Download - Overview of Blower Technologies
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Rich Knoelke Mulcahy Shaw Water
Questions or Comments: [email protected]
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• Four New Turbo Blowers
• New Diffusers with Tapered Layout
• DO Control System
• Automated Air Valves
LaCrosse WI WWTP
CASE STUDY
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Year Total KWH
2006 4,753,219
2007 5,677,565
2008 6,271,078
2009 6,206,803
2010 6,229,169
2011 6,118,722
2012 4,706,782
2013 4,464,431
28.81% - decline from 2008
CASE STUDY
LaCrosse WI WWTP
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Sterno, Sweden Case Study
• 50% High Efficiency Blowers
• 38% New Diffusers
• 12% D.O. Control System
Breakdown of Savings
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LaCrosse WI Case Study
• $50,000 High Efficiency Blowers
• $38,000 New Diffusers
• $12,000 D.O. Control System
Breakdown of Annual Savings
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BLOWERS
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Presentation Outline
1) Comparison of Positive Displacement vs Centrifugal
2) Summary and Explanation of Different Blower
Technologies
A) Positive Displacement
B) Centrifugal ( Includes High Speed Turbo – New)
3) Evaluation Process
A) Application Compatibly
B) Energy Cost
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• Positive Displacement entraps a volume of gas and reduces it
• Centrifugals are dynamic and use velocity to overcome pressure
8
Positive Displacement vs Centrifugal
Blower Technologies
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Positive Displacement vs Centrifugal
• Centrifugal-variable flow vs constant pressure
• Positive Displacement-variable pressure vs constant flow
9
Flow Capacity
Pre
ssure
0 100 %
Centrifugal
Positive
Displacement
100 %
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Positive Displacement vs Centrifugal
1
Flow Capacity
Pre
ssure
0 100 %
Centrifugal 1) Multistage
2) High Speed Turbos
3) Single-Stage
Integrally Geared
Positive Displacement 1) Twin Lobe
2) Tri Lobe
3) Screw
100 %
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Positive Displacement vs Centrifugal
• Constant Pressure
• Constant Flow
1
Flow Capacity
Pre
ssure
0 100 %
100 %
Varied Applications
for Wastewater
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Centrifugal vs. Positive Displacement
• Varying Speed of a PD blower
• As speed decreases so does flow and ability to produce pressure
• Constant back pressure is maintained
• Flow is reduced
1
Flow Capacity
Pre
ssure
0 100 %
Positive
Displacement
100 %
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Centrifugal vs. Positive Displacement
• Varying Speed of a PD blower
• As speed decreases so does flow and ability to produce pressure
• Constant flow is maintained with variable pressure
1
Flow Capacity
Pre
ssure
0 100 %
Positive
Displacement
100 %
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Centrifugal vs. Positive Displacement
• Varying the speed of centrifugal blower
• As speed decreases the curve shifts down left
• Constant back pressure is maintained
• Flow is reduced
1
Flow Capacity
Pre
ssure
0 100 %
Centrifugal
100 %
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Centrifugal vs. Positive Displacement
• Varying the speed of centrifugal blower
• As speed decreases the curve shifts down left
• Constant flow is maintained with variable pressure
1
Flow Capacity
Pre
ssure
0 100 %
Centrifugal
100 %
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• Mid 1800’s Cornsville, IN
• Root’s Brothers trying to improve the water wheel
• 1st Design was made out of wood
• Discovered the new invention could move a quantity of air
• “The Roots” Blower
Blower Technologies: Positive Displacement
History of Positive Displacement Blowers
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Blower Technologies: Positive Displacement
Common Types in Wastewater
• Rotary Lobe (AKA Roots Blower)
- Twin Lobe
- Tri Lobe
• Screw Blower
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• Best for low flow, high pressure applications
• Low horsepower offering
• Can withstand Frequent Starts/Stops
• Up to 80% Turndown
• Economical
• Flexibility with Blower Package
• Common Product
Blower Technologies: Positive Displacement
Positive Displacement Advantages
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• Several regular maintenance items
• Problems at higher capacities – Valve & seal leakage
– Mechanical friction
– Flow discontinuities increase rapidly and lower efficiency
• Pulsation
• Loud
