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Page 1company presentation 201223/11/2012
One Day National Workshop onCommon Effluent Treatment Plants
CII - Sohrabji Godrej Green Business Centre, Hyderabad
Technical Session II: Treatment Technologies & Monitoring
23 November 2012
Energy Efficient Turbo Blowers for Aeration
Kiron C. Pande - Godrej & Boyce Mfg. Co. Ltd.
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43%
33%24%
Energy CostAerationPretreatmentDewatering & Sludge treatment
Effluent Water Treatment
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Positive Displacement type, Twin Lobe Air Blower
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Volumetric Turbo
Multi stageTurbo blower
Low speed Turbo
- η Increase over 10%- No Volumetric pulsation
Efficiency Increased over 40%
Blower
Direct driven High Speed
- η Increase over 10%
- η Increase over 20%
- Increase stability
Increasing Energy Efficiency
High Speed Turbo
High Gear Ratio
Multi stageTurbo blower
Rootsblower
PD
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Turbo Blowers
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Energy Efficiency
certified by:
Korea Energy
Management
Corporation
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User selectable Control Modes with KTurbo
• Constant Flow• Constant Pressure• Constant Power• D.O. Control
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Constant Pressure Mode
Constant Flow Mode
Constant Current Mode
User Selectable Control Modes
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Core Components & Salient Features• Permanent Magnet Motor: a) Power required only to rotate
& not for magnetizing of rotor; b) Can be started & stopped any number of times; c) High Efficiency even at part load
• No Gear Box: No transmission loss due to direct drive & no lubrication required.
• Variable Speed Drive for achieving high speed, smooth starts (reduced starting current) & energy efficient capacity control as part of the Blower package.
• Air Foil bearing for high speed operation (used in Jet engines)
• Oil Free air• Low Noise: 80 dB against 100 dB of PD blowers• Entire range is air-cooled & no need of water for cooling.
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Comparison with PD Blowers
Parameter PD Blower
KTurbo Blower
Aero Efficiency 55% 77%Drive Efficiency (Motor+Coupling+Invertor)
82% 92%
Total Efficiency at 100% Load 45% 70%Total Efficiency at 50% Load 22.5% 67%Starting Current compared to Rated Current
250% Below 5%
Maintenance Overhaul Air FiltersLife 5 Years Semi-
permanentFoot Print Large SmallerNoise Level 95-110 dB Below 80
dB
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PD Blowers Performance
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Typical model at 1800 RPM; Average total efficiency is 45%
PD Blowers Performance
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PD Blowers Performance
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Single Stage Turbo Blowers Performance
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High Speed Turbo & PD Blower Performance
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High Speed Turbo & PD Blower Performance
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(Benefits with KTurbo )1) Discharge Temperature : Less
than 20° C than Roots type. => Change Aerated water
temperature: less than 3 ℃ than with Roots blower used earlier
2) Capacity control : Operating 1㎥ /min
=> Protect for excessive aeration 3) Oil-less System => 100% oil-less air 4) Reduce energy consumption:
more 40% (Before using roots blower)
5) Noise level : 82dB @ 1m (as against earlier 105dB with Roots blower)
Aeration: Coca Cola (Korea)
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SunRiver: North America installation
• Before : 2 Units of 100hp Multi Stage• After: 1 Unit of TB100-0.8 (70% Operation)
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Control Configuration for DO (Dissolved Oxygen)
Intrinsic Feedback control
DO data( 4 ~ 20mA)
Flow Control
※ DO Sensor (Endress+Hauser Co.)
