ifat 2010 technical seminar trip report

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Technical Seminar Trip Report September 22, 2010 for Engineered Equipment Integration Co.

By: Don Voigt, P.E., CEM

www.equipintegration.com

Introduction

This summary represents a technical seminar trip report - to Europe in September of 2010. The main

purpose of this trip was to conduct a review of best practices in energy conservation in water and

wastewater systems at a world-wide environmental equipment conference. This conference is known

as IFAT technical conference and is held in Munich, Germany approximately once every three years (

see http://www.ifat.de/link/en/16607391 ) . It is recognized as the worlds largest exhibition of

water/wastewater and environmental renewal equipment.

Subsequent to the attendance at the three day conference, my spouse, MaryAnn and I, traveled more

than 1,000 miles in a mini vacation trip through the mountains and valleys of southern Germany and

Austria from farms to mountain tops, a great adventure in experiencing how these stern folks work,live, and enjoy life (see Chapter III of this report).

Chapter I International Water and Wastewater Equipment Exhibition (IFAT). Munich Sept 2010

This conference is held approximately once every three years and represents a broad cross section of

manufacturers of environmental and municipal equipment related to water, wastewater, and solid

waste utilization/recovery. Attendance is generally in the range of 120,000 people and brings a broad

cross section of world engineers/technicians, plant operations staff, and managers together.

On my previous visit to this conference (2008), I had reported on a strong growth in green energy

technologies from solar power to biogas recovery and re-use. I also observed a significant marchtoward single home/cluster wastewater treatment technologies where these (latter mentioned

technologies) were growing at an incredible rate.

As overall perspectives from this conference, I sense the

following:

1. Attendance was significantly less at this conference

vs previous (110,000 this year). And, exhibits and

hospitality booths were generally smaller and

more conservative in their offerings. The two

story booths of the past have all but disappeared

and obtaining a beer in a booth (common practice

to serve beer in booths) was often a challenge. All

of this suggested a more conservative marketing

approach and of course suggested a more

restricted financial budget.

2. In past IFAT conferences, there has always been a

particular technology which had been the talk of



the show. I did not see such a technology, this year though my focus was more on energy

and energy conservation technologies. It seemed that this year there were more of the same

vs the new and innovative of the past. But, again, this is only my perspective.

3. There seemed to be less equipment on the floor and more exhibits and posters showing

installations. Again, this is often driven by cost and budgets are obviously being tightened.

4. Most booths had some theme related to operating costs reductionssome of these were energy

related. Operation and maintenance costs were a focal point and lots of buzz words working off

of total cost of ownership. I was amazed at the number of booth staffers who were willing to

quote delivered prices right on the floor for equipment being shown.

5. Since my focus for this conference was related to energy issues, it was natural to be aware of

the blower/aeration vendors on the exhibit floor.

Aeration, after all, accounts for on average

40% of the typical wastewater treatment energy

cost. For blowers, it was interesting to note the

comparison of WEFTEC 2009 to IFAT 2010. Such acomparison showed a dramatically higher number

of turbo blowers at WEFTEC vs IFAT. It seems

that, in Europe, the PD blowers like Aerzen and

Kaeser are still the mainstay of the smaller

capacity (1,000 to 5,000 cfm) aeration blowers

(vast majority of our municipal plants). High

speed Turbo blowers were shown in 4 booths that

I saw (Turblex, Atlas Copco, and Piller) but it was

dramatic to see the apparent minimal number of

Turbo style blowers and more of the PD (Positive

Displacement) blowers on display. Atlas Copco hadtwo blower technologies sitting side by side in their

booth their new screw compressor (as is offered at

Port Washington) and their Turbo Blower recently introduced into the market. Either one was

offered on the floor for about $20,000 US. That seemed to be an incredible bargain price

but, its a long way from the shop floor to an

operating installation. They (Atlas Copco) say that

they are marketing through factory direct people

yet, the Port Washington blower was through a

distributor. When I pushed the sales person to

give me his opinion on the merits of one vs the

other, he stated that the screw compressor might

be less efficient but it is simpler to understand

and maintainI could see that this would be true.

