Bronswerk provides process design, thermal design, and mechanical design services to help clients optimize plant efficiency and recover waste heat. Their Radiax compressor can significantly reduce the size and energy usage of vapor recompression systems. Their Whizz-wheel fan uses curved blades to lower noise levels by 6-20 dB compared to conventional fans, reducing energy usage by 45-60% for the same airflow. Case studies show their technologies helped a client in Mexico debottleneck a gas compression module by 40% in space usage and 24% in energy, and helped a refinery in Germany reduce fan noise by 20 dB while lowering energy usage by 56%.

1. Optimizing plant efficiency
Heat recovery and saving energy
Hans van Essen
Den Haag – April 22 2015

2. Content
• Introduction Bronswerk
•Radiax®
– Case 1: Mechanical vapour recompression
• Whizz-wheel®
– Case 2: Debottlenecking – ACHE offshore
– Case 3: Debottlenecking – ACHE refinery
• Site survey

3. History:
1940
1988 – Privately owned
2015

4. What we do:
• Process design
• Thermal design
• Mechanical design
• Manufacturing
• Supply
• Installation & Commissioning
• After market

5. Radiax®:
Developing the Radiax® started from the beginning, a fully
new principle compressor / turbine / pump was designed.

6. Radiax® :
Key features:
• Compact (up to factor 10)
• Fully integrated drive and seal system
• Oil free system behavior
• Flexible in extended ranges
• No surge and No stall
• Flat pressure vs flow curves (no specific work point)
• High pressure ratio
• High efficiencies over extended ranges

7. Radiax® :
Applicatoins
- Wet compression & wet expansion
- Well gas conditioning for gas turbines
- Waste Heat Recovery (ORC & RC)
- Vapour recompression

8. CASE 1: Steam Recompression

9. Case description :
Stripper
flash drum
Steam ejector
4 bara
7000 kg/h
144°C / 4 bara
Water: 312352 kg/h
HP steam
2500 kg/h
3,29 bara
4500 kg/h
3,29 bara
Operating cost: €537.000,- / year

10. Solution :
Stripper
Flash drum
4 bara
7000 kg/h
144°C / 4 bara
Water: 312352 kg/h
2,85 bara
7000 kg/h
Radiax
2,85 bara
E-power: 200kW
Operating cost: €137.600,- / year
• OPEX reduction:
€400.000,-/year
• ROI: <2 year

11. Whizz-wheel®:
Develop ultra low noise fans to meet the stricter client
requirements.

12. Conventional :

13. Whizz-wheel®:
Main features
•Rim
•Small hub
•Blades are fully curved

14. Whizz-wheel® :
Developed for low noise: 6 – 20 dB lower noise
Benefits:
• 45 - 60% lower absorbed power
• Up to 40% more cooling air flow with same absorbed power
• Or a combination
• Minimal vibrations
• Rigid construction
• Less sensitive to wind

15. Whizz-wheel® :
Trends:
• Upgrading existing facilities
• Decreasing OPEX
– absorbed motor power
– Maintenance
• More strict noise requirements

16. CASE 2: Debottlenecking
2 new gas compression modules – Mexico
Litoral-A

17. Case description :
Plant
• Existing platform
• Two new gas compression trains (modules)
Challenges:
1. Plot space
2. Maximal absorbed power
3. Maximum noise level

18. Solutions :
Conventional Whizz-wheel®
Plot space area 582m2 412m2
Installed motor power 390 kW 308 kW
Sound pressure level 90 dB(a) @ 1m <85 dB(a) @ 1m
Total height 7,6m 7m
Total weight of units 141 ton 126 ton

19. Results:
• 40% reduced plot space
• 24% lower absorbed power
• 8% reduced height
• 12% less weight
• No noise issues
Quote PM: “without the whizz-wheel we could not have
executed this project.”

21. CASE 3: Debottlenecking
Air Cooled Coolers – Germany

22. Case description:
Plant
• 120.000 barrels/day
• Located in a populated area
• More then 60 fans
• Different services
Challenge:
• Reduce high noise
emissions

23. Solutions :
Option 1: Standard low noise fans
• Noise level of 72 dB(a)
• 12,6 kW absorbed power
Option 2: Whizz-wheel ® system
• noise level of 66 dB(a)
• 5,6 kW absorbed power

24. Results:
• 20 dB(A) proven lower noise
• 56% lower absorbed power
• 5% more airflow
• Installation during operation

26. Site Survey
What is your specific challenge? Or where can you safe
energy
With a Site Survey the problem can be identified and a
solution is within reach!

27. Thank you for your attention.
Questions?
Let’s talk more in our booth (No. 12)

28. How to contact us:
Hans van Essen
essen@bronswerk.com
+31-33-24-72-562
www.bronswerk.com