The inTernaTional magazine of The gea group issue 05 marCh 2008

The wonders of olive oil healThy demand for goaTs milk CreaTing The righT aTmosphere for arT

generaTe is published by the gea group aktiengesellschaft, an international technology group with operating subsidiaries in around 50 countries. listed on mdaX stock index, the company focuses on specialty mechanical engineering especially process engineering and equipment. The principal markets in which it operates are foodstuffs, dairy, beverages, brewery systems, pharmaceuticals, biotechnology, cosmetics, petro-chemical, biofuels, energy technology as well as marine. The gea group is one of the worlds market and technology leaders in 90 per cent of its businesses. The group, headquartered in Bochum, germany, reported sales of eUr 4.3 billion in 2006 and employed some 19,200 people as at september 30, 2007. Thermal engineering

welcome to the fifth issue of generaTe, published by the gea group aktiengesellschaft.
Dear Readers, One of the biggest challenges the world faces today is the need to provide for the energy supplies of the future in ways that will minimize the impact on the environment. We need more energy than ever before to fuel both the worlds traditional powerhouse economies and the rapidly developing economies in countries like China, India, Brazil and Mexico. As our feature article in this issue suggests, the answer is likely to be found not in one but in a range of energy sources: fossil fuels and nuclear power will continue to be used, but complemented by an array of technologies from wind power to geothermal. Whatever the combination of energy sources, GEAs businesses will be at the forefront of the efforts to develop them. GEA is making a difference in more than just energy generation. Were improving the energy usage of whiskey distillers and boosting the productivity of the US dairy industry through our technical innovations. In this issue, we look at the shipping industrys response to challenges created by environmental pressures, how cultural institutions can benefit from climate control technology, and the myriad benefits of olive oil. Of course, staying at the cutting edge of technology needs an organization that is fit and strong. GEA enjoyed a successful year in 2007, has a full order book and is one of the technology leaders in 90 per cent of the markets in which it operates. All this should ensure we remain well placed to help meet the needs of our customers worldwide.
Jrg oleas
Chairman of the Executive Board GEA Group Aktiengesellschaft

farm sysTems

emission ConTrol

air TreaTmenT

proCess engineering

pharma sysTems

proCess eqUipmenT

refrigeraTion

meChaniCal separaTion

Contact gea group aktiengesellschaft dorstener strae 484 44809 Bochum Tel: +49-(0)234-980-0 fax: +49-(0)234-980-1087 www.geagroup.com

FEATURE STORY THE HEAT IS ON WITH THE WORLD DEMANDING MORE POWER, DIVERSITY IS THE KEY TO PROVIDING IT

HOLIDAY ON ICE

The rise of urban ice rinks

HOW TO DO IT

Step-by-step guide to pressing olive oil

LIQUID GOLD

Cholesterol buster, digestion aid, culinary godsend, fuel and cosmetic

SUPER NANNY

Goats milk growing in popularity

WHISKEY GALORE

New process saves energy

Q&A

Sea change: Tony Mason tells us how the shipping industry is handling environmental challenges

INNOVATION IN DAIRY INDUSTRY

CULTURAL REVOLUTION

Unique valve boosts US milk output and cuts dairy costs

Ensuring the best environment for museums and theaters

A DAY IN THE LIFE

Steffen Bersch is GEA`s guy in Dubai

ART IN ENGINEERING

THE LAST WORD

Global news from GEA

GENERATE MAGAZINE ISSUE 05

IN TODAYS TECHNOLOGY-DRIVEN WORLD, THERES SOMETHING WONDERfULLY OLD-fASHIONED AND ROMANTIC ABOUT OUTDOOR ICE SKATING. AND WITH URBAN ICE RINKS BECOMING INCREASINGLY POPULAR, SKATERS ARE VOTING WITH THEIR fEET AT RINKS IN fAMOUS CITY SETTINGS ACROSS THE WORLD.

GEA And icE GEAs expertise with refrigeration technology goes back over 45 years, in the shape of Netherlands-based Grasso and Grenco businesses. Industrial refrigeration manufacturing specialist Grasso has been supplying refrigeration equipment for ice rinks in Europe since the 1960s, helping to build the worlds third 400-meter ice skating circuit in Amsterdam in 1961 and the first with direct expansion of ammonia in the tubes. All Grassos ice rink systems use environmentally friendly refrigerants. Grenco B.V. is a market-leading developer, designer, engineer and service provider of refrigerating

installations in the Netherlands and a key supplier to the countrys temporary and permanent ice rinks. For example it has recently converted the cooling system of a 400-meter outdoor skating track in Ijsbaan Kennemerland to liquid carbon dioxide and added a state-of-the-art skating rink inside the circuit. Grenco adapted and updated the existing compressors to create a system that allows the rink and the track to be at different temperatures and even permits different temperatures on the straights and the corners of the circuit. Grenco has also supplied ice rinks in Belgium, France, Spain and the UK.

ong before it became a leisure activity, skating was a vital means of travel and winter trade along rivers. The pioneers of ice skating strapped sharpened animal bones to their footwear to cross Europes frozen wastes some 4,000 years ago. Todays modern ice skates, made of steel, first It looks as though outdoor skating rinks took shape in the Netherlands in the One of the most famous is at Somerset are here to stay. Temporary sites in 13th century when sharp edges were House in London, just off the Strand. The tourist locations with historic buildings added to the bottom of the skates, elegant eighteenth-century palace is a as a backdrop are proving an irresistible enabling skaters to propel themselves superb setting for skaters from November draw. As well as being fun, its a healthy without needing wooden sticks. to January. Although not the first temporary activity. One hour on the ice can burn outdoor rink in Britain, Somerset House has nearly 500 calories unless you reward Skaters have taken advantage of really caught the public imagination since yourself with a hot chocolate and whipped naturally occurring ice for hundreds skating began there in 2000, prompting cream afterwards. of years. The first rink with artificially other cities to follow suit. frozen ice was the Glaciarium, opened in London in 1876 at a cost of 20,000 Paris was one of the first continental for use by noblemen and gentlemen in European cities to host a temporary ice rink certain conditions. Since then, ice rinks when it built one in the Hotel de Ville in 1996. have become a far more inclusive leisure It opened an even more spectacular rink in pursuit. 2004 on the first floor of the Eiffel Tower, 50 meters above ground level. Surely settings Theres nothing new about the appeal dont get much better than that. Berlin, of outdoor artificial rinks: The famous Hamburg and Cologne are among the German Rockefeller Center in New York City has cities to put up rinks in the winter, the latter hosted ice skating for over 70 years. constructing a huge one every year on the That rink first opened on Christmas Day Heumarkt. Bruges, Brussels and Bratislava in 1936 and is now a popular venue for have all followed the trend. Not to be outdone, skaters from October to April every year, Moscow has constructed a temporary rink in with over 250,000 people taking to the ice Red Square, overlooked by the onion domes each season. of the Kremlin.
GENERATE MAGAZINE ISSUE 05

Its in the last decade, though, that outdoor skating on temporary ice rinks has really taken off and these days outdoor skating can be held against the backdrop of some of Europes most stunning buildings and under the stars. In colder climates, artificial rinks can be made enclosing a level area of ground, filling it with water, and letting it freeze. But todays urban ice rinks are made by building a bed of sand or slab of concrete and running pipes across the rink which contain frozen fluid so water placed on top will freeze. Nowhere is this more popular than in Britain. Two fifths of Europes 90-plus temporary rinks are in British cities and towns.

Temporary rinks have been put up even further afield, and in some unlikely locations. Mexico Citys famous Zocalo Square was the venue for a 3,000m2 rink from December 2007 to January 2008, with capacity for 1,200 skaters at any one time. Japan and Dubai also have temporary rinks and a city center rink in Seoul in South Korea, opened in 2004, attracts close to 200,000 visitors from November to February.

Pressing olive oil

Since 1990 global demand for olive oil has more than doubled. As a result the major producing countries have been under intense pressure to boost yields in an energy efficient way while improving quality. This has gone hand-in-hand with the development of new and better technology in the shape of high performance separators. Spain, the top producing country, supplies 40 per cent of the worlds olive oil. More than 95 per cent of this is extracted using a two-phase process which produces a first class product and, because it uses less water than other systems, is better for the environment. This is how it works

WASHING & CRUSHING First the harvested olives are cleaned of any leaves and twigs, then washed to remove sand and soil. This is important because foreign particles could spoil the purity and flavor of the oil. Washed olives are fed into a hammer mill where they are crushed into a paste by highspeed rotating hammers.