The screw compressor is very small in size for

what it delivers. Yet, it does have conventional

bearings and gear reducer and will require routine

maintenance (mechanical) which has not been the

case for Turbo type compressors. In going from

the Atlas Copco booth to the Kaeser compressor

Atlas Copco Screw Compressor

and Turbo Blower (latter on right)



booth, the Kaeser sales person had a Kaeser conventional lobe PD compressor and next to it

a screw compressor which he claimed to be identical to the Atlas Copco compressor. When I

asked him if there was an advantage of one over the other, he told me that the screw

compressor would be more costly than the rotary lobe compressor for smaller flows but

added that their screw compressor is made of non corroding material while Atlas Copco is using

a Teflon coated design which he claimed will be required to be periodically recoated. He was

going to send me a comparison and he clearly inferred that Atlas Copco was stretching the facts

to claim an improved efficiency for the screw compressor for low pressure and low flow

applications (stating that the screw compressor is more intended for higher pressure

applications).

Regarding the Turblex and ABS and similar/other booths, I did not spend equivalent time there

but they had equipment similar to the WEFTEC 2009 equipment in their booths. HSI and Kturbo

and Neuros did not seem to have booths at this conference at least I did not see them. Tim

Dobbins (of Turblex) advised that they are working with ASME and another standards group in

developing standards for comparing turbo style blowers and they will be putting on technical

seminars at their facility in Missouri this coming year for engineers. Not sure I want to go

through the arduous trip to their factory for such a seminar but Im sure it will be interesting.He also alluded to the fact that they are apparently moving everything to the Chicago area in

about 18 months (related to the Siemens consolidation?).at least that is what I believe he

said. Then, it will be very convenient.

For diffusers for the infusion of air into conventional waste treatment basins, it was near

universal consensus (also see chapter II below) membranes are the device of choice. The style

of membrane is in debate depending upon site/tank constraints but membranes were the

method of choice. I did not see a ceramic diffuser on display,

anywhere.

6.

Regarding methane/bio gas recovery, I didnt see anythingnew or remarkable. I observed that people are going to heat

exchangers on about everything hot in order to recover and

re-use energy. Engines nearly all have some type of siloxane

cleaning skid. Most have heat recovery on exhaust and engine

heat. Many are using common engines by a common

manufacturer and their specific claim to uniqueness is in their

systems approach to providing a system vs an engine or

components. As I guess we knew was coming manufacturers

want to be offering more than hardware, they want to provide

systems and turnkey approaches.

7. In the area of controls/automation, I was enlightened to find that installing watt meters on small

motor loads is not as common as I had thought. Most manufacturers of motor control centers

offer watt meters as a built in option at about $300 premium per motor starter. Of the booths

toured, only Siemens seemed to be focused on energy monitoring as part of their

SCADA/Control center offering. A company called Schraml (a European SCADA systems

integrator) was doing energy monitoring and transmittal and alarming but they are limited to

European work. So, Siemens seemed to me in the best position to leverage their knowledge

in the USA markets. In speaking to the USA Siemens Control Systems Sales manager, he did not



seem to be seeing much demand for energy monitoring on

remote sites nor in main control systems overall. That

seemed interesting and disappointingbut, he may be

disconnected from what is going on on the street. I just

dont know.

8. There was a lot of talk on the floor about general

directions for biosolids disposal/reuse. As you may recall,

Europe had for the past 5 years been going away from

reuse of biosolids and had been co-incinerating sludges

on the basis that the cradle to grave problems with

toxins in sludges held too much liability for the industry. This time, I heard that this whole

concept is now being re-thought and that taking biosolids back to the land after

disinfection is the new vogue. So, there were new green house type dryers being shown

where heat recovery from other processes is used to dry the sludges in continuous plough and

auguring buildings.

Chapter II The State of Things in Europe

At IFAT, the European community gathers together to team up in providing an overview of water and

wastewater services. The German equivalent of the EPA is the DWG and they lead the overall report

writing on the conditions of markets in Europe and of course more specifically, Germany. There

were several excellent papers provide on the conditions of the water and wastewater market and these

are on CD and available through my office. This is an overview of the key elements on the CDs based

on my interests.

1. 99% of Germanys citizens are connected to public wastewater treatment works. About 90%

are connected to public water works. This is higher than most other European nations butFrance and England are not too far behind.

