One Day National Workshop on
Common Effluent Treatment Plants
CII - Sohrabji Godrej Green Business Centre, Hyderabad
Energy Efficient Turbo Blowers for Aeration
Kiron C. Pande - Godrej & Boyce Mfg. Co. Ltd.
Technical Session II: Treatment Technologies & Monitoring
23 November 2012
23/11/2012
company presentation 2012
Page 1
Effluent Water Treatment
Energy Cost
Aeration
Pretreatment
Dewatering & Sludge treatment
33%
24%
43%
Page 2
Positive Displacement type, Twin Lobe Air Blower
Page 3
Increasing Energy Efficiency
PD
Volumetric
Turbo
- η Increase over 10%
- No Volumetric pulsation
Low speed Turbo
- η Increase over 10%
High Speed Turbo
High Gear Ratio
Roots
blower
-η Increase over 20%
- Increase stability
Direct driven
High Speed
Multi stage
Turbo blower
Multi stage
Turbo blower
Blower
Efficiency Increased over 40%
Page 4
Turbo Blowers
Page 5
Page 6
User selectable Control Modes with KTurbo
• Constant Flow
• Constant Pressure
• Constant Power
• D.O. Control
Page 7
User Selectable Control Modes
Constant Current Mode
Constant Pressure Mode
Constant Flow Mode
Page 8
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.
Page 9
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%
22.5%
67%
250%
Below 5%
Overhaul
Air Filters
5 Years
Semipermanent
Large
Smaller
95-110 dB
Below 80 dB
Total Efficiency at 50% Load
Starting Current compared to Rated Current
Maintenance
Life
Foot Print
Noise Level
Page 10
PD Blowers Performance
Page 11
PD Blowers Performance
 Typical model at 1800 RPM; Average total efficiency is 45%
Page 12
PD Blowers Performance
Page 13
Single Stage Turbo Blowers Performance
Page 14
High Speed Turbo & PD Blower Performance
Page 15
High Speed Turbo & PD Blower Performance
Page 16
Aeration: Coca Cola (Korea)
(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)
Page 17
SunRiver: North America installation
• Before :
2 Units of 100hp Multi Stage
• After:
1 Unit of TB100-0.8 (70% Operation)
Page 18
Control Configuration for DO (Dissolved Oxygen)
Intrinsic Feedback control
HMI Display
Flow Control
DO data
( 4 ~ 20mA)
※ DO Sensor (Endress+Hauser Co.)
Input: 0.015 ~ 60 ppm
Output: 4 ~20mA
Page 19
Schematic of KTurbo installation in WWTP plant
Page 20
Picture of KTurbo installation in WWTP plant
Page 21
Picture of KTurbo installation in WWTP plant
Page 22
KTurbo blowers supplying air to WWTP plant
Page 23
Construction of Single & Twin Turbo Blowers / Comp
Intake
Silencer
Power
In
BOV
Silencer
Controls
Inverter
Page 24
2 Pole permanent magnet
(SmCo) with high strength
retaining ring
High performance
electric core
H Class Insulation
winding
Discharge
PM Motor
& Impellers
Scroll
Stainless steel
casted Impeller
Radial airfoil
bearing
Intake
Thrust disk &
Thrust bearing
Radial airfoil
bearing
Page 25
(1) Air foil bearings
•
•
•
•
•
Core Technologies
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
Page 26
History of Foil Bearings
High Temp Solid Lubricant
-PS304 ; NASA
-KOROLON1350F ; MiTi
Third Generation Bump
(KTurbo)
Multi-Pad Bump
MoS2
Reversed Multi-Layer
Teflon-S
• Radial variation
• Circumferential variation
• Axial split/variation
Simple Bump
Multi-Leaf
• MiTi have made major research
• KTurbo has > 1000 units experiences
• KTurbo has TC series
High Capacity, High Speed, High Damping, High Temperature
Page 27
Core Technologies
(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%)
Page 28
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.
Page 29
Efficiency of PM motor & Induction Motor
Page 30
1. Stainless Steel
Core Technologies
(3) Features of KTurbo Impeller • 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
Page 31
Built-in Flow Meter
Bell mouth is more
accurate than Orifice,
because it needs only
one sensor.
 P  p 
Q  60  cd  A  

P


1/ k
k 1


 k    P  p  k 
 2  R T  
[m,K, sec, Pa, m 3 / min,Cd  0.99]
  1 

 k 1   P  


Page 32
Discharge Duct
Discharge pressure : P
Discharge Temp
: T2
Blow-off
Valve
Silencer
Suction Flow rate dP : dP3
Suction Temp
: T1
Filter Pressure Drop : dP1
Blower core
Inverter
Air Flow
measuring
Measurement System
Inlet Reducer
Air out
Air in
Impeller
< Air Flow calculation, Q >
Q ≈ Q (T1, Po , dP3)
T1
+
dP3 [Differential pressure]
Page 33
HMI with touch screen
Page 34
HMI: Main Screen
Page 35
HMI: Operating Curves display
Page 36
HMI: Data Logged every second
CF memory is applied
•Data logging every 1 sec, 1 min, 1hour
•All event recording
Page 37
HMI: On-line trend display
CF memory is applied
•Data logging every 1 sec, 1 min, 1hour
•All event recording
Page 38
Multi-Group Control
CCR
(Central Control Room)
SCADA or DCS or PLC
MCP1
TB #1
MCP2
TB #2
TB #3
TB #4
TB #1
TB #2
TB #3
TB #4
Page 39
Foundation
Concrete pad
Anchor bolting
case-1
Anchor bolting
case-2
Page 40
First stage
Pre filter
Secondary stage
Medium filter
Air Filters
Filter Cover
Motor Room
Pre
85%@ 10㎛
4-8 weeks
Final
99%@ 10㎛ or 68%@2㎛
5-12 months
ΔP
21-44mmWTR
Page 41
Customers
Page 42
Customers
Page 43
Thank You!
Godrej & Boyce Mfg. Co. Ltd.
Compressed Air Solutions
Godrej | Electrical & Electronics
Pirojshanagar, Vikhroli, Mumbai – 400079. India
Tel.: +91-22-67962251 to 2255
Fax: +91-22-67961410 / 67961525
E-mails: kcp@godrej.com; jayraj@godrej.com; roshe@godrej.com;
www.godrej-airsolutions.com
Page 44