MALAXATION This process allows the microscopic droplets of oil to concentrate so that they can be extracted more easily. The paste is stirred slowly in a specially designed mixer, called a malaxer, at low temperature. Surprisingly, extra virgin olive oil, usually labeled as cold or first pressing, can actually be warmed up to 27C (80F). Lower grades can be warmed to between 30 and 35C (86-95F).

ExpErts in oil rEcovEry GEA company Westfalia Separator, one of the world leaders in providing separators and decanters for a wide range of applications and industrial sectors, has been involved in the olive oil recovery business since the 1950s. In the 1990s the company harnessed its process and engineering know-how to develop an environmentally friendly two-phase separation process. This eliminated the need to dilute the olive paste with water, which was later wasted. It also increased yield and the quality of the product. The launch of decanters with CETEC technology in 2001 brought a further increase in yield of one to two percentage points.

olivEs

pUlp

2-stAGE mAlAxEr

lonG lifE Some olive trees can live for thousands of years. It is believed that a tree from the olive grove where Plato established his academy was still standing in the 1980s, making it more than 2,300 years old. vAlUABlE Gift According to Greek mythology Athens was named after the goddess Athena when she offered the city an olive tree. The locals much preferred this gift to Poseidons offering of a salt water spring. pEAcE siGn Olive leaves have been symbols of peace since Biblical times. They are a key feature of the United Nations emblem and the Great Seal of the United States.

SEPARATION A decanter separates the oil from the pomace solids and water by centrifugal force. The oil is then polished with self-cleaning, high performance separators. A second decanter stage can recover some more oil from the pomace. Nothing is wasted as the pomace can then be separated into pits and pulp: olive pits make good fuel while the pulp may be sold as fertilizer or a high-fiber additive for animal feed.

STORAGE After processing the olive oil is stored in large containers in cool, dry and dark rooms. Once it has settled, usually after about two months, it is filtered, bottled and sold.

2-phAsE dEcAntEr cEntrifUGE

oil

pomAcE

GENERATE MAGAZINE ISSUE 05

H OI GO OM L Of L H D ER A A IT S P TH S B AND DES S E N EOP M EE , f CR IS U E N O I IN TR LE DIT A R C BED C IT B E S E KI RE ION EC RR TAP NT IT TC A O A L U A HE SIN AL ME NE E I RIE S L N GL BE M AN NG S, Iq S N O U AR Y S Ef RE DI RED OL ID OU OU ITS AW ET. IE IVE N GH , O A NO NT D T- L RE W TH A IV , E fTE E O Of W OR R I IL LD N .

Acid tEst Olive oil is graded according to the FFA (free fatty acid) content. Extra virgin comes from the first pressing of the olives and contains no more than 0.8 grams of FFA per 100 grams of oil. virgin is also cold pressed and acidity must not exceed two per cent. olive oil generally virgin oil blended with lower grade refined olive oil.

Today global olive oil consumption is at an all-time high. According to the International Olive Council 2.9 million tonnes were consumed in 2006/7.
uring the 1990s scientists were keen to discover why, despite a rich diet, the French were less likely to suffer from cardio-vascular diseases than their north European neighbors or people in the United States. The answer pointed to a high intake of fruits, vegetables, wine and olive oil. As if to confirm this, Jeanne Calment, who died in 1997, made history as the longest-living human since records began. Born in the Provenal city of Arles, she lived for an astonishing 122 years. This sprightly woman, who took up fencing at 80 and was still riding her bike when she was 100, attributed her amazing longevity to olive oil which she added to all her food. She even used it as a moisturizer. Olive oil is the healthiest vegetable oil because it is high in antioxidants, which strengthen the immune system, and monounsaturated fats, which help to regulate cholesterol and ward off cancer and heart disease. It is also gentle on the stomach, promoting the healing of ulcers and aiding digestion. The heart-friendly properties of olive oil were pinpointed in 2005 by researchers at the Monell Chemical Senses Center in Philadelphia, who found that the naturally occuring chemical oleocanthal had similar properties to ibuprofen. However, as you would need to swallow 500 grams of olive oil to equal one dose of ibruprofen, its unlikely to take off as a headache cure. Nevertheless, the research helped to explain further the health advantages of the Mediterranean diet. It is believed that olive trees were first cultivated on Crete around 3500 BC. Since then olive oil has brought great wealth, power and well-being to Mediterranean countries. As well as a myriad of culinary uses for frying, marinades, sauces, salad dressings and preserving cheese, fish, sausage and vegetables its also found in soap and provided fuel for oil lamps. In fact olive oil was the original fuel for the Olympic torch. Jeanne Calment was not the first to appreciate the cosmetic value of extra virgin olive oil. In Greek and Roman times athletes used to rub it over their bodies. Lovers of natural beauty remedies continue to praise its versatility. As well as being an excellent moisturizer, it can be used as an eye makeup remover and as a shaving oil, especially for sensitive skin. When mixed with sea salt it makes a good natural body scrub or you can add it to melted beeswax for an effective lip balm. There are hundreds of olive varieties, ranging from the Greek Kalamata to the French Picholine. Their color reflects the degree of ripeness. Olives harvested at the beginning of the season are green, whereas the black, or fully ripe olives are collected later. On average, a single olive tree bears around 20 kilograms of fruit a year, which is equivalent to three to four liters of oil. Like wine the quality of olive oil is determined by the area of cultivation and climate. Oils are graded according to the content of oleic acid, a simple unsaturated
GENERATE MAGAZINE ISSUE 05

fatty acid. The lower the content of oleic acid, the finer and fruitier the taste. So, for example, extra virgin, the top grade, has no more than 0.8 per cent acidity (0.8 grams of free fatty acid per 100 grams of oil). Around ninety-five per cent of the worlds 750 million olive trees are in the Mediterranean region. Spain is by far the largest producer, with more than 200 million olive trees, followed by Italy, Greece and Turkey. Olive plantations can also be found in Australia, South America, the United States, South Africa and the Middle East and their numbers are growing. Today global olive oil consumption is at an all-time high. According to the International Olive Council 2.9 million tonnes were consumed in 2006/7, more than double that for 1990/91. With people becoming more aware of the link between what they eat and major diseases, olive oils important contribution to a healthy diet is assured for the foreseeable future.

THE GOAT IS THE TRENDIEST ANIMAL IN fARMYARDS ACROSS THE WORLD. NOT SO LONG AGO, PEOPLE WERE RELUCTANT TO EVEN TRY GOATS MILK. NOT ANY MORE. INCREASED AWARENESS Of GOATS MILKS POTENTIAL HEALTH BENEfITS MEANS THAT DEMAND HAS NEVER BEEN HIGHER. THE GOATS TIME IN THE SPOTLIGHT HAS ARRIVED.
istorically known as the poor mans cow, goats are one of the worlds oldest domesticated animals. They have been kept for their milk, meat, hair and skins for more than 10,000 years. These incredibly versatile animals eat pretty much anything and need far less grazing space than cows. In many developing countries, goats milk is an important source of protein, phosphate and calcium as cows milk is not always available. In global terms, more people drink goats milk than milk from any other animal, even though goats milk production accounts for approximately two per cent of the audited world milk market. Asia, Africa, and South America are the populous continents where goats milk has always been popular. Its taken longer for goats milk to crack the markets in the developed countries; but increasingly health-conscious customers and a desire for innovative new products mean goats milk is the worlds fastest growing dairy product. In Europe, the market is growing by ten per cent every year and this increased demand has resulted in bigger herds, the introduction of high-tech milking equipment and improvements in milk quality. france, Switzerland and Greece have traditionally been among Europes leading goats milk producers but the Netherlands has become one of Europes biggest exporters of the product as the market has developed. More than 75 per cent of all goats milk in the Netherlands is exported to Germany, france and England. The Netherlands 375 goat farms, the biggest of which have around 1,000 animals, produce over 150 million liters of milk, with high-yield goats each producing more than 950 kilograms of milk per year. But all this has only been possible thanks to the entrepreneurial spirit of the goat farmers and state-of-the-art milking equipment developed by GEA company WestfaliaSurge. Already a global force in milking cows, WestfaliaSurge has adapted to the markets needs by creating a bespoke rotary parlor for goats the AutoRotor Capri 90. Jan van de Ven and his wife Jean are typical of progressive Netherlands goat farmers. They farm 1,200 Saanen goats in 2,000 square meters in Oirschot near Eindhoven. Van de Ven says Saanens larger and stronger than other breeds are more sensitive than cows. They need more care with feeding and husbandry, but on the other hand require much less space and food. Moreover they are cleaner and easier to milk. The goats are milked twice a day by just two people. Everything else is fully automatic. Once the barn gate is opened, an automatic driver herds the goats in the direction of the rotary parlor. Attracted by food in the milking box, the animals allow themselves to be attached to the cluster (the milking equipment) and enjoy the ride on the carousel, which is 14.5 meters in diameter. Goats are notoriously impatient so the clusters need to be attached quickly. And their propensity to chew everything in sight meant WestfaliaSurges engineers had to design totally bite-resistant equipment. The AutoRotor Capri 90 holds 72 goats and all 1,200 at the van de Vens farm can be milked in just 90 minutes. Prior to its installation, this process took four hours. The farms milk is collected by one of the Netherlands three goats milk co-operatives, before being further processed to produce cheese, yoghurt and other finished products. WestfaliaSurges latest generation milking control unit measures the milk yield of each goat and shares the data with the herd management program. It enables the farmer to assess each goats profitability. Operating without state-of-the-art technology simply isnt a viable business option for large-scale goat farmers. In just 20 years the market for goats milk and associated products has changed beyond recognition. And the huge demand looks set to continue. from GoAt to hEro GoAts milk At-A-GlAncE > The worlds most popular dairy product
> Goats were first kept as domesticated animals