2. About ½ of the population in Germany is served by a water utility which is operated by a private

corporation/contractor. Veolia is the dominant

player in this market in Germany/Europe but

there are many others. This is a growing trend

private operations since it tends to fix the

municipalities expenses and reduce

management/dispute issues which are not

traditionally handled easily in a political

atmosphere (municipal politician atmosphere).

A significantly small portion of the population isserved by private managed wastewater

operators but where these privatizers operate

(mostly very large utilities), they are doing well

and growing.

3. Costs of water and wastewater (per gallon) are

rising but at a rate less than inflation. The cost

German Paper Industry Costs Reduced

Continuous Tracking of Energy Band



of water is on average - $2.00/cubic meter (I calculate this to be about $1.00/100 gallons).

The consumption of water is about 130 liters per day per person. This is about ½ to 1/3rd

of our

USA consumption. Costs to produce and distribute water are under a constant and precise

microscope. This is partially due to the strict regulations on costs and partially due to the

natural tendency of Europeans to refine costs to their finest elements. They provide in the

documents pie charts with costs for various aspects of water services from infrastructure (80%

of the costs) to labor to electricity/power. Wastewater similarly is well documented and the

cost for wastewater is listed at about $2.50/cubic meter or $0.40/inhabitant per day.

Interesting numbers and I do not know the equivalent comparison in the states left for you to

compare/evaluate. Here in wastewater it is acknowledged that most of the costs for the

user are long term infrastructure construction, upgrade and maintenance. They did note that

sewers can be considered 100 year life investments.

4. Due to the effects of strong water conservation measures throughout Germany, and, due to

populations expected to decline in Europe, there is concern that any further reduction in

consumption is potentially a detriment to the network due to required flushing and low flow

maintenance.

5. About 60% of the sewers in Europe are combined sewers

thus, explaining why many manufacturers have developed

treatment processes for combined sewers.

6. Wastewater treatment in most of Europe has matured to

advanced treatment such that most wastewater plants

either already have nutrient removal in their process or they

are planning on adding this at the next upgrade. There has

been quite a bit of R&D focused on low energy methods for

nutrient removal. Much of this in tandem with Universities

(private/public partnerships). One project showing promiseis the use of rotating drum screens (very fine mesh) for

phosphorous removal/reduction. Treatment facilities in

Europe generally utilize on-line instruments for nutrient monitoring and control. These are just

now becoming of interest in the smaller plants in the USA.

7. Biosolids disposal in Germany has been undergoing transitions. About 60% of their biosolids are

placed back on the land and 40% incinerated or placed in landfills. Over the past 5 years, there

had been a trend to go to incineration as the best solution. This had been driven by industries

and farmers fearing for liability in the toxic contents which had been appearing in sludges. In

recent years, the trend has been back to land disposal/renewal due to the reduction of toxins

found in sludges (better monitoring at industrial plants) and the looming need to reduce energy

consumption in all matters. The latter driver has also seen the growth of low temperature

dryers which use heat recovered from nearby heat sources (such as industries). And, a number

of manufacturers were showing greenhouse type dryers where sludges are mixed with

previously dried cake and use of natural temperature/sun is used to hurry the process along.

With land being relatively plentiful in the states, these processes are likely to gain traction in

certain parts of the US.



8. Regarding aeration for activated sludge wastewater basins, beyond the large competitive

situation with various blower and diffuser vendors, one speaker gave an intriguing presentation

on the importance of analyzing oxygen transfer as a systems approach vs attempting to define a

single diffuser or blower technology as best. He was a PhD in charge of research for a large

network of wastewater plants (looked like about 50 plants) of various design/operation in the

Rhine valley portion of Germany near colon, I believe). Though the paper is in German

language, he gave the talk (which I was able to attend with my seminar paid entrance fee) in

German but with an English translator. A most impressive presentation and again focused

on the need to look at each plant/process as a system. Nearly all of their plants have converted

to some type of membrane diffuser and he had evidence that diffuser life can extend upwards

to 10 years but very dependent on load and air flow rates. I will make every effort to have the

paper translated. If you wish a copy, let me know.

