With a heritage that extends back to 1919, Kaeser Compressors is an industry leader in industrial compressed air equipment, including rotary lobe and rotary screw blower packages, rotary screw compressors, vacuum pumps, portable diesel screw compressors, air treatment components and other system accessories. Wastewater treatment plants across the country rely on us for air system solutions that are engineered for long life and continuous energy savings. Our products represent continuing advances in innovation, technology and performance. Kaeser’s built for a lifetime™ quality coupled with our commitment to energy efficiency provide our customers with the lowest life-cycle costs possible.
Kaeser Compressors, Inc.
511 Sigma Drive
Fredericksburg, VA 22408
Contact: Ally Jordan
In 2019, Kaeser Compressors assumed control of the venerable line of PillAerator turbo blowers, strengthening its ability to serve the wastewater industry — or wherever else atmospheric process air is needed on a constant pressure level. Watch this video to understand what inspired the decision, as Manual Dias, Business Development Manager at Kaeser, covers the advantages that turbo blowers offer versus other types of blowers. Al Moreno, Kaeser's District Manager, then highlights the company's screw blower technology, followed by Global Product Manager Peter Werhahn, who provides the business case for investing in turbo blowers.
Kaeser Compressors' rotary screw blowers offer superior performance, fast installation, low noise operation, and lowest life cycle costs to help wastewater treatment plant operators and designers revolutionize their plant's aeration system.
Precision management of dissolved oxygen (DO) allows wastewater treatment plant operators to maintain optimal biological conditions in their activated sludge basins. However, older blowers and a lack of advanced aeration oversight can sabotage that effort while substantially wasting money. Master controls allow the blowers in each basin to be interconnected to improve system stability, provide backup, equalize blower run time, maintain ideal DO levels, and maximize energy efficiency.
Upgrading the aeration system in a wastewater operation is typically burdensome because of the design work, permits, construction, and commissioning required for a structure before a new blower system can be installed. An affordable, purpose-built blower system delivered in its own secure, weatherproof enclosure may be a viable alternative that can be commissioned sooner and at lower cost than one that requires renovations or new construction.
Industrial manufacturing and processing facilities have long relied on air system performance audits to maximize their compressed air station while minimizing energy consumption. Wastewater plants could significantly benefit from the same approach for aeration blower systems but have been slow to adopt the practice. However, the overall potential operating benefits of an air system performance audit are too big to ignore.
It’s common for wastewater treatment plant operators and design engineers to get comfortable with one type of blower for aeration. However, multiple blower technologies are available to consider when designing a new system. Understanding the difference between them, as well as the pros and cons of each based on the specific application, is critical to the decision-making process.
This article gives an inside look at factors that impact pressure stability and operating efficiency, how to identify potential drawbacks in an air system, and what to specify for greater efficiency.
In municipal and industrial wastewater treatment, there has been a shift from manual to automatic process control in order to increase efficiency and improve effluent quality.
In 2012, the Town of Francesville in Indiana contacted Air Diffusion Systems to provide a solution for several suspended solids violations and energy efficient treatment. Air Diffusion Systems was able to provide an unique solution to correct biochemical oxygen demand (BOD) and total suspended solids (TSS) problems using Kaeser Compressors’ CB Com-paK blowers.
Energy is a huge portion of a wastewater treatment plant’s operating costs, with aeration blowers a significant user. System splitting with an adaptive master controller reduces electrical, maintenance, and initial investment costs.
This product brochure covers Kaeser’s line of CBS, DBS, EBS, FBS and HBS series rotary screw blowers. These screw blower systems feature the world-renowned Sigma Profile™ and are specifically designed for even the most demanding blower applications.
Kaeser Compressors has revolutionized compressed air controls with the sigma Control2.
Kaeser’s custom engineered solutions are compressed air and vacuum systems built to specification for the most demanding and challenging installations. Whether in custom enclosures or modified ISO shipping containers, these complete systems are designed for exceptional reliability, simple maintenance, and superior energy efficiency no matter what the installation limitations may be. They eliminate space, weather, and accessibility constraints and can significantly reduce construction, installation, and operating costs.
Comparing blower performances across different manufacturers and technologies has long been a difficult task. For many years, it was all too easy to present data that, although accurate, was potentially misleading. Manufacturers were selective about what information they published as well as what conditions they chose to specify performance. The result was a numbers game the buyer frequently lost. Fortunately, the Compressed Air and Gas Institute (CAGI), in cooperation with its members, has developed a tool for a fair comparison between blowers.
Energy is the single highest operating cost in a wastewater treatment plant. More specifically, the energy to operate blowers for aeration is the single highest energy consumer.
Kaeser has been designing and manufacturing superior industrial machinery since 1919. With nearly a century of manufacturing experience, we pride ourselves on upholding our traditions of quality and craftsmanship. Our reputation for reliability, energy efficiency, and excellent service has helped us grow into a global leader in blower and compressed air technology.
Kaeser Com-paK blower systems offer the best combination of quality construction, reliable performance, and ease of ownership. The Com-paK design features a full scope of supply that is unmatched in the industry. Our complete package design minimizes time and money spent on engineering, procurement, documentation, and installation. Com-paK units arrive fully assembled and ready to operate.
