aerzen usa - ohio water environment association of blower technologies tm 031512.pdf · evaluation...
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AERZEN USA
Efficiency Comparisons Between Aeration
Blowers
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Evaluation of Blower Technologies
Introduction
Aeration System Largest Consumer of Power in WWTP 50% to 60% of plant operating cost
Life Cycle Costs far exceeds Initial Capital Costs
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Evaluation of Blower Technologies
Introduction
Purpose of Presentation Evolution of Blower Technologies Matching the Technology to the Application Right-Sizing of Blowers Accurate Evaluation of Overall Costs
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Evaluation of Blower Technologies
Traditional Blower Technologies
Two Lobe Positive Displacement Variable Speed
Multi-Stage Centrifugal Inlet Throttle Valve or Guide Vanes Variable Speed
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Evaluation of Blower Technologies
PD Blower Design Principles
Positive Displacement Blower Constant volume against varying pressure Flow changes by varying speed with VFD Large Turndown (Typically 4:1) Easily adapts to changes in pressure & temperature Widely used / Low initial cost
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Evaluation of Blower Technologies
PD Blower Evolution
Two-Lobe to Three-Lobe Technology Pulsation Cancellation Less wear and tear on components and piping
Single Forging of Shaft and Impeller Stronger, More Stable at Higher Speeds
More Effective Noise Reduction Quieter packages
Upgraded Seals (Piston Ring) Longer maintenance intervals on internals
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Evaluation of Blower Technologies
2-Lobe Conveying Cycle
Atmospheric pressure
System pressure
Abrupt pressure equalization causes noise and shocks (pulsations) 4 times per revolution.
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Evaluation of Blower Technologies
Three-Lobe Conveying Cycle
Integrally cast return
ports gradually
pressurize casing
Squeeze pulse is 180° out of phase with Pressure pulse.
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Evaluation of Blower Technologies
Limitations of PD Blowers
Efficiency Slip between Rotors Less efficient at Lower Flows Less efficient at Higher Pressure
GM60S
0.5
0.52
0.54
0.56
0.58
0.6
0.62
0.64
0.66
0.68
0 500 1000 1500 2000 2500
INLET FLOW - ICFM
AD
IAB
ATI
C E
FFIC
IEN
CY
%
8 PSIG10 PSIG12 PSIG
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Evaluation of Blower Technologies
Compressor Design Principles
Positive Displacement Compressor (VML) Used since the 1940’s (Deep Cell Aeration) Rotors mesh, compressing air inside housing Flow changes by varying speed (VFD) Best around 20 to 30 psig Higher capital cost (2X PD blower)
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Evaluation of Blower Technologies
Compressor Design Principles
Positive Displacement Compressor (VML) Used since the 1940’s (Deep Cell Aeration) Rotors mesh, compressing air inside housing Flow changes by varying speed (VFD) Best around 20 to 30 psig Higher capital cost (2X PD blower)
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Evaluation of Blower Technologies
Limits of Screw Compressors
Efficiency Less efficient at Lower Pressures
VML60
0.5
0.55
0.6
0.65
0.7
0.75
0.8
0 500 1000 1500 2000 2500 3000
INLET FLOW - ICFM
AD
IAB
ATI
C E
FFIC
IEN
CY
%
8 PSIG10 PSIG12 PSIG
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Evaluation of Blower Technologies
Adaptation to WWTP Use
Low Pressure: 3 – 7 PSIG Twisted Lobes
High Pressure: 7 – 15 PSIG Screw Compressor
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Evaluation of Blower Technologies
Centrifugal Design Principles
Multi-Stage Blower Widely used technology High Flow, Small Footprint High Efficiency at Design Point
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Evaluation of Blower Technologies
Centrifugal Design Principles
Centrifugal Blowers (Dynamic Compression) Kinetic Energy to Potential Energy
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Evaluation of Blower Technologies
Centrifugal Evolution
Multi-Stage Repeats the Compression
Process in Series Relatively low speed 3600 RPM
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Evaluation of Blower Technologies
Centrifugal Evolution
Turbo Blower – Gear Drive High efficiency, even at turndown Bullgear raises Impeller Speed (Single Stage) Inlet guide vanes and discharge diffuser vanes Complex control system High capital cost More Cost Effective >400HP
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Evaluation of Blower Technologies
Centrifugal Evolution
High Speed Turbo Blower Newest in WWTP market (<5 years) Air-Foil Bearings, Permanent Magnet Motor Integral VFD and Control System More Affordable than Gear Drive Wide Range of Sizes Life Cycle Cost Payback
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Evaluation of Blower Technologies
Centrifugal Design Principles
Dynamic Compression Sweet Zone of Efficiency
Must Reside on Performance Map Flow too Low or Pressure Too High: Surge Flow too High or Pressure Too Low: Choke Performance Varies with Air Density Summer (High Loads, Low Air Density) Winter (Low Loads, High Air Density)
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Evaluation of Blower Technologies
Centrifugal Design Principles
Surge Sweet Zone
Choke
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Evaluation of Blower Technologies
What is Surge?
Compressor generating more air than needed by the system.
