problems such as the example above, and for reducing wear, pressure loss or in general creating a more homogenous flow of the gas or air in the plant to maximize efficiency. Finally, the success of performance improvements as a result of replacing a fan in an existing casing, can be verified.

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TLT-Turbo Secures Ventilation Works for Swiss Baregg Tunnel Project

TLT-Turbo (GmbH), a leading supplier of ventilation equipment and systems has received a contract to provide longitudinal ventilation and escape route ventilation for the Baregg Tunnel project through a call for tender by the Swiss Federal Roads Office, ASTRA, based in Zofingen, Switzerland.

The scope of TLT-Turbo’s delivery on the project includes 16 stainless steel, dual-speed jet fans. The jet fans will meet the project’s temperature requirement of 250 °C/2 h. The contract also includes the supply of an extensive array of services including project management, documentation of performance and technical specifications, inspections, QA, testing, training of operating personnel and future maintenance. The order is currently being processed with completion of the installation expected by January 2024.

The Baregg tunnel and the Neuenhof covering are part of Switzerland’s N01 route, located between the exits and entrances of Baden-West and Wettingen. This section is known as one of the busiest sections of the Swiss national road network.

TLT-Turbo Head of Tunnel and Metro division, Jürgen Steltmann, said: “We scoped out this project by starting with a dimensional survey and inspection of the existing tunnel structure. This will be followed by planning, fabrication, factory tests and finally delivery and installation. We are confident that our approach will result in a ventilation solution that meets the requirements of the Baregg Tunnel project and ensures and safe environment for commuters.”

TLT-Turbo has over 100 years of experience in ventilation technology and has been developing, manufacturing, and constructing fans and ventilation systems for more than 40 years. This extensive experience has been consistently incorporated into the development of their tunnel ventilation systems.

According to Steltmann, to ensure a safe environment inside tunnels, TLT-Turbo’s foremost consideration is smoke. “In an emergency, smoke is one of the major hazards for people in an underground tunnel. Our ventilation systems provide clear visibility for escape routes. In case of fire, our Metro and Tunnel fans provide smoke free emergency exit routes.”

“Our other key considerations are quality, noise abatement and energy efficiency. Our fans are tested according to EN 12101-3 give tunnel operators peace of mind that they are receiving ventilation equipment that meets their specifications and is of the highest quality. From there, TLT-Turbo combines specially selected materials, highly heat-resistant motors and design precision to blend quality assurance with the highest economic efficiency,” Steltmann explains.

The aerodynamic features of TLT-Turbo’s Jet Fan range guarantee low power consumption and installation costs. They also help to keep the acoustic noise low. These fans may be used in tunnel sections as jet fans with free inlet and outlet and as axial fans in ducted installations. The success story of these fans started in the early 1970’s in the Alps and several important Alptransit-routes have been equipped with TLT-Turbo tunnel fans since then – including ventilation for the longest railway tunnel worldwide in the Gotthard Base Tunnel.

“Our track record combined with the fact we have well-trained, experienced staff who collaborate with leading international consultants to ensure that we meet expected international standards are what have made TLT-Turbo not just a supplier, but a preferred tunnel and metro ventilation partner renowned for redefining ventilation quality and performance,” Steltmann concludes.

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Join us for a live webinar on Basics of Fan Aerodynamics and Optimization Potentials

Date: May 19, 2021 | Time: 1:00 p.m. – 2:00 p.m. (CET)

During a short journey through the topics of fan aerodynamics, our TLT-Turbo fan experts pick you up at the aerodynamic basics and show you which improvements are possible through aerodynamic optimizations.

Starting with the basic understanding of volume flow and pressure rise, the journey continues via the origin and definition of the operating points to the various aerodynamic control types of fans in technical systems. You will understand the differences between fan types and the definition of efficiency. The journey ends with the identification of different optimization potentials of axial fans and how TLT-Turbo can support you in optimizing them.

Unable to make the Live Webinar? Visit www.tlt-turbo.com to view the simulcast after the live date.

We look forward to hosting you!

Regards,

TLT-Turbo

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