9. Biogas recovery and use is a top level issue throughout Germany. Most wastewater plants with

an anaerobic digester have recovery in place and are looking to improve upon it. The smaller

plants use simple gas generator sets with heat recovery on any new installation (recovering heat

from exhaust manifolds and from the engine itself). There were multiple vendors at the IFAT

conference who advised that they are in the midst of setting up dealer networks in the states.Most of these advised that the need is not for good salesmanship but rather for good

capability to repair and maintain the units. Most of the vendors offering such systems admitted

to some need for pre-cleaning of gases for siloxane and similar materials. The systems are

almost always sold as systems designed by a vendor with system efficiency warrantees.

10. Europe (and Germany) have

committed to a very tough set of

standards for energy involving

both use of renewables (Biogas

being a very prevalent area of

effort) and reduction of consumption. They are not looking

to Nuclear(actually

decommissioning several nuclear

plants recently) but are looking to

wind, biogas, biofuels (grease

recovery for instance) and solar.

Reduction of consumption is the

norm. From the continued

reduction in their size of autos to

the prevalence of windmills and

solar panels..the evidence of their commitment is ubiquitous. The commitments are backed

by legislation and fueled with specific tariffs intended to change human values/behavior. These

are a people of firm commitments (some say stubborn). They build upon a consensus based on

scientific knowledge. We have much to learn from the Germans and the world community as a

whole.

Heat Exchanger to Scavenge Heat from Sewers and Utilize for Buildings



Chapter III - Travelling through the countryside of Germany and Austria

After the conference, MaryAnn and I traveled through southern Germany, Bavaria/Austria (and we

watched for unique energy related concepts honest!). We found the landscape full of solar panels,

windmills and wood burning stoves. Roads were incredibly well maintained and dominated by small

compact cars. There were still the larger Mercedes Benz cruisers on the Autobahn but the vast majority

of folks in Europe are embracing the idea of conservation of resources. Bicycles, walking, and mass

transport carry the bulk of those traveling. Autos are most often small Fiats or VW types with diesel

engines and stick shift being standard. Of course, gas is still averaging $1.40 (EURO)/liter (or

$7.00(US)/gallon). This actually down from the last visit but is still enough to make one pause when

the average tank fill is around $75. Houses are small/compact and often more like apartments than

separate homes. Likewise, motel rooms are smaller and more efficient in power consumption than

USAas has been the case for a long time.

Shopping in the streets of cities is an entirely unique

experience vs USA. No Wall marts, Kmarts, nor super

malls. Towns have maintained the central city

shopping areas with little stores with a bakery on everyblock, an ice-cream shop next door, followed by clothing,

shoes, and womens negligee (wow, women in Europe

really wear those skimpy strings?). On evenings and

weekends, the streets of downtowns are full of families,

biking, walking, and sitting in street cafes. A real

dichotomy to our drive to Wal-Mart philosophy.

By the way, I see how McDonalds is growing their business through a very aggressive addressing of the

markets in Europe. They locate McDonalds in either gas stations (like in the USA), in independent

buildings like Port, but also in downtown walking arcades with no auto access right in the middle of

the block. Their stores are of a completely different motif vs USA. In Europe, McDonalds generally has acompletely separate latte/coffee bar away from the hamburger/french-fry counter. The coffee/latte

bar sells mostly expensive latte with lots of flavors and selections and at a very high price (vs standard

coffees we find at our McDonalds). And, their decorating or interior designs are incredible. Two floors

and really cool chairs/lounges and a very special kidsarea with toys and bean bags and things unlike

our slides for kids. Very intriguing and very expensive and, very successful. Id buy McDonalds

stock!

Should you wish to obtain copies of various handouts/CD, I can arrange for these to be reproduced and

sent to you. Simply let me know. I also have about 6 deep stack of literature to peruse through and

will send an update as I complete the review. Finally, I have a series of photos representing both

chapters above both from IFAT and from the traversing of farm, field, and village alike.

Respectfully,

Don Voigt, P.E., CEM

Energy Audit Engineer

Providing Certified Energy Reviews for Cost Reduction

www.equipintegration.com

414-940-9281

A Bakery on Every Block

ifat 2010 technical seminar trip report

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