Compressor’s inability to continue working against the already-compressed air behind it.
Oscillation of discharge pressure and flow rate.
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Evaluation of Blower Technologies
Centrifugal Design Limitations
Control Is Essential Protect the Blower Satisfy System Air Requirements
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Evaluation of Blower Technologies
Centrifugal Blower Control
Multi-Stage: Throttling Valve / Inlet Guide Vanes Speed Control (VFD)
Gear Drive Turbo: Inlet and Discharge Vanes, Speed Control Control System (PLC)
High Speed Turbo: Motor Control (Speed, Current) Control System (PLC or CPU)
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Evaluation of Blower Technologies
What Technology to Choose?
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Evaluation of Blower Technologies
Start With the System
System Flow Requirements Minimum, Maximum, Average Factor in Diurnal Minimum
Pressure (Constant or Varied, and How Much) Site Conditions (Elevation, Ambient Range) Control Requirements On/Off, VFD, Combination
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Evaluation of Blower Technologies
Performance Comparison Specific Power Comparison Delta Hybrid D62S, GM 60S, and TB100-1.0
(Inlet T1=68F, P1=14.5 PSIA, RH=0%) P2=11.6 PSIG
10.0
12.0
14.0
16.0
18.0
20.0
400 800 1200 1600 2000
Flow SCFM
SCFM
/kW
D 62S
GM 60S
TB100-1.0
19.125.8
23.2
20.7%
11.6%
3%
6%3%
Performance Advantage
Vs. PD
Hybrid Comparable
to Turbo
Temperature Issues at Low Flow
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Evaluation of Blower Technologies
Temperature Concerns
Temperature Limits Turndown at Higher
Pressures for Standard PD
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Evaluation of Blower Technologies
Performance Comparison
Comparable Design Point
Efficiency Difference in Flow Range
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Evaluation of Blower Technologies
Performance Comparison
Comparable Efficiency
Throughout Greater
Turndown
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Evaluation of Blower Technologies
Performance Comparison
Break-Even Point
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Evaluation of Blower Technologies
Sensitivity Analysis
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Evaluation of Blower Technologies
Pressure Variation
L2
L1
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Evaluation of Blower Technologies
Site Conditions
+ 98ºF (36ºC)
+ 76ºF (24ºC)
+ 30ºF (-1ºC)
14.7 psia (1.013 bar abs)
+ 115ºF (46ºC)
+ 55ºF (13ºC)
- 17ºF (-27ºC)
12.2 psia (0.84 bar abs)
14% Variation in O2 Content
31% Variation in O2 Content
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Evaluation of Blower Technologies
Why Site Conditions Matter
Density affects compression ratio Higher Elevations Limit PD
Percent O2 impacts aeration requirements ICFM vs. SCFM
Maximum flow on Hottest Day Perfect Storm Design
Minimum flow on Coldest Night More Likely
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Evaluation of Blower Technologies
System Control Requirements
On/Off Cycling PD Blower / LP Screw / Multi-Stage - Good NEMA Motor (4-6 starts/hour) VFD Extends # of Starts
Turbo – Challenged if cannot run unloaded High Frequency VFD may limit daily starts Airfoil Bearings limited to 20,000 starts
Or <20,000 (Depending on Design)
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Evaluation of Blower Technologies
36
Scrolling/Idling Discharge
Through Bypass
Normal Discharge
Scroll
Idling/Scrolling Function
Air Foil Bearing
Bypass Valve Opens RPM Drops to ~10,000 Sufficient to maintain
“loft” on Bearings Minimal Power Draw
(Avg 2%: 2 – 5 kW) Avoids Bearing Wear Avoids Start/Stop Cycles Useful in SBR/MBR
Systems
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Evaluation of Blower Technologies
Right-Sizing
Minimum demand on coldest day
Maximum demand on hottest day
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Evaluation of Blower Technologies
Right Sizing Options
One 100% Unit/System with common spare. Base Load, Upper Flow Range
Two 50% Units with Common spare. Greater Net Turndown More Machinery
Base Load Machine, Swing Machine Mixed Technology Optimize Efficiency Throughout Range
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Evaluation of Blower Technologies
Life Cycle Costs
Energy Usage Anticipated Operating Points Assign Time and Conditions Require Manufacturer to Provide TOTAL kW Include ALL Mechanical & Electrical
Losses ASME PTC-13
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Evaluation of Blower Technologies
Life Cycle Costs
Installation Indoor or Outdoor Integral VFD or Separate Available Footprint
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Evaluation of Blower Technologies
Life Cycle Costs
Maintenance: PD (Blower, Compressor):
Annual Oil Change Belt Change (12-18 months) Air Filters as needed Bearings/Seals (15-20 Years)
Turbo: Air Filters: Prefilter (1-2 Mos), Fine Filter (6 Mos) Impeller Cleaning (3 Years) Electronics (capacitors) (5 Years) PM Motor (10 Years)
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Evaluation of Blower Technologies
Your Final Decision
Accurate Energy Cost Evaluation Life Cycle Costs Proven Technology Serviceability Accountability of the Manufacturer
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AERZEN USA
Thank you for your Attention