SPÄNEX-Extraction system
With the new extraction system from SPÄNEX, the theatre workshops of the Leipzig Opera save several thousand euros in electricity and heating costs per year.
Leipzig Opera's theatre workshops manufacture all the equipment and scenery required for the stage design, not only for the Leipzig Opera itself but also for five other performance venues. All the processing machines were connected to the existing extraction system, which had been installed and put into operation in 1994. The old system was getting on in years and was no longer up to date, especially with regard to energy consumption. The old plant can be described in brief as follows:
- Central external airlock filter system.
Two extraction fans arranged on the raw air side with extraction volume flows of 8,900 m³/h each and motor outputs of 18.5 kW each.
Pneumatic transport system, motor power transport fan 7.5 kW.
Exhaust air operation throughout.
Fresh air system fan motor 5.5 kW, required max. heating power approx. 230 kW.
Long extraction pipelines between the workshops and the installation site of the filter system.
After an intensive planning phase, the company Kaufmann & Winter, together with its partner, the company SPÄNEX, submitted an offer that fully met the customer's requirement profile, whereby the spatial conditions did not pose any difficulties either, as the dust extractors from SPÄNEX scored points due to their compact housing dimensions. Another plus point of the SPÄNEX dust extractors with regard to the awarding of the contract was the extremely low operating noise level.
A compact dust extractor (see Fig. 2) with an air capacity of 10,000 m³/h was installed on the ground floor, equipped with antistatic filter elements that are cleaned with compressed air (Jet Pulse System) and a 0.5 m³ chip collection container with integrated discharging unit..
An identical dust extractor with an air capacity of 7,000 m³/h was set up on the second upper floor.
The air cleaned in the compact extractors can be fed back into the workrooms as return air due to a residual dust content of < 0.1 mg/m³, so that no additional supply air system is required.
The filling level in each container of the compact dust extractor is monitored by a sensor and when a certain filling level is reached, the discharging system with the rotary valve (decoupling element) and the transport fan are put into operation. The control system ensures that only one container is emptied at a time.
The electrical circuit for the entire system is equipped with an automatic lock slide control and speed control of the extraction fans via frequency converters.
The processing machines installed on the intermediate floor of the turnery are extracted via a separate small dust extractor (see Fig. 3).
After two years of operation, the advantages of the new extraction system are obvious. The management of the theatre workshops of the Leipzig Opera are enthusiastic about the results achieved with the new system: "Our expectations have not only been met but exceeded with the new extraction system. We are particularly impressed by the enormous savings in electricity costs (approx. 50 %) and heating oil (approx. 19,000 ltr/year) as well as the quiet operation of the new system. The handling of the project was also convincing for us. The dismantling of the old system and the installation of the new system was completed on time during the break in the season, so that there were no unscheduled interruptions.“
Advantages at a glance
- State-of-the-art plant technology based on compact dust extractors
- 3 dust extractors SMU - SMU 100, SMU 70, SMU R-15
- 100 % air return into the working rooms
- Enormous electricity cost savings (approx. 50 %)
- High savings of heating oil (approx. 19,000 ltr/year)
- Very quiet operation of the extraction unit
- Excellent project handling, dismantling of the old plant and installation of the new plant
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