Innovative hall air purification for die casting production at ZF Gusstechnologie
ZF Gusstechnologie produces high-quality automatic transmission housings and other automotive components in Nuremberg. The seven die casting machines produce large quantities of particulate matter containing separating agents and oils, combined with high process waste heat. These conditions result in extreme temperatures and increased air pollution. The aim of the project was to protect employees, safely fall below legal limits and at the same time create a pleasant indoor climate.
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- sector: Metal industry and thermal processes
- customer: ZF Gusstechnologie GmbH
- location: Nürnberg, Germany
- Category: production infrastructure
- solution: Extraction & filter technology, Worker protection, Emissions & immission protection, Indoor air purification, airing, heat recovery
- KPIs: Exhaust air flow rate of up to 160,000 m³/h, residual emission well below 1 mg/m³, process heat dissipation up to 800 kW, 100 percent fresh air operation even at —16 °C outside temperature
- Year of execution: 2022
Project details
INFRANORM® created a dry dust removal system for ZF that reliably separates sticky, oily exhaust air. Hydrated lime dosing creates a dry protective layer on the filter cartridges, which binds moisture and ensures a consistently low pressure loss. This ensures long downtimes and minimal operating costs. The purified exhaust air is fed by a rotary heat exchanger guided.
As a result, the heat contained in the process can be used to preheat the fresh air. This makes it possible to operate 100% fresh air even at an outside temperature of minus 16 degrees without using additional heating energy. Three fans connected in parallel deliver up to 160,000 m³/h of exhaust air, while four supply fans ensure draft-free filtered air distribution via laser-perforated textile air ducts. The zone regulation enables uniform, demand-based air conditioning of the entire hall.
The result: Cleaner air, lower temperatures, high operational safety and significantly lower heating costs.
“The requirements of the Environment Agency are important to us — which is why we opted for a filter system so as not to pollute the environment. Air quality has improved significantly. The built-in heat dissipation with fresh air also significantly improves workplace quality. Heat recovery efficiently saves many costs. The systems deliver what they promise. We would choose INFRANORM® again.”
Anatoly Gusser
Hall manager, ZF Gusstechnologie
The customer company
ZF casting technology is part of the global ZF Group and produces high-quality die cast components for the international automotive industry. At the Nuremberg site, complex components such as housings for automatic transmissions are manufactured on state-of-the-art equipment. ZF focuses on high quality standards, energy efficiency and sustainable production.
Learn more about this project
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synopsis
The project at ZF Gusstechnologie shows how modern dust removal and hall air technology improves Employee health protects, improves production conditions and reduces energy costs. INFRANORM® has answered the challenge of sticky exhaust air components, high process heat and particulate matter pollution with a robust, energy-efficient overall solution.
The profit for ZF casting technology:
- Extraction flow rate up to 160,000 m³/h
- significantly improved air quality
- Process heat dissipation up to 800 kW
- full fresh air temperature even in winter
- long filter life and low operating costs
In short: A powerful, sustainable and reliable air purification solution for demanding die casting processes.