Presentation on theme: "Page 1 company presentation 201223/11/2012 One Day National Workshop on Common Effluent Treatment Plants CII - Sohrabji Godrej Green Business Centre, Hyderabad."— Presentation transcript:
Page 1 company presentation 201223/11/2012 One Day National Workshop on Common 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. Energy Efficient Turbo Blowers for Aeration Kiron C. Pande - Godrej & Boyce Mfg. Co. Ltd.
Page 3 Positive Displacement type, Twin Lobe Air Blower
Page 4 VolumetricTurbo Multi stage Turbo 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 stage Turbo blower Roots blower PD
Page 9 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 10 Comparison with PD Blowers ParameterPD BlowerKTurbo Blower Aero Efficiency55%77% Drive Efficiency (Motor+Coupling+Invertor)82%92% Total Efficiency at 100% Load45%70% Total Efficiency at 50% Load22.5%67% Starting Current compared to Rated Current250%Below 5% MaintenanceOverhaulAir Filters Life5 YearsSemi- permanent Foot PrintLargeSmaller Noise Level95-110 dBBelow 80 dB
Page 15 High Speed Turbo & PD Blower Performance
Page 16 High Speed Turbo & PD Blower Performance
Page 17 KTurbo (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)
Page 18 SunRiver: North America installation Before : 2 Units of 100hp Multi Stage After: 1 Unit of TB100-0.8 (70% Operation)
Page 19 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
Page 20 Schematic of KTurbo installation in WWTP plant
Page 21 Picture of KTurbo installation in WWTP plant
Page 22 Picture of KTurbo installation in WWTP plant
Page 23 KTurbo blowers supplying air to WWTP plant
Page 24 InverterPower In Controls Intake Silencer BOV Silencer Construction of Single & Twin Turbo Blowers / Comp
Page 25 PM Motor & Impellers 2 Pole permanent magnet (SmCo) with high strength retaining ring High performance electric core H Class Insulation winding Radial airfoil bearing Thrust disk & Thrust bearing Stainless steel casted Impeller Scroll Intake Discharge
Page 26 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
Page 27 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
Page 29 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 30 Efficiency of PM motor & Induction Motor
Page 31 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 Impeller Core Technologies
Page 32 Built-in Flow Meter Bell mouth is more accurate than Orifice, because it needs only one sensor.
Page 33 Discharge Duct Blow-off Valve Silencer Blower core Inverter Discharge pressure : P Discharge Temp : T2 Suction Flow rate dP : dP3 Suction Temp : T1 Filter Pressure Drop : dP1 Air Flow measuring Air in Air out Impeller Inlet Reducer T1 dP3 [Differential pressure] + Q ≈ Q (T1, Po, dP3) Measurement System