10,000 years ago in Iran

> Revered in Egypt: milk and cheese were placed

in pharaohs burial chambers

> Widely consumed by the Ancient Greeks

and Romans
> Goats milk started to become more available

again in the 1970s

> As well as being a good source of protein, goats

milk is more easily digestible and less allergenic than cows milk
> The plethora of products available now includes

goats cheese, feta cheese, ice cream, yoghurt, fudge, chocolate and skin care products

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BY 2030, THE INTERNATIONAL ENERGY AGENCY PREDICTS, THE WORLD WILL NEED 50 PER CENT MORE ENERGY THAN TODAY, WITH MUCH Of THAT INCREASED DEMAND COMING fROM CHINA, INDIA AND OTHER RAPIDLY DEVELOPING ECONOMIES. Steve HobSon ExAMINES THE CONSIDERABLE CHALLENGES THE ENERGY INDUSTRY fACES AS IT TRIES TO BALANCE THE WORLDS INSATIABLE ENERGY DEMANDS AND DIMINISHING OIL RESERVES WITH THE NEED TO PRESERVE THE ENVIRONMENT fOR fUTURE GENERATIONS. PHOTOGRAPHY: PETER DAzELEY STYLING: SABRINA JARD

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both processes currently rely largely on the same fossil fuel sources that would have provided the transport fuel. Our demands for electricity, heat, and transport are growing faster than ever. According to US Department of Energy figures, global energy demand which rose by around 42 per cent between 1980 and 2000 (from 283 quadrillion British Thermal Units [btu] in 1980 to 400 quadrillion btu in 2000) will nearly double again in the years to 2030. Fossil fuels No one is sounding the death knell for fossil fuels. The World Energy Council (WEC) points out that there are still extensive reserves of fossil fuel but they are being depleted faster than ever. For example, the Estimated Ultimate Recovery (useable reserves) of conventional oil was originally 387 billion tonnes. Of this, about 143 billion tonnes had been exploited to the end of 2005 and within the next ten years fully half of the reserves will have been extracted. More fossil fuel reserves are likely to be discovered: for example, so-called unconventional sources such as the immense oil sands in Canada. The question of whether these unconventional sources will be fully exploited is a complex one: some have already been tapped and it is technically possible to recover most of them. Changing directions Its not the first time the energy industry has needed to make a step change. A recent example is the switch to using gas as both a direct source of heat and as a clean and efficient fuel for electricity generation. The industry originally depended on thousands of miles of pipeline transporting the gas from the source to the user. That network is still being extended, but it requires huge investment. Its also inflexible and restricts the gas market, a very real concern when three countries Russia, Iran and Qatar hold around 50 per cent of the worlds natural gas resources. Cooling and liquefying the gas, however, allows it to be transported by ship. Overcoming this technical challenge has been the basis for developing a global market for liquefied natural gas (LNG). Now twelve countries export natural gas and ten more may become exporters in the next few years. Whether its pipelines or LNG plants, GEAs Thermal Engineering Division takes a leading position in supplying cooling components for these applications. Developments like LNG have broadened the options available for the global energy market. But the sheer rate of growth in demand and increasing fears over the future of fossil fuels have sent the energy supply industry back to the drawing board to look at how energy is delivered and used.

he need for bodily warmth and for cooking food was what drove the first humans to make use of fire, and it has been a constant of our search for the best energy sources for thousands of years. Our energy needs may be more varied now and electricity was discovered long ago but heat still forms the basis of many of our systems. Since much of our electricity production has relied on producing steam to move the turbines that produce power, the energy industry has been focused on finding and exploiting the best heat sources. And that has generally meant extracting fossil fuels such as coal, oil and gas. Its not just demand for electricity and process heat for industry putting pressure on fossil fuel resources. They also provide fuel for transport and feedstock for the chemical and manufacturing industries. And, while electricity and hydrogen have both been mooted as potential fuels for the transport industry, this is shifting, not removing, the burden. Electricity must be generated and hydrogen produced and
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There are finite and renewable energy resources. The first are the organicallybased resources of coal, oil, gas and tars, along with the uranium and thorium resources used as nuclear fuel. Renewable energy sources include solar, photovoltaic, wind, wave, tidal and bioenergies. There are no reserves to be mined; instead, exploitation is a matter of harvesting them whenever they are disposable. Perpetually available they may be, but they cant always be guaranteed to match the place or time of demand. The answer, then, is diversity: a mix of renewable energy sources; robust and extensive energy networks that make the best of the energy available at any one time; and storage, either electrical or in the form of an energy carrier such as hydrogen, or biofuels. The costs of abating emissions of carbon dioxide will drive up the price of using fossil fuels, as will the increasing burden of extracting them. Carbon capture and storage (CCS) is expected to be commercially viable by around 2020 and will allow fossil fuels such as gas, oil and coal to be used without contributing to carbon emissions. CCS involves extracting carbon from the fuel either pre- or postcombustion before transporting it via pipelines to underground storage on- or offshore. Its economics are expected to be greatly improved when used in conjunction with enhanced oil recovery, where the liquefied carbon dioxide is used to help extract more oil from depleted fields. Coal power stations on the UKs North Sea coast are ideal proving grounds, and the UK government is holding a competition to develop viable CCS among power station operators. Bob Taylor, Managing Director of UK generation at German energy giant Eon, says that, as well as contributing to a reduction in the UKs carbon emissions, it is vital CCS is developed for fitment to India and Chinas rapidly growing fleets of coal-fired power stations. The UK Government wants to see a small scale demonstration of CCS by 2014 and applied to 300 to 400MW plant by 2018. >

GEothErmAl EnErGy One of the lesser-known forms of electricity generation, geothermal energy, is power generated from beneath the earths crust. Hot water from below the earths surface is extracted and converted into electric power. Geothermal steam and hot springs have been used for centuries but geothermal energy wasnt used to make electricity until 1904 when a steam field in Italy powered a small generator to light four bulbs. The utilization of geothermal energy has reached the state of industrial application. The geothermal power plant Unterhaching in Bavaria, Germany, is a perfect example of cross-divisional collaboration within the GEA Group: GEA Energietechnik GmbH and 2H Kunststoff GmbH, both from the Thermal Engineering Division, have delivered the cooling towers including the cooling tower fills. GEA Ecoflex GmbH from the Process Equipment Division supplied plate heat exchangers. Unlike many other renewable energy sources, geothermal energy can produce a constant source all year round. Geothermal energy currently accounts for less than one per cent of the worlds energy but a range of pilot projects are underway around the globe to explore its potential.