• Limited high horsepower offering
Blower Technologies: Positive Displacement
Positive Displacement Disadvantages
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Lobe
•Twin lobe (or tri) impellers rotate transports the air around the periphery of the housing
•External Compression causes vibration and pulsations
• Belt Driven
Blower Technologies: Positive Displacement
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Screw
http://www.comer-srl.net/product.html
Blower Technologies: Positive Displacement
• Internal Compression
•The Rotation causes less vibration and pulsations
• Gear or Belt Driven (Depending on the manufacturer)
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Screw
http://www.comer-srl.net/product.html
Blower Technologies: Positive Displacement
1 2 3 4
Air enters the compression chamber
Air is moved to the discharge as the rotors turn
The air is compressed as it is transferred
Air is pushed out into the pipeline
1
2
3
4
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Blower Technologies: Positive Displacement
Lobe VS Screw
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Screw Blower Lobe Blower
Vs.
Performance Comparison
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Blower Technologies: Centrifugal
Common Types in Wastewater
• Multistage Centrifugal
-commonly incorrectly referred to plainly as “centrifugal”
• High Speed Turbo
- Magnetic Bearing
- Air Bearing
• Integrally Geared Single Stage
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Blower Technologies: Centrifugal
Range by Product
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• Wide operating range
• Low maintenance
• High horsepower capabilities
• High efficiency potential – Varies based on size
• High speed capability
• Reasonable output sound range
Blower Technologies: Centrifugal
Centrifugal Advantages
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• Can be less efficient and unstable at low flows
• Limitations on starts/stops
• Complicated control systems
• High overhead costs
Blower Technologies: Centrifugal
Centrifugal Disadvantages
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• Air is forced through the impeller
• Velocity of air is converted to pressure (mostly in the diffuser)
• Increase is staging allows for an increase in pressure
• Used for Air and Gas applications
Blower Technologies: Centrifugal
Inlet Outlet Multistage
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• First utilized in natural
gas compression
• They operate at high
impeller speeds and can
operate at pressure
ratio's in excess of 4:1
• Light weight and
compact
Blower Technologies: Centrifugal
Single-Stage Integrally Geared
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• Two Kinds:
1) Magnetic Bearing
2) Air Bearing
• Impeller forces air to rim of impeller, increasing the velocity
• Newest Technology
High Speed Turbo
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Magnetic Bearing
• Rotor is magnetically levitated and makes no contact with housing
Operating principle:
– Position sensor detects
displacement
– Electromagnets get
activated, shaft is attracted
to the opposite direction
Blower Technologies: Centrifugal
High Speed Turbo
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Blower Technologies: Centrifugal
Air Bearing
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Turbo Performance Envelope
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Evaluation
Main Aspects
1) Application Compatibility
2) Energy/ Life Cycle Cost
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Evaluation
Application Compatibility
1) Site Conditions
2) Frequency of Starts/Stops
3) Frequency of use
4) Pressure Levels (constant or variable)
5) Turndown
6) Noise Level
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3
Pressure
• Constant Pressure – Aeration Tank
• Variable Pressure – Digesters, SBRs
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4
Frequency of Starts/Stops
• Continual Operation – Aeration Tank
• Frequent Starts/Stops– Digesters, SBRs
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4
Turndown
• Wide Range of Operation
• Multiple Blowers
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Efficiency
• Focus on the power of the complete blower package,
commonly known as “Wire to Air”
• Standard: ASME PTC-13 (under development)
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Evaluation
• Efficiency vs. Capital Costs
• Focus on the power required to deliver a specified flow and pressure at the discharge of my blower system
• Wire to Air Power
4
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