Input: 0.015 ~ 60 ppm Output: 4 ~20mA
HMI Display
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Schematic of KTurbo installation in WWTP plant
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Picture of KTurbo installation in WWTP plant
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Picture of KTurbo installation in WWTP plant
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KTurbo blowers supplying air to WWTP plant
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Inverter
Power In Control
s
Intake Silencer
BOV Silencer
Construction of Single & Twin Turbo Blowers / Comp
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PM Motor&
Impellers
2 Pole permanent magnet (SmCo) with high strength retaining ring
High performance electric core
H Class Insulation winding
Radial airfoil bearing
Radial airfoil bearingThrust disk &
Thrust bearing
Stainless steel casted Impeller
Scroll
Intake
Discharge
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Core Technologies(1) Air foil bearings
• Self-acting hydrodynamic float on air• Bump foil acting as a spring• The first generation
– Axially & circumferentially uniform elastic support elements• The second generation
– Variable axial OR circumferential compliance characteristics• The third generation
– Foil support in axial, circumferential AND radial direction
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History of Foil Bearings
Simple Bump
Reversed Multi-Layer
Multi-Leaf
High Capacity, High Speed, High Damping, High Temperature
Multi-Pad Bump
Third Generation Bump(KTurbo)
• Radial variation• Circumferential
variation• Axial split/variation
• MiTi have made major research• KTurbo has > 1000 units experiences• KTurbo has TC series
Teflon-S
MoS2
High Temp Solid Lubricant- PS304 ; NASA- KOROLON1350F ; MiTi
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(2) High-speed & high-power PM motor/driver• PM motors
– High-speed & high-power (50 hp ~ 600 hp / 20,000 rpm ~ 70,000 rpm)
– High efficiency (> 95%)• Sensor-less Inverters
– Cost-effective– High efficiency (> 97%)
Core Technologies
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Why PM motor ?
No magnetizing power is necessary Lower heat generation means less cooling loss. Smaller rotor means less friction loss No slip means high efficiency even at part load
condition.
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Efficiency of PM motor & Induction Motor
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1. Stainless Steel• SUS630, 17-4PH
2. Optimum Specific Speed• Maximum efficiency
3. Optimum back sweep angle• Maximum efficiency• High Rise to surge• Wide operating range
4. Splitter Blade• Larger flow capacity• Higher efficiency
5. Leaning• Higher structural
strength
(3) Features of KTurbo ImpellerCore Technologies
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Built-in Flow Meter
Bell mouth is more accurate than Orifice, because it needs only one sensor.
]99.0min,/m Pa,sec,K,[m, 11
260 3
1/1
d
kk
k
d CPpP
kkTR
PpPAcQ
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Discharge Duct
Blow-off ValveSilencerBlower core
Inverter
Discharge pressure : PDischarge Temp : T2Suction Flow rate dP :
dP3Suction Temp : T1Filter Pressure Drop : dP1
Air Flow measuring
Air inAir out
Impeller
Inlet Reducer
T1 dP3 [Differential pressure]
+
< Air Flow calculation, Q >
Q ≈ Q (T1, Po , dP3)
Measurement System
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HMI with touch screen
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HMI: Main Screen
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HMI: Operating Curves display
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CF memory is applied• Data logging every 1 sec, 1 min, 1hour• All event recording
HMI: Data Logged every second
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CF memory is applied• Data logging every 1 sec, 1 min, 1hour• All event recording
HMI: On-line trend display
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CCR(Central Control Room) SCADA or DCS or PLC
MCP1
TB #1 TB #2 TB #3 TB #4
MCP2
TB #1 TB #2 TB #3 TB #4
Multi-Group Control
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Foundation
Anchor bolting case-2
Anchor bolting case-1
Concrete pad
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Air FiltersFirst stagePre filter
Secondary stageMedium filter
Filter Cover
Motor Room
Pre 85%@ 10 ㎛4-8 weeks
Final 99%@ 10 ㎛ or 68%@2 ㎛5-12 months
ΔP 21-44mmWTR
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Customers
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Customers
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Thank You!Godrej & Boyce Mfg. Co. Ltd.
Compressed Air SolutionsGodrej | Electrical & Electronics
Pirojshanagar, Vikhroli, Mumbai – 400079. IndiaTel.: +91-22-67962251 to 2255
Fax: +91-22-67961410 / 67961525E-mails: [email protected]; [email protected]; [email protected];
www.godrej-airsolutions.com