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WIND POWER IS PROBABLY THE fASTEST GROWING Of THE NEW POWER SOURCES.
Renewable energy Tapping renewable energy resources has proved challenging. In some cases, such as wind power, exploiting the resource has sent engineers back to re-examine technologies that have been used for centuries and consider how they can be re-engineered for modern purposes. In others, such as solar photovoltaics, there have been true technological leaps. Their common thread is the need to step up these niche technologies to meet a significant proportion of global energy and power needs. Wind power is probably the fastest growing of the new power sources. The European Wind Energy Association puts the number of wind turbines in use worldwide at 85,000, providing 94GW of electricity capacity. The capital cost of onshore wind is relatively low, and can be staged as more turbines are added to an existing wind farm, so it is often the first choice for new renewable energy. Major suppliers and volume production had combined to bring down capital costs, but in recent years the popularity of wind power has been too high for the industry to manage. Turbine
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manufacturers have full order books for years to come and so have companies providing installation and commissioning services, especially in the offshore wind sector. Photovoltaics (PV) is unique in the variety of potential applications it offers, from large stand-alone panel arrays to thin films or glasses integrated into buildings. It can also be installed in stand-alone applications far from the electricity grid to feed directly into the building supply. That means the potential for different types of installation is enormous. The European Photovoltaics Industry Association estimates that installed peak capacity could grow by around 35 per cent annually, from the around 1000MW installed worldwide in 2005. The growth of the industry has been slowed by three major factors: the price and availability of silicon, a vital material; the high capital cost of the panels; and the problems of providing financial credit for domestic levels of power generation. Problems with silicon supply may ease during the next few years as new manufacturing facilities come on line. High sales volumes (the industry hopes) will start to bring down capital costs.

As the PV industry grows, a second solar industry is developing alongside: using the suns heat. Collecting and concentrating the suns energy with specially shaped mirrors can allow it to be used to produce steam for driving a conventional steam turbine. It is a new way to use a familiar technology that fits well into our existing energy networks; and it is growing fast in areas which can rely on sunshine, such as California and Spain. bio-energies Biomass and biofuels are, similarly, a new way to fuel familiar technologies. Fossil fuels are directly replaced with their plant-based equivalents: wood or other solid biomass for coal, or vegetable oils for fossil oil. It is an attractive solution, as it will also fit directly into our existing energy infrastructure, sometimes in stages. The UK, for example, will soon require transport fuels to include a mix of up to five per cent plant-based equivalents. There are questions over the costs and environmental impact of refining and transporting the necessary quantities of bio-energies. But the biggest question is over their production: they compete for space with existing crops, not least food crops; and there was an outcry when cash crops such as palm oil were seen to be the cause of destruction of virgin forest. Large-scale hydropower is another part of the renewable energy portfolio. The different types of hydropower include waterwheels, hydroelectricity (dams) which is the most widely used, and damless hydro (using the kinetic energy of rivers, streams and oceans). They enable low cost energy to be used at long distances from the water source. Although hydroelectricity doesnt give out harmful emissions and is cheaper than energy generated from fossil fuels, it may not be a major option for the future in developed countries as there is little scope for further development and the building of new dams may present environmental problems. Other technologies, such as oceanbased devices that abstract energy from waves and tides, are at an early stage of development but are likely to encounter the issues of supply-chain development that have checked the wind industry. Renewables target All these energy sources will be needed to meet our needs, and at ever faster rates of deployment. In January 2008, the European Commission published detailed plans on how its member states would together produce 20 per cent of their primary energy supplies from renewables by 2020. It is a big increase and will fuel the European market for all these technologies, but it will not allow the EU to dominate world markets. Demand is growing still faster in areas such as China and India. >

GEAs rolE in thE EnErGy indUstry As countries and energy companies around the world explore how to meet future energy needs, GEAs Thermal Engineering Division will be with them every step of the way. Heat transfer technology plays a central role in the worlds power stations, oil refineries, petrochemical plants, gas pipelines and GTL (gas to liquid) and biomass facilities. central to GEAs energy offering are: > Air Cooled Heat Exchangers (also known as Air Fin Coolers) for direct dry cooling, which are used in any application where heat needs to be transferred in large quantities. Air cooling is used at all modern industrial facilities (from energy generation to energy transportation) air is unlimited, free and does not require treatment. > Air Cooled Condensers, for direct condensing, which are used to condense steam. > Wet cooling (a two-step method water is cooled in a Wet Cooling Tower and then the cooled water cools or condenses the fluid or steam). > Indirect dry cooling by means of Heller cooling towers (a two-step method water is cooled in a Dry Cooling Tower and the cooled water cools or condenses the fluid or steam). > Special applications (e.g. de-sublimination, crystallization). The Thermal Engineering Division has businesses worldwide. GEA has invested heavily in China and it is paying off with a host of contracts to supply Air Cooled

Condensers for the fleet of coal-fired power plants and Air Fin Coolers for the petrochemical refineries that will power the China of the future. The boost of Indias economy is great news for its petrochemical industry and GEA is supplying components there, too. South Africas power industry is also developing at a fast rate. GEA is currently heavily involved in the development of new power stations there, winning one of the largest orders in the history of its Thermal Engineering Division in December 2007 for the design, manufacture, supply and erection of Air Cooled Condensers for Medupi power station. South Africa is experiencing energy shortages and GEA is also involved in projects that will recommission power stations shut down in the 1990s. The growth of refineries, GTL plants and gas processing plants in the Middle East has created a new market for air cooling as water is scarce. Thus, GEA company Batignolles Technologies Thermiques opened a new manufacturing site for Air Coolers in Qatar to tap into this market. Historically, GEA has been a major player in the energy sector, building its first Air Cooled Condenser in 1939, and the Groups reputation for knowledge, reliability and engineering excellence means it is well positioned to benefit from projected increases in energy consumption. And its not just GEAs Thermal Engineering Division that plays a leading role in the energy industry. The division teams up with different GEA businesses to offer clients integrated engineering solutions to both energy production and boosting energy efficiency.

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is EnErGy lABEllinG workinG? Essentially, there are two routes to diminishing carbon emissions from electricity use: cutting the carbon intensity of power generation (reducing the carbon dioxide emissions per KWh by using more nuclear or renewable energy, improving the efficiency of fossil fuel plants etc); or reducing the energy intensity of consumption (bringing down the MWh per square meter by improving energy efficiency of buildings or appliances or reducing energy-hungry activities). The US Department of Energys Federal Energy Management Program has called upon Federal agencies to reduce energy use by 35 per cent by 2010 on 1985 levels; while last year the European Union set a target of saving 20 per cent of its energy consumption compared to projections for 2020. In 1985, the EU introduced an energy rating scheme covering white goods and light bulbs. Appliances are rated from A (the best) to G (the worst) based on energy and water efficiency. In 2004, two new categories for refrigerators and freezers were added, where A+ indicates appliances that consume 30-42 per cent of standard energy consumption and A++ those consuming under 30 per cent. With sales of A-rated white goods rising from 20 per cent to 60 per cent in the first three years, the scheme was a success but any gains were more than wiped out by modern consumers insatiable demand for electronic gadgets. Incandescent light bulbs, which waste 95 per cent of electricity consumption, have been specially targeted. Many governments are proposing to phase out incandescent lighting and replace it with more efficient technologies such as compact fluorescent lamps (CFLs) and light emitting diodes (LEDs). To encourage the use of energy-efficient lighting in homes, the European Commission set up the European Design Competition Lights of the Future. This years awards will be presented at the Light+Building event to be held as part of a giant trade fair in Frankfurt in April 2008.

GrEEn UrBAn dEvElopmEnt According to urbanists and statisticians, the human race has just reached the point where more than half of the worlds population lives in cities. By 2050, twothirds of the global population will call a city home. Can cities be green, reinvent themselves as exemplars of sustainable development? Theres a queue of designers, engineers, architects and politicians who say emphatically yes. The environmental and political imperatives surrounding the need to cut greenhouse gas emissions have already persuaded the UK Government to lead the world by committing to the ambitious goal that all new homes will be built to a zero carbon standard by 2016. The house building industry has signed up to this. Work is also now underway to look at equally tough energy efficiency targets for new commercial and industrial buildings. Ministers also want to see ten so-called eco-towns climbing off the drawing board by the end of the decade. Each will be a small new town of at least 5,000 to 20,000 homes and all will have to achieve zero carbon development. This will be delivered by a mix of renewable energy projects, domestic microgeneration systems, and community heating projects based on combined heat and power systems and ultra energy-efficient new dwellings. Meanwhile, internationally, two city-scale projects are beginning to make waves. Consultants Arup are working on what is claimed to be the worlds first sustainable city at Dongtan in China. The city will get the bulk of its energy from wind turbines and bio fuels. The designers envisage a city powered by local, renewable energy, with super-efficient buildings clustered in dense, walkable neighborhoods. At the same time the United Arab Emirates has announced plans to start building Masdar, a multi-billion-dollar green city in the desert. This 50,000-inhabitant city will feature narrow streets, squat buildings with shaded courtyards and no cars. Solar and wind energy will power the city and its water desalination plant. The target is definitely zero carbon with energy supplied by photovoltaics, solar power, wind, waste to energy and other technologies.

