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Energy-saving aerosol and fume extraction in a Dörries Scharmann machining center

The company Alstom Power Service in Berlin provides maintenance, service and repair for power-generating turbines. A Dörries Scharmann machining center, featuring a partially open hood, produces a great deal of emulsion mist and fumes during turning/milling due to the size of the workpieces. LTA was given the task of preventing this. A model AC 3061 LTA air filter was installed which suctions off the aerosols and fumes with a maximum suction capacity of 7400 m³/h. At the same time, the purified filter exhaust is used to create an air curtain over the openings on the machine, preventing any uncaptured fumes from escaping. The particles entering the air current are guided to the suction openings of the filter, where they are filtered out.

The LTA model AC 3061-V-A air filter

The LTA model AC 3061-V-A air filter on a Dörries Scharmann machining center

The LTA model AC 3061-V-A air filter on a Dörries Scharmann machining center
The LTA model AC 3061-V-A air filter on a Dörries Scharmann machining center, suction side

The LTA model AC 3061-V-A air filter

The LTA model AC 3061-V-A air filter on a Dörries Scharmann machining center, suction side

The LTA model AC 3061-V-A air filter

The LTA model AC 3061-V-A air filter on a Dörries Scharmann machining center, exhaust piping

The LTA model AC 3061-V-A air filter on a Dörries Scharmann machining center, exhaust piping
LTA Luftfilter AC 3061-V-A an einem Dörries Scharmann Bearbeitungszentrum, Rückführkasten

LTA Luftfilter AC 3061-V-A

LTA Luftfilter AC 3061-V-A an einem Dörries Scharmann Bearbeitungszentrum, Rückführkasten

The project manager at Alstom Berlin had this to say

Which factors were most important in our decision to go with LTA?

LTA proposed a solution in which no heat was lost from the machine hall. The purified air is recycled. The air curtain solution is very compact and doesn’t require any bulky hood for opening and closing to be installed on the machine. A major effect can be achieved with relatively little capacity. Other offers were based on extracting large quantities of air. This would also ensure that no aerosols escape, but the required capacity would be enormous. With other offers, the cooling effect would have had a negative effect on the machine's geometry. With LTA, however, the low suction capacity means this isn't the case.


How was the collaboration between Alstrom and LTA from the quotation phase to the end of the project?

LTA gave us expert advice. They provided a detailed project engineering plan, complete with 3D drawings. This way, the problems were illustrated clearly, and the right solution could be worked out. LTA provided excellent guidance and support throughout the implementation and completion of the project.


How is Alstom benefiting from the project, and how much has the air situation improved for Alstom?

At Alstom Company, we take the working conditions of our employees very seriously. We set strict specifications using an EHS (evironment, health and safety) roadmap, which, for the most part, far exceeds legally required standards.

This project sets an example for the rest of the company. The results we achieved with regards to air quality outside the machine were very good. An additional effect is that the temperatures inside the machining area were improved. LTA's scope of delivery for this project included the model AC 3061 cleanable air filter plant with mounted accessories, external control panel and console, a nozzle plate for optimized particle capture, the entire piping, recycling caisson, as well as the assembly and start-up of the entire plant. Advantages of the plant include the high filtration efficiency of the electrostatic precipitator, as well as the use of cleanable filter elements. Thanks to the cleanable filter elements on electrostatic precipitators, we can clean off the filter inserts whenever we need, all without the high cost of disposing of old filters and purchasing replacements. What’s more, because the electrostatic precipitator loses so little pressure, it is highly energy-efficient. With just 4.8 kW, it attains a standard blower capacity of 16,800m³/h.

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Erwin Junker Maschinenfabrik GmbH
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Junkerstraße 2
77787 Nordrach
Germany