Sustainability
Ball Valves
Service life extension by DG series ball valves with ceramic ball, used in zinc production
Industry: metal processing
Medium: zinc slurry, max. 10bar(g) at 50°C operating temperature
Task:
- Medium highly abrasive, with coarser solid particles
- High switching frequency
- Increase of service life
Solution / valves used: 3-piece ball valve type DG1 6696
- Solid ceramic ball
- Wear resistant PEEK seat ring
- Damping of pneumatic actuators for impact-free switching movements
Result
- Significant savings in raw materials by extending the service life from 2 weeks (stainless steel ball valve) to 12 month
- Approx. 60,000 switching operations in 12 month
- Significant cost reduction due to reduced production downtime
- Sustainable solution due to easily replaceable internal parts (the valve does not have to be disposed of when worn out!)
Butterfly valves
Reduction of the CO2 footprint through two-part butterfly valves
Task:
Revision. The functionality of a defective butterfly valve must be restored.
One-piece butterfly valves:
- Housing construction from Far East: Simple service not posssible => Required spare part: Complete valve
- Ship: 18g CO2 per kg product on 1,000km; butterfly valve DN150 8,5kg from Far East; Delivery distance: approx. 7.000km ship + 300km truck from harbor
Two-piece GEFA butterfly valves:
- Two-piece body design makes replacement of internal parts very easy => Required spare part: seat ring (body reusable) [High resource conservation]
- Truck: 178g CO2 per kg product on 1,000km; seat ring DN150 0,564kg from EU; delivery distance max. approx. 2,100km
Knife Gate Valves
Energy cost savings when using DOMINO control knife gate valves AT200R as replacement for butterfly valves on aeration basins in wastewater treatment plants
Medium: air, 70°C, inlet pressure: 1,65 bar abs., volume flow: 3.700Nm³/h
Task:
- Improvement of the control characteristics of the manually operated butterfly vales used so far
- Automation of the plant control
- Reduction of energy consumption by using valves with low pressure loss
Problem solution: DOMINO AT200R
Installation of electrically operated GEFA-DOMINO control knife gate valve DN250 with optimized special control orifice instead of the used butterfly valve DN300 with a pressure loss approx. 1,98 mbar with fully opened valve and max. flow rated.
Result: Savings in energy costs, automation of conversion costs amounting to approx. 50,000€ after approx. one year of operation after commissioning.
Filter technology
Sustainable building and industrial use of rainwater when using GEFA backwash filter series FW / M100 and Y-Strainer
Industry: Plant constructors / Heating and air conditioning / Engineering offices
Medium: Rainwater
Task: Sustainable use of rainwater
Solution: Purification of the medium to ensure further processes by GEFA filter technology series FW, M100, Strainer type FY and Strainer type FCY
Advantages:
- Building services: around 50% of drinking water consumption can be saved by using rainwater in public buildings. Futher positive effects can be achieved in process water circuits through fresh water reduction
- Industrial use: Cooling with rainwater in industrial circuits and processes alone results in a high savings potential in drinking water costs. Further operating costs can be saved, since rainwater does not have to be softened or desalinated
Saving of potable water to compensate by sustainable filtration of the cooling medium in the bypass flow by GEFA backwash filters of the FW series
Medium: cooling water, 25°C up to max. 10 bar
Volume flow: 250m³/h
Nominal width: DN250
Separation size: 50µm
Task:
- Filtration of cooling water of an open cooling circuit
- Protection of the downstream plant components against green algae and particles in the open cooling tower
- Filtration of the cooling water with a separation size of 0,05mm = 50µm in the bypass stream
Solution: GEFA Backwash Filter FW Series
- Robust construction in a compact design
- Stainless steel SS 304 1.4301 as standard (high quality on request)
- High quality materials used
- Separation size from 30-800µm (more on request)
Conversion:
- Cleaning of the cooling medium, operated from the pressure side, from green plants and particles in the selected separation size.
- The filtration of the cooling medium in the bypass process results in a saving potential, depending on the circulation of approx. 30-40% from the compensation with cost-intensive drinking water.
- The function of the downstream components is ensured by the filtration of the medium and the operational safety is still guaranteed.