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ReGIon INDUSTRIALIZED NATIONS* EASTERN EUROPE/ FORMER SOVIET UNION DEVELOPING NATIONS ASIA MIDDLE EAST AfRICA CENTRAL & STH. AMERICA TOTAL DEVELOPING NATIONS TOTAL WORLD
Source: Energy Information Administration *US, Western Europe and Australia

eneRGY ConSUMPtIon
(qUADRILLION BTU)

1990

2001

2010

2025

182.8 > 211.5 > 236.3 > 281.4 76.3 > 52.5 > 13.1 > 9.3 > 14.4 > 53.3 > 59.0 > 75.6

85.0 > 110.6 > 173.4 20.8 > 12.4 > 20.9 > 25.0 > 14.6 > 25.4 > 34.1 21.5 36.9

89.3 > 139.1 > 175.6 > 265.9 348.4 > 403.9 > 470.8 > 622.9

the energy outlook World energy prices are likely to continue rising because of the combination of falling supplies of fossil fuels and rising demand from emerging economies. Past experience shows that when oil prices in particular rise too high, demand in the developed economies especially in the US falls, correcting prices downwards. But the picture has changed. While the developed world still accounts for most of the world energy consumption, the developing economies especially in Asia are increasing consumption fast (see table). No country has ever managed to increase its gross domestic product without increasing its energy consumption and this will certainly hold true for China and Indias surging economies. In 1990 the developed world used more than double the non-industrialized nations. By 2025, the developing world will be consuming only five per cent less than the industrialized nations. Those emerging economies expected to see the largest increases in wealth and hence energy demand are the BRICS Brazil, Russia, India, China and South Africa. China and India are currently seeing gross domestic product growth running at almost ten per cent a year and energy consumption is outpacing this growth as domestic and industrial electricity demand rockets. The International Energy Agency (IEA) calls the consequences of Chinas and Indias rise in energy demand alarming, and warns in its 2007 World Energy Outlook: If governments around the world stick with current policies the worlds energy needs would be more than

50 per cent higher in 2030 than today. China and India together account for 45 per cent of the increase in demand in this scenario. It forecasts that world energy demand will hit 17.7 billion tonnes of oil equivalent (toe) by 2030, up from 11.4 billion toe in 2005. Worryingly for the climate, fossil fuels will account for 84 per cent of this increase in demand, with oil consumption rising 37 per cent to 116 million barrels per day (Mbbl/d) in 2030, while coal demand will leap 73 per cent. Most of this increase in coal use will be in China and India. China is both the worlds largest producer and consumer of coal, currently exporting around 50 million tonnes of its massive 2.3 billion tonnes annual production. Coal analysts McCloskeys expects Chinas coal consumption to rise rapidly to 3.3 bnt by 2011, partly fuelled by coal-fired generating capacity rising at 90 gigawatts (GW) a year. After 2009, however, rising output and stabilizing demand are expected to more than cover this domestic increase and China will have a rising surplus for export. The global energy industry knows the world can no longer rely predominantly on fossil fuels and that renewable forms of energy must become an increasing part of the energy supplies of the future if greenhouse gas emissions are to be reduced. And the steep increase in demand for energy as more and more people in the developing economies aspire to own cars and have electricity means looking long and hard at options to power the worlds economies. Our future depends on it.

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IN SCOTLAND THEY PREfER IT STRAIGHT OR WITH A LITTLE WATER. IN MADRID SERVED WITH ICE AND COLA. PEOPLE IN SHANGHAI MIx IT WITH GREEN TEA AND IN NEW YORK ITS THE BASE fOR A VARIETY Of COCKTAILS. SCOTCH WHISKY IS UNDOUBTEDLY A POPULAR DRINK ENJOYED BY MILLIONS AROUND THE WORLD.

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hen the clock strikes midnight on December 31 millions of people across the English-speaking world join hands and welcome the New Year with a rousing chorus of Auld Lang Syne. Written by the famous Scottish poet Robert Burns (the title means times gone by), the song has become an anthem to goodwill and the soundtrack to the traditional Scottish New Year festival of Hogmanay. This involves a ritual called first footing whereby the first person to enter the house after midnight determines your luck for the rest of the year. Ideally, the first footer should be a tall, dark and handsome man fair hair is associated with Viking invaders bringing coal for the fire, cakes, a coin and whisky. Famous export Scottish emigrants may have taken the spirit of Hogmanay to other parts of the world with Auld Lang Syne but nothing has quite captured the imagination, or the palate, as that other famous export, Scotch whisky. Of course many countries, such as the US, Canada, Ireland and India, produce their own versions of the spirit, spelled whiskey, but just about every bar in the world will have Scotch. The whisky industry contributes EUR 4 billion a year to the Scottish economy and provides 41,000 jobs for its citizens. Annual overseas sales are a staggering EUR 3.3 billion. The top five markets are france, Spain, South Korea and Venezuela, topped by the US which spends a whopping EUR 535 million a year. And demand is soaring in growing markets such as Brazil, China, India, Mexico and Russia. In China alone, annual consumption has risen from 700,000 to 5.7 million liters over the past ten years.

The projected demand in these markets is the reason why leading drinks company Diageo is investing EUR 133.8 million on expanding its whisky production in Scotland. This investment is one of the largest ever in the industry and will create around 200 jobs over the next few years. Official records show that the Scots have been distilling whisky since 1494 and, over the centuries, theyve developed it into a fine art. Since the 19th century, its been produced under strict license if done incorrectly, distilled spirits can be poisonous. Today Scotch whisky is protected by international law. This means that it has to be distilled in Scotland and aged for at least three years to be called Scotch. There are five whisky-producing regions: Speyside, Highland, Lowland, Campbeltown and Islay. Malting and distilling Whisky is made by first baking barley to convert it into malt. This is then ground and mixed with water to produce a mash. Its the water, combined with the peat used to fuel the malting ovens, that gives the different whiskies their unique flavor. After the mash has been fermented, it is distilled and then aged for up to three years for blended whisky and eight years for single malts. A single malt is, as the name suggests, the product of one distillery, whereas blended can be a mixture from several distilleries. Distillation is based on the different boiling points of water 100C (212f) and alcohol 78.5C (173f). The fermented mash is fed into the top of the still, a cylindrical tower filled with perforated plates, and steam pumped into the bottom. Water vapor from the fermented liquid condenses onto the plates and is held there by the pressure from

the steam, separating it from the alcohol. The process requires a large amount of energy to create the steam. How to reduce this has been a concern of familyowned whisky distillers William Grant & Sons. The company turned to GEA Wiegand for help. And a team headed by Dr Daniel Bethge and Paul Hildenbrand was only too happy to oblige. Our first idea was to use an open heat pump but this would have destroyed the taste of the whisky, says Dr Bethge. Instead they adapted the mechanical vapor recompression technology that GEA Wiegand has used successfully for other applications. When the vapor from the steamed solution condenses, the steam is pressurized, causing its temperature to increase even higher. The heat from the condensed vapors can then be re-used for the evaporation process. It is a closed loop cycle, explains Dr Bethge. The energy required is lower and less water is needed during the distillation. Patented process The process reduces the amount of energy for alcohol production by a double-digit percentage and will cut operating costs by thousands of euros. GEA Wiegand is patenting the process, which offers huge potential, and is currently in negotiations with William Grant & Sons and Diageo. This ground-breaking innovation won Dr Bethge and his team the GEA Product Innovation Award, a worldwide competition to bring out the best in GEAs top talents. Mechanical vapor recompression can also be applied to bio-ethanol production. Apart from the enormous cost-saving, expected to be several million euros, it will make a major contribution to climate protection.

tEchnicAl innovAtion GEA Wiegand designs, manufactures and supplies plants for the chemical, pharmaceutical and food industries as well as for environmental applications. The company offers complete alcohol processing lines. Its engineers design systems for the treatment of raw material, fermentation and distillation, all of which are manufactured in GEA Wiegands own workshops under stringent quality controls. In addition the company has its own research and development center in Germany for testing the latest technology in the fields of distillation and evaporation.

