As part of an ongoing plant modernisation programme, a leading manufacturer of active pharmaceutical ingredients set out to upgrade a critical element of its Balance Tank Vent process. The existing blower package had delivered reliable service for more than two decades, but evolving regulatory requirements and the need to maintain the highest standards of safety and operational reliability made replacement the natural next step.
The process itself presented a unique challenge. It required the safe handling and recirculation of potentially flammable vapours within the Balance Tank Vent system, making equipment selection a critical consideration.
Any replacement solution would need to combine process reliability with full compliance for operation within a hazardous area environment.
Having successfully supported the application for over 20 years, AERZEN was selected to provide a new generation of ATEX-certified gas boosters designed specifically for demanding process gas duties.
Designed for hazardous process applications
Unlike conventional air blowers, AERZEN gas boosters are engineered specifically for the safe handling of toxic, corrosive and flammable gases. Every aspect of the design is focused on protecting both personnel and process integrity.
To meet the demands of the application, the units feature uprated nodular cast iron housings manufactured, providing the strength and ductility required for hazardous service. Stainless steel silencers and ancillary components offer enhanced corrosion resistance, ensuring long-term reliability in challenging operating conditions.
Gas-tight sealing arrangement incorporating double radial lip shaft seals with a grease barrier, supported by piston-ring labyrinth seals and neutral chambers. This design helps prevent the escape of process gases whilst maintaining efficient operation throughout the blower’s service life.
For additional safety assurance, the units are TÜV-certified as explosion-proof and have been hydrostatically tested to pressures of up to 31.5 bar. The complete package, including motors and instrumentation, is certified to ATEX Category 2, Zone 1, IIB, T3 requirements.
Having successfully supported the application for over 20 years, AERZEN was selected to provide a new generation of ATEX-certified gas boosters designed specifically for demanding process gas duties, (before and after)
A reliable solution for the future
The replacement installation comprises two AERZEN GM 4S Delta Blowers arranged in a duty/standby configuration and mounted on the existing plinths, minimising disruption during the upgrade process.
Today, the blowers play a vital role in safely removing and recirculating potentially flammable vapours within the balance tanks. This process not only supports safe operation but also helps maintain effective mixing and replenishment of microorganisms within the system.
By upgrading to a modern AERZEN ATEX-certified solution, the customer has strengthened process safety, ensured compliance with current regulatory expectations, and secured the long-term reliability of a critical production asset.