Written by Kaeser’s system experts, this whitepaper compares rotary lobe and screw blowers, isochoric and isentropic compression, and how to properly apply these technologies for designing an energy efficient system.
Kaeser’s complete line of air system products includes industrial electric and portable gasoline and diesel rotary screw compressors with the highly efficient Sigma Profile™, rotary lobe and screw blowers, compressed air boosters, and vacuum packages.
Kaeser Compressors’ Blower System Installation Guide: Layout Considerations for a Reliable, Energy Efficient, and Safe Blower System provides essential tips for planning and installing a blower system. Written by Kaeser’s blower and engineering experts, this e-book includes installation diagrams, information on piping, ventilation, controls as well as additional resources for ongoing energy management.
Kaeser screw blowers use up to 35 percent less energy than conventional rotary blowers and even achieve significant energy savings compared to currently available screw blowers.
The overall wastewater treatment process is complex, and each step is integral to ensuring water is properly purified. Effluent ends up in the plants, containing substances that must be removed before the water can be properly cleaned and returned for use. The range of potential contaminants is almost endless, and can include food, pulp, waste, or other substances. Afterwards, the water requires further scrubbing, with the aid of bacteria. It is in this part of the process that compressed air (ideally provided by energy-efficient rotary lobe blowers) plays a vital role.
The next big thing is here and it’s the Industrial Internet of Things (IIoT). With pundits waxing philosophical on this big breakthrough, it’s hard to cut through the noise and understand what the IIoT actually is and how it applies to individual plants. I offer the following as a definition. The IIoT means collecting, interpreting, and applying data to actively improve processes or operations. To understand how the IIoT applies to a wastewater treatment plant, look no further than your front yard.
System controls are critical to a wastewater blower system. Without them, a system with multiple blowers operating on their individual controls will run more than necessary and result in wasted energy. Maintenance costs increase and worst of all: process performance suffers.
As part of her tour marking the opening of this year’s Hannover Messe, German Chancellor Angela Merkel and Polish Prime Minister Beata Szydlo paid a visit to Kaeser Kompressoren’s trade show booth. Naturally, Kaeser was delighted to welcome Chancellor Merkel and Prime Minister Szydlo. For her part, the Chancellor was enthusiastic about the power of innovation demonstrated by the Coburg-based compressed air system provider.
Wastewater treatment plants provide a critical service to our communities. WWTP systems operate continuously and equipment must be completely reliable and sustainable. Kaeser delivers exceptional air system solutions for wastewater treatment operations that are engineered for long life and continuous energy savings.
When it comes to the costs of running a wastewater treatment plant, the conversation tends to begin and end with blowers. These machines are a staple in wastewater operations, gobbling up energy and running up the power bill as they function, so it’s worth taking the time to make the right investment.
Wastewater managers are always under pressure to reduce costs. Lowering the electric bill — which also saves precious resources — is a high priority.
At a wastewater plant, aeration is king. As a central part of the treatment process and the major contributor to energy costs, operators are constantly looking for ways to improve the aeration stage by revamping, replacing, or modifying the blowers and their packaging.
When it opened in 1846, the Danube-Main (Ludwig) Canal was an ambitious engineering project intended to put the recently founded Kingdom of Bavaria on the map as a modern industrial power.
A Kaeser EBS series screw blower is making wastewater treatment considerably more efficient and effective at the Goldsteig dairy factory in Cham in the Upper Palatinate region in Germany.
Farming operations to plan and control fish reproduction have been around since the 15th century and are a sophisticated, mechanized arm in the food production industry today. In Poland, traditionally, trout farms are relatively small family businesses where product quality remains high during every stage of the process. Learn how Kaeser’s rotary blowers turned a rural fishpond into an automated aqua farm by delivering air to ensure the fish are raised in the best possible environment.
Kaeser Compressors, Inc. has been awarded the 2015 AGENT (Assist, Grow, Educate, Network, & Thrive) Award by the City of Cypress, California.
Kaeser Kompressoren SE, the international headquarters of Kaeser Compressors, Inc., recently gathered with local dignitaries and construction company representatives to lay the cornerstone of their new administrative building.
Just a year after breaking ground on a major expansion project, Kaeser Kompressoren SE, the international headquarters of Kaeser Compressors, Inc., has held a topping out ceremony to celebrate adding the roof to one of the new industrial rotary screw compressor production halls.
Renowned economic magazine Wirtschaftswoche, has commissioned a study by Munich Strategy Group (MSG) to closely examine medium-sized companies in Germany and how truly innovative they are.
The Moundsville Wastewater Treatment Plant in West Virginia chooses not to fix a broken blower unit, but rather to correct an outdated approach. The result is a savings of $50-60K a year in energy costs.
Since the day we opened our doors, Kaeser's mission has been to deliver long term value to our customers. Discover the Kaeser difference for yourself.
Kaeser's blower product manager, Stephen Horne, explains how wastewater treatment facilities can benefit from utilizing blower package and system integration for increased efficiency.