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Air ENGINEERING SOLUTIONS Air Case Studies Midal Cables International
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Tomago, NSW, Australia

Midal Cables International

William Chan
Product Manager - Gas & Special Projects
The Problem

Midal Cables International (MCI) is Australia’s newest and most innovative manufacturer of alloy rod and conductor.

Edwards & Vickerman were retained by MCI to provide mechanical services to their new $60M plant at Tomago NSW, producing 50,000 tons of aluminium bar and cable for domestic consumption and export. The specification called for an on-site nitrogen generation system, including:

  • Variable speed 2-stage rotary screw, oil flooded, enclosed type air compressors.
  • Refrigerated Air Dryers, pre/final filters, Air receivers
  • Nitrogen generator with a capacity of 21.8 Nm3/hr / 99.95% N2 purity (500 ppm-02 / 10 barg / -50C pressure dew point)
  • Desiccant dryer and 3 buffer tanks
Key Takeaways

  • 2x

    Variable speed 2-stage rotary screw oil flooded air compressors

  • 2x

    Refrigerated Air Dryer 

  • 1x

    Desiccant Dryer 

  • 1x

    Nitrogen Generator 

  • 5x

    Air Receivers  

 

SOLUTION

CAPS supplied the following equipment on the basis of an in-depth financial analysis over 10 years covering; Running cost comparison, Maintenance cost, & Potential compressor re-build costs.

  • 1 x R160NE-APF 160kW 2 Stage Variable speed Oil flooded Rotary Screw Compressor
  • 1 x R132NE-A 132kW 2 Stage Variable speed Oil flooded Rotary Screw Compressor
  • 1 x UP5E-30-14 Oil flooded Rotary Screw Compressor
  • 1 x DPS10-14 Desiccant Dryer
  • 1 x HX2000K-4 Refriegerated Air Dryer
  • 1 x HX1500K-4 Refriegerated Air Dryer
  • 2 x VR5000S 5000 Litre Air Receiver and accessories
  • 2 x VR1000-1750 1000 Litre Air Receiver
  • 1 x VR1500-1100 1500 Litre Air Receiver
  • 1 x IMT-PN2000 German-made Inmantec Nitrogen Generator
  • Pre and Post Filters

Midal Cables were very satisfied with the Ingersoll Rand plant and Transair pipe installation, which continues to perform well and met all pre-sales performance and energy usage projections.

The service and technical input from CAPS, Matt Broadbent in particular, was exceptional. The compressors, nitrogen generation plant and components were sourced early in the project and held in stock to meet the tight installation programme.

Jonathan Vickerman
Managing Director
EV Consulting
BENEFITS

The tangible technical benefits of the nitrogen generation system include:

  • Two-stage airend and tri-rotor HPM variable speed motor.
  • Smaller space requirements and reduced operating costs compared to a liquid bulk nitrogen system.
  • No nitrogen evaporation/wastage.
  • Efficiencies generally assessed as 13% higher than the competition.

 

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