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OMY. AL ECON E GLOB ORLDS IN OF TH F THE W LYNCHP G IS A CENT O LOBAL 90 PER SHIPPIN ND AS G ARY AORDIN Y SEA, A AN EXTR ORTED B SP PPING RE TRAN THE SHI A OW ONTEXT GOODS S TO GR N THE C E RIGHT. I ONTINU OOKS B RADE C ABOUT L T UTURE NCERN RYS F TAL CO OKE INDUST ONMEN RATE SP NVIR E WING E ET, GEN THE OF GRO R PLAN OU ERAL OF URE OF OUT ARY GEN THE FUT (ICS), AB SECRET ASON, IPPING TONY M R OF SH BE STRY IS WITH AL CHAM NG INDU ATION SHIPPI NGE. INTERN ATIONAL RN ATE CHA E INTE ND CLIM HOW TH SIONS A IR EMIS KLING A E NORfOLK TAC zO
RAPHY: PHOTOG

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thE intErnAtionAl chAmBEr of shippinG The International Chamber of Shipping (ICS) is the principal international trade association for the shipping industry. The aim of the ICS is to act as an advocate for the industry on issues of maritime affairs, shipping policy, legal and technical matters, including ship construction, operation, safety and management, and to develop best practice in the industry.

Q. The International Maritime Organization (IMO), which is responsible for global regulation of the shipping industry, is currently focusing particular attention on environmental issues. How is the merchant shipping industry responding to these issues? A. Successful and concerted progress has undoubtedly been made by governments and industry with regard to reducing oil pollution, eliminating harmful air emissions and tackling issues relating to environmental damage that may be caused by the movement of ballast water or by ships hull coatings. But concern about ships air emissions and the separate issue of global warming and the need to reduce carbon dioxide emissions are now at the top of politicians environmental agenda. The reduction of ships emissions occupies center stage in the regulatory debate, with potentially major implications for both shipping economics and the image of the shipping industry. Shipping, being a global transport industry, requires uniform international rules in order to operate efficiently. But the shipping industry also has to respond to more general concerns about climate change with the desire for ambitious targets for the reduction of carbon dioxide emissions emerging as a mainstream political issue in many countries. Q. What are the key environmental challenges the industry faces? A. The immediate challenge is the IMOs review of its Convention for the Prevention of Pollution by Ships (MARPOL) and the expected introduction of more stringent controls, especially with regard to sulphur emissions and the sulphur content of fuel. But whilst the shipping industry appreciates the political impetus to the debate, it has been important to remind governments that the agreed terms of reference for the current round of IMO discussions have been to focus on the technical and objective scientific arguments relevant to a variety of solutions. The IMO is about to consider the latest proposals on the approach that might be

taken. Possible options include reducing the current sulphur cap in Sulphur Emission Control Areas (SECAs), such as the Baltic Sea, from 1.5 per cent to 1.0 per cent. It has also been suggested that such a cap should apply everywhere, and be achieved by a mandatory switch to the use of distillate fuels by 2010. Q. What does the industry feel about these proposed measures? A. ICS, which represents the industry, has proposed a new goal-based approach to emissions reduction and has called for a holistic consideration of emission reduction measures. It has drawn attention to the need to take account of the environmental justification for the proposed improvements, and to consider fully the relationship between measures to reduce local air pollution, such as sulphur, and the subsequent implications for CO2 /greenhouse gas emissions. In particular, we have argued that there should be choice with regard to compliance measures. The prevailing view of the shipping industry is that IMO should focus on the environmental outcome required, but should encourage different ways of achieving the agreed emission reduction goals. Technical innovation certainly needs to be stimulated but, where regulation requires technical solutions, it should be established whether proven and robust technology does in fact already exist. Above all, any new regulations should be aimed at delivering an overall net environmental benefit. The shipping industry does not wish to solve one problem by creating another. Methods for reducing sulphur emissions should not inadvertently lead to an increase in greenhouse gas emissions, for example by generating additional CO2 from oil refineries. It might be the case that CO2 emissions from shipping, as opposed to shore-based refineries, would not be increased by switching to distillate. But the responsible and honest approach is to suggest that the regulators consider the wider implications of their decisions and that the issues of sulphur and CO2 are linked.

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GEA And thE shippinG indUstry GEA company Westfalia Separator has an award-winning range of high performance engine room products and systems that help ships of all sizes protect the marine environment. Using centrifugal force, the products separate solids and water from fuel and lube oils to ensure that discharges into the sea stay well within environmental guidelines. The engine room products, marketed by Westfalias Mineraloil Systems Business Unit, treat fuel oil, lube oil and hydraulic oil. Products for processing bilgewater and sludgewater at sea are grouped together as SeaProtect Solutions and consistently achieve an oil content of less than 5ppm on some of the worlds biggest ships. Since being launched in 2005, SeaProtect Solutions has quickly established an enviable position in the marketplace and in 2006 won the environmental protection category of the much-coveted Seatrade Dubai International Maritime Awards. As the amount of cargo transported grows in future years, Westfalia Separator Mineraloil Systems will be working closely with ship manufacturers and ship owners to protect the worlds oceans.

Q. So the shipping industry does not have a fundamental objection to the proposal for a switch to distillate fuel? A. In principle, despite the considerable economic costs, many sections of the industry have no objection to a switch to distillate fuel for those shipowners who see this as the most practical solution. But, depending on who pays the bills, it is far less attractive to some shipping sectors than others, and there are also big questions about the ability of the oil industry to deliver the quantities needed if the whole world fleet was required to burn distillate everywhere. The environmental benefit of using low sulphur fuels far from land in the middle of the ocean also needs careful examination. The majority view amongst ICS members is that other compliance options such as the extension of SECAs and the development of exhaust scrubbing technology should also be fully explored before the industry settles for one single solution, the implications of which have not been properly evaluated. Q. What is the industry doing to reduce carbon emissions? A. Shipowners are under pressure to reduce carbon dioxide emissions to mitigate the impact on climate change although, at a time when fuel prices are expected to remain high, cutting CO2 should be a matter of enlightened self-interest. A number of recent media reports have incorrectly suggested that shippings total carbon dioxide emissions are greater than those of aircraft. There is actually a lack of definitive data, but most expert sources estimate that shippings total carbon emissions are considerably less than those of aviation. But in any case such reports are not comparing like with like. Maritime transport is responsible for the transport of 90 per cent of all world trade, including almost everything that we buy in the shops. More to the point, in terms of carbon produced by every tonne of cargo transported one mile, shipping is at least two or three times cleaner than road or rail transport and around 20

times more environmentally efficient than air transport. With regard to concern about reducing carbon dioxide emissions, transport by sea is actually part of the solution rather than the problem. However, this is not to say that shipping does not have a part to play in reducing carbon dioxide emissions, and ICS is taking an active role to achieve this, not least by stressing the need for the IMO to address CO2 in parallel with the review of MARPOL proposals on air pollution. Addressing carbon dioxide emissions is indeed a major challenge, especially as maritime trade is expected to continue increasing steadily. The future, of course, is uncertain, but the volume of world trade has increased by 50 per cent in the last 15 years and is predicted to continue expanding. The IMOs authority for discussions about reducing CO2 emitted by ships is derived from the Kyoto Treaty. Progress at the IMO has been complicated by maritime administrations in some emerging economies, which have argued that under the current Kyoto framework they should be excluded from any new global rules on maritime CO2 emissions. Work is continuing on the measurement of greenhouse gas emissions from ships, the establishment of some sort of carbon indexing system, and the development of more fuel efficient engine technologies. An important issue will be how shipping can respond to the European Unions declaration in March 2007 that it intends to cut across the board its total carbon dioxide emissions by between 20 per cent and 30 per cent by 2030, and persuade the rest of the world to do likewise. Discussions about reducing carbon dioxide emissions in shipping have probably not yet really begun in earnest, but as the political demand for action increases and the Kyoto Treaty comes up for review before expiry in 2012, the shipping industry will need to be ready to respond.

fUtUrE oUtlook The shipping industrys status as the single most cost-effective method of transporting goods over long distance is likely to remain unchallenged. Over the last 40 years total seaborne trade estimates have increased from six thousand billion tonne-miles to 27 thousand billion tonne-miles. And some experts are predicting that shipping trade could triple as world commerce continues to expand. The ships of the future are going to be bigger, faster and more environmentally friendly. They wont come cheap a new tanker can cost around $120 million and their sheer size will necessitate the building of new ports across the world. South Koreas first tanker was built at Hyundais Ulsan shipyard in the 1970s and since then the countrys shipbuilders track record of on-time delivery, productivity and quality has enabled it to dominate the construction of cargo and bulk carriers. Europes shipbuilders primarily focus on the rapidly growing cruise ship industry. worlds BiGGEst ship Big is certainly beautiful in the world of container ships and the Emma Maersk is the biggest of them all. Owned by the Danish conglomerate AP Moller-Maersk Group, her maiden voyage was in September 2006. At a quarter of a mile long and 61 meters high, its the longest ship ever built and its powered by the worlds biggest diesel engine and can carry 11,000 containers, 1,400 more than its closest rival. She travels at more than 25 knots/47km/h. All with a regular crew of 13. The ships route from China to Europe and back again reflects the development of China as a manufacturing and exporting powerhouse. How long Emma Maersk retains top container ship spot remains to be seen.

