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One Day National Workshop on Common Effluent Treatment Plants

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 .

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One Day National Workshop on Common Effluent Treatment Plants

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  1. 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 company presentation 2012

  2. Effluent Water Treatment

  3. Positive Displacement type, Twin Lobe Air Blower

  4. PD Volumetric Turbo - η Increase over 10% Low speed Turbo High Speed Turbo • ηIncrease over 20% • Increase stability Direct driven High Speed High Gear Ratio Roots blower Multi stage Turbo blower Multi stage Turbo blower Blower Efficiency Increased over 40% Increasing Energy Efficiency - η Increase over 10% - No Volumetric pulsation

  5. Turbo Blowers

  6. Energy Efficiency certified by: Korea Energy Management Corporation

  7. User selectable Control Modes with KTurbo • Constant Flow • Constant Pressure • Constant Power • D.O. Control

  8. User Selectable Control Modes Constant Current Mode Constant Pressure Mode Constant Flow Mode

  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.

  10. Comparison with PD Blowers

  11. PD Blowers Performance

  12. PD Blowers Performance • Typical model at 1800 RPM; Average total efficiency is 45%

  13. PD Blowers Performance

  14. Single Stage Turbo Blowers Performance

  15. High Speed Turbo & PD Blower Performance

  16. High Speed Turbo & PD Blower Performance

  17. 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)

  18. SunRiver: North America installation • Before : • 2 Units of 100hp Multi Stage • After: • 1 Unit of TB100-0.8 (70% Operation)

  19. 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

  20. Schematic of KTurbo installation in WWTP plant

  21. Picture of KTurbo installation in WWTP plant

  22. Picture of KTurbo installation in WWTP plant

  23. KTurbo blowers supplying air to WWTP plant

  24. Intake Silencer BOV Silencer Power In Inverter Controls Construction of Single & Twin Turbo Blowers / Comp

  25. High performance electric core 2 Pole permanent magnet (SmCo) with high strength retaining ring H Class Insulation winding Discharge PM Motor& Impellers Scroll Stainless steel casted Impeller Radial airfoil bearing Intake Radial airfoil bearing Thrust disk & Thrust bearing

  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

  27. History of Foil Bearings Third Generation Bump (KTurbo) • High Temp Solid Lubricant • PS304 ; NASA • KOROLON1350F ; MiTi Multi-Pad Bump MoS2 Reversed Multi-Layer • Radial variation • Circumferential variation • Axial split/variation Teflon-S Simple Bump • MiTi have made major research • KTurbo has > 1000 units experiences • KTurbo has TC series Multi-Leaf High Capacity, High Speed, High Damping, High Temperature

  28. 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%)

  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.

  30. Efficiency of PM motor & Induction Motor

  31. Core Technologies • Stainless Steel • SUS630, 17-4PH • Optimum Specific Speed • Maximum efficiency • Optimum back sweep angle • Maximum efficiency • High Rise to surge • Wide operating range • Splitter Blade • Larger flow capacity • Higher efficiency • Leaning • Higher structural strength (3) Features of KTurbo Impeller

  32. Built-in Flow Meter Bell mouth is more accurate than Orifice, because it needs only one sensor.

  33. 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 Air out Inlet Reducer < Air Flow calculation, Q > Q ≈ Q (T1, Po , dP3) Air in Impeller + T1 dP3 [Differential pressure]

  34. HMI with touch screen

  35. HMI: Main Screen

  36. HMI: Operating Curves display

  37. HMI: Data Logged every second • CF memory is applied • Data logging every 1 sec, 1 min, 1hour • All event recording

  38. HMI: On-line trend display • CF memory is applied • Data logging every 1 sec, 1 min, 1hour • All event recording

  39. CCR (Central Control Room) SCADA or DCS or PLC MCP1 MCP2 TB #1 TB #2 TB #3 TB #4 TB #1 TB #2 TB #3 TB #4 Multi-Group Control

  40. Foundation Concrete pad Anchor bolting case-1 Anchor bolting case-2

  41. Air Filters

  42. Customers

  43. Customers

  44. 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

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