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WHERE WOULD WE BE WITHOUT MILK AND, MORE TO THE POINT, WITHOUT BEING ABLE TO DRINK IT SAfELY?

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dAiry BrEAkthroUGh Tuchenhagen Flow Components' new generation of valves, which enable dairy plants to continue operations while the other half of the plant is being cleaned, is taking the US dairy market by storm.

During the process the milk is fed through heated pipes, raising the temperature of the milk to 71.7C (161F) for 15-20 seconds, enough to kill the harmful bacteria. In the US, pasteurization has been hailed as one of the all-time public health successes, as milk now accounts for just one per cent of disease from contaminated food or water, compared to 25 per cent in 1938. The Food and Drug Administrations (FDA) Director of Dairy and Egg Safety said in 2006 that drinking raw (unpasteurized) milk was like playing Russian roulette with your health. But even though selling untreated milk is illegal in 25 states and Washington, D.C., many choose to play the game. There has been a backlash against pasteurization from some health-conscious consumers who believe that the process harms the milk. Sadly, since 1998, 800 people in the US have been taken ill as a result of drinking raw milk or eating cheese made from unpasteurized milk. Thankfully, this is a tiny minority of consumers. In 2005, each person in the US consumed, on average, 32 pounds of cheese, 8.6 pounds of yogurt, 27 pounds of fat-free milk, 81 pounds of reduced fat milk, 57 pounds of whole milk and 26 pounds of ice cream. Meeting this demand requires production on an industrial scale. A combination of vast herds some farms have as many as 20,000 cows and modern milking technology have made milking a 24/7 operation. You would expect that processing the milk would require the same intensity. Processing milk on a 24/7 basis in a typical dairy plant requires the use of Mixproof valve technology. This enables the plant to be cleaned in sections while production continues in other parts of the plant. Although this technology has been on the market for some time and is widely used outside the US, the FDAs Pasteurized Milk Ordinance (PMO) regulations didnt

permit its use in US dairy plants. PMO regulations stated that a Mixproof valve could not be cleaned until all milk had been removed from it. Therefore, US dairy plants were required to shut down for two to three hours a day in order to clean the pipework. During this cleaning period, the plant could not sustain production. In April 2007, in a landmark decision, the FDA lifted the restriction on Mixproof valves for the first time in US dairy plant design but only for the new generation of valves designed by GEA company Tuchenhagen Flow Components. This revolutionary new valve has been specially designed so that one half of it can be cleaned, while the other is in operation. This is a huge breakthrough for the dairy industry, which will allow significant productivity increases and cost reductions for dairy facilities all over the US, says David Medlar, President of Tuchenhagen Flow Components. Around 1,000 of the new valves have already been installed in multiple dairy plants across the US. Practically overnight these plants have gained up to 30 per cent additional production time and, in turn, substantial increases in operating profit. The US dairy industry is now poised for a major change and, with the unique valve, Tuchenhagen Flow Components is leading the revolution in the worlds biggest milk market. With milk consumption showing no let-up the two key parts of the US dairy industry collecting the milk and processing it can now work together round the clock.

hakespeare coined the phrase, the milk of human kindness, to describe compassion for others. It seems appropriate that an actual glass of milk should be at the heart of a very touching example of compassion involving a distinguished American physician. Dr Howard Kelly (1858-1943), who was to become one of the founders of Johns Hopkins, the first medical research university in the US, was on a walking trip in Pennsylvania when he called at a farmhouse for a glass of water. But the little girl who answered the door brought him milk instead. Years later the girl went to him for surgery. The operation was a success and she was discharged, along with her bill on which Dr Kelly had written: Paid in full with one glass of milk. This story helps to highlight the value placed on milk. for centuries people have been consuming milk and associated dairy products. Being full of essential nutrients particularly protein, vitamins and minerals, such as calcium milk is widely regarded as natures miracle food. Unfortunately, during the milking process, it can be infected by potentially deadly bacteria, such as Salmonella, E.coli and Listeria. Which is why pasteurization invented by and named after the french scientist Louis Pasteur in 1864 has become such a vital part of the milk production process around the world.

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LAYS USEUM DISP EED IONS, M ART COLLECT L PERFORMANCES N ICA TO GIVE AND THEATR ANT SPACES JUST ELEG RIGHT MORE THAN O NEED THE THEY ALS PERLY THEIR BEST. S AND A PRO CONDITION ENERATE MOSPHERIC AT IRONMENT. G ATE. ENV CONTROLLED E CULTURAL CLIM TH CHECKS OUT
Organic objects, for instance, contain relatively high proportions of water. When the air is dry, they give off water which could make them shrink, crack or become brittle. In damp air, conversely, they absorb water, with the chance of swelling, warping or other deformation. Composite objects may expand and contract at different rates. Temperature and humidity control through carefully designed units is vital. A night at the theater Theaters and similar spaces have their own requirements. Air conditioning is essential in many locations; but there is also a need for quiet running so as not to interfere with the performance. The recently refurbished Admiralspalast entertainment center in the heart of Berlin

isit an art gallery, a museum, a national library or a theater, and what takes your eye will obviously be the display or the performance you came to see. But often, what goes on behind the scenes may be just as important and may make all the difference to that buildings future. Take an art gallery, for example. Excessively high light levels can cause oil paintings to fade or darken, so its normal for them to be displayed away from direct sunlight. Equally important though are temperature and humidity levels. Extremes in those variables can cause both wooden frames and canvases to swell and shrink. Wood and canvas are relatively resilient, but

paint can crack and flake off as the frame and the canvas move. The result could be irreparable damage to masterpieces. The answer is to closely monitor and control the environment where paintings are stored or displayed. In winter, an acceptable level would be a temperature of 18-21C (65-70F) and a relative humidity of 40-45 per cent, while in summer the figures would rise to 21-24C (70-75F) and 45-55 per cent. Naturally, paintings need to be kept away from additional heat sources such as furnace vents, or from excessive humidity which can cause mold growth a common problem in basements. Historic buildings and museum collections also require stable environmental conditions.

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is a testament to what can be achieved. The present building was constructed in 1911 and converted to a theater in the 1930s. It was closed in 1997 and remained empty and unused until August 2006. It is now once again a home of art and culture, entertainment and social gatherings; and the century-old building boasts a state-of-the-art ventilation system. The project managers faced a challenging task since the renovation plans stipulated extensive preservation of the building shell and the indoor facilities. They also needed to replace the entire existing ventilation system because the old facilities either no longer functioned or did not meet current regulations. Nevertheless, using two compact but advanced air-handling units from GEAs Air Treatment Division, the managers were able to meet the specifications.

Today, the heating, ventilation and air conditioning system at the theater guarantees comfort for up to 1,700 theatergoers, by providing up to 37,000m3/h of conditioned and temperature-controlled air. Indeed, cooling without drafts is possible up to a temperature of 27C (80F). Other facilities in the complex will also be served by the system: these include the theater foyer, the fourth level swimming pool, the Grand Caf, the Keller Club and the conference room. The frequency converters and free-running fans allow continuously variable control of the air output, as required. This feature boosts energy economy, since one half of the air output needs only one eighth of the full-output electric power for the fans. Both the air-handling units make use of adiabatic cooling: this is an environmentallyfriendly system whereby air flowing in from

outdoors is cooled by evaporative heat loss of exhaust air, requiring no electric energy. Last but not least, the quietness of any theater ventilation system is vital. Here again the GEA air-handling units score heavily: their low air speed effectively eliminates any noise problem. The maximum noise is just 30 dB(A) one meter from the air outlets. At this level, even when the actors only whisper on the stage, they will easily make any sound from the ventilation inaudible.

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WHEN SteFFen beRSCH MOVED TO DUBAI TO HEAD UP GEA COMPANY WESTFALIA SEPARATORS MIDDLE EAST OPERATIONS HE NOT ONLY HAD TO GET USED TO A CHANGE OF CLIMATE BUT ALSO DIFFERENT WORKING HOURS AND WAYS OF DOING BUSINESS. AND, AS GeneRAte DISCOVERED, HES ENJOYING EVERY MINUTE.
espite a 4.30am start, a six-hour flight delay, late meetings and having to fit in talks with Jordanian customers the following day, Steffen Bersch is remarkably cheerful. Im in a very good mood, he laughs. But then talking to customers and winning new business is what Bersch enjoys most about his job as General Manager for Westfalia Separators Dubai office. Also this particular trip, to the Jordanian capital of Amman, meant leaving behind the heavy rain which had earlier flooded parts of Dubai. Bersch is responsible for all Westfalia Separators activities across the Middle East region. The visit to Amman was to discuss supplying his companys products for energy and service projects in the region. A lot of business in the region is run through partner and contracting companies based in Amman, he explains. Due to the high power demand, the energy sector is currently by far the biggest market in the region for Westfalia Separators centrifuges, which are an essential part of the oil treatment process. Other important areas are growing as the Middle East countries recognize the need to create their own added value to products by investing in, for example, pharmaceuticals, food and industrial products, says Bersch. Environmental technology is also a growth area that is providing major opportunities for us.

is an organization with someone to solve every problem, whereas here you have to be master of everything, he says. There is a lot of administration work because Dubai is such an international city that almost everyone you hire needs to have a visa and work permit. And that includes Bersch himself. He moved to this boomtown from Bochum, Germany, with his wife and two children in August 2007. As well as acclimatizing himself to the searing summer heat 50C (122F) during the day and 37C (98F) at night Bersch has had to get used to a different way of working. Friday is the Muslim holy day so the working week generally runs from Sunday to Thursday and some companies operate Saturday to Wednesday. It took me some weeks to get used to the different times, Bersch recalls. Because I can only get in touch with headquarters for four days of the week, I have had to organize my time accordingly. But during those four days we can be sure of fantastic support from our colleagues in Germany. Another difference is the way negotiations with customers are conducted in Dubai. Typically there is a lead partner who can make a decision at the end, whereas in Europe for example, you have to deal with procurement groups which means you have to convince more people. Bersch and his family have embraced the international lifestyle of Dubai. The two children are happily settled in an American school which includes pupils from 70 countries. The climate means that he can indulge his love of cycling all year round. When I was in Germany it was not possible to cycle in the winter, he says. Now I train twice a week with a group of cyclists in Dubai and my kids are also taking part.

IT IS VERY DIFFERENT FROM WORKING AT OUR HEADQUARTERS IN GERMANY WHERE THERE IS AN ORGANIZATION WITH SOMEONE TO SOLVE EVERY PROBLEM, WHEREAS HERE YOU HAVE TO BE MASTER OF EVERYTHING
Traveling accounts for around 40 per cent of his time, otherwise his working day revolves around the Dubai office where he heads a team of ten sales engineers, service engineers and administrative staff. He is also responsible for a network of 20 agents representing the company in the different countries across the region. In addition to selling the companys products, Bersch and his team look after the servicing and repair of existing machines. It is very different from working at our headquarters in Germany where there

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Designer dress fabric? A shoal of metallic fish? In fact this striking picture shows a disk stack in a separator bowl. It splits the product to be separated into a large number of thin layers, thereby increasing the clarification area and shortening the sedimentation distance that the separated particle has to cover.

Centrifugal separation technology is a key process used in a broad spectrum of applications: dairy technology, beverage technology, edible oil processing, oils and fats recovery, starch technology, chemistry, pharmaceuticals, biotechnology, marine, oil field technology, energy as well as industrial and environmental technology.

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BAvAriAs finEst GoEs Alcohol-frEE One of Bavarias most famous wheat beers is soon going to be available alcohol-free as a result of a unique process developed by GEA Wiegand. The new beer de-alcoholization plant at family brewer Private Weissbierbrauerei G. Schneider & Sohns Kelheim site will use a process first developed by Wiegand in the 1980s. Based on the falling film evaporator principle, its the only known process of its type without recirculation or redilution. Tuchenhagen, one of GEAs brewery specialist companies, is working with Wiegand on the new plant. The result is a natural product, able to satisfy the most demanding palettes and preserving the reputation of this proud brewery. www.gea-wiegand.com nEw phArmA procEssinG linE in thE nEthErlAnds GEA Pharma Systems (GPS) has developed a complete processing line for one of Europes most successful manufacturers of generic medicines. Synthon BV, based in the Netherlands, manufactures a range of products for worldwide distribution through its marketing partners. It required new equipment for a partner manufacturing plant to up-scale production of one of its products, and chose the GPS Nica system after an exhaustive evaluation process. The project includes the supply and integration of granulation technology with GEA pelletizing systems, coating technology and fluid bed drying. www.niropharmasystems.com

risE of thE roBots The acquisition of the global license for the T!TAN robotic milking system from PUNCH Technix nv of Vijfhuizen in the Netherlands has boosted GEA WestfaliaSurges leading position in the worlds dairy equipment business. T!TAN is currently the only system that enables the use of robotic milking on virtually all farms, regardless of their size, and is seen as the perfect complement to WestfaliaSurges existing range. The robotic milking equipment will continue to be manufactured at PUNCH Technixs plant for WestfaliaSurge. WestfaliaSurge will also take over all PUNCHs existing robotic milking contracts, with sections of the PUNCH Sales and Service Team being integrated into the organization. The unique T!TAN system offers the financial economies of scale necessary to cope with herd growth and increases the number of potential new customers for WestfaliaSurge. www.westfalia.com wiEGAnd rEcEivEs tEchnoloGy lEAdErship AwArd GEA Wiegands work in the bioethanol market has been recognized with a European award for technology leadership. The 2007 Frost & Sullivan Award is given for technological excellence, superb customer support and timely delivery of technology. Wiegands bioethanol technology is the most advanced on the market. It can help cut operating and energy costs, reducing plants carbon footprint in the process. In addition, it offers a host of plant support services, from training and maintenance to operation and upgrading. The company also has superior fuel ethanol drying technology. Wiegand has pioneered key technology developments in this challenging area, including molecular sieves and complex membranes. No other company has such a deep understanding of rectification, evaporation and separation techniques. www.gea-wiegand.com

GEA powErs AhEAd in soUth AfricA GEAs Thermal Engineering Division has won a turnkey order for a brand new fossil-fuelled power station in South Africa. GEA Aircooled Systems will be designing, manufacturing, supplying and erecting the air-cooled condensers for the Medupi Power Station in Limpopo Province. The end customer is Eskom, South Africas leading power producer. The Medupi Power Station is an integral part of the countrys policy to increase installed power capacity. The major portion of the equipment and services for Medupi will be put in place between 2008 and 2013, and will result in significant work for GEAs Johannesburg-based operation. GEA Aircooled Systems has extensive experience in the field of air-cooled power plants in South Africa, having previously supplied Eskom with air-cooled condensers for both the Matimba and Majuba Power Stations. www.gea-energytechnology.com

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GENERATE is the external magazine of the gea group. published three times a year, it is distributed to gea group offices across the world. EdiToRiAl boARd Peter Caspar Hamel ( v.i.s.d.p.) Nina Remmer Katrin lamprecht generate@geagroup.com PRoduCEd by Merchant www.merchant.co.uk in collaboration with: lang Communications copywriting www.lang-communications.co.uk JohnstonWorks design www.johnstonworks.com PRiNTEd by laupenmhlen druck GmbH & Co. KG www.l-d.de PHoToGRAPHy Cover & feature: peter dazeley Page 20-21: Zoe norfolk Page 28-29: marcus wilson-smith Page 30-31: Jrg winde
published by gea group aktiengesellschaft, dorstener strae 484, 44809 Bochum, germany. all rights reserved.