Energy Efficient Turbo Blowers

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CII Green Cementech 2010

Energy Efficient Turbo BlowersEnergy Efficient Turbo Blowersfor Cement Industryfor Cement Industry

Green Cementech 2010

LetLet’’s make Indian Cement Plantss make Indian Cement PlantsWorld Class in Green!World Class in Green!

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Types of Air BlowersTypes of Air Blowers• Positive Displacement type

Twin Lobe, Tri Lobe blowe rs (Roots blowe rs) with belt dr iven induction motorsApplicat ions: For constant flow & var iab le pressureFlow rate: F rom 5m3 /hr t o 57,117m3 /hrPressure: Up t o 0.2 k g/cm2 with single stage & up to 1. 8 kg/cm2

with double stageVacuum: Up to 0.5kg/cm 2

• Centrifugal (Turbo) typeWith belt driven or direct driv en induct ion m otorsApplicat ion: conventiona l Centrif uga ls prov ide v ariable f low & constant pressure

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Convent ional Positive Displacement t ype, Convent ional Positive Displacement t ype, Twin Lobe Air BlowerTwin Lobe Air Blower

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Centrif ugal Blowers: Practically there is thin line differentiating Centrifugal Fans & Centrifugal Blowers

K Turbo Blowers are very different from conventional centrifugal / turbo blowers as their performance curve is controlled & adjustable

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(Twin Lobe Positive Displacement)

Improving Energy EfficiencyImproving Energy Efficiency

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Turbo Blowers from K Turbo Inc., S. Korea

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Core C omponents & Salient Feat ures

• Permanent Magnet Motor: a) Power requir ed only to rotate & not for magnetizing of r otor; b) Can be started & st opped any num berof times; c) High Eff iciency even at part load

• No Gear Box: No t ransmission loss due to d irect drive & no lubr ication required.

• Variable Speed Dr ive for achiev ing high speed, smoot h starts (reduced starting current ) & energy eff icient capacity contro l as part of the Blower package.

• Air Foi l bear ing for h igh speed opera tion (used in Jet engines)

• Oil Fr ee air

• Low No ise: 80 dB against 100 dB of PD blowers

• Enti re range is a ir-cooled & no need of wate r for coo ling.

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Comparison with PD blowersComparison with PD blowers

Below 80 dB95-110 dBNoise Leve l

Smal lerLargeFoot Pr int

Semi-permanent

5 YearsLife

Air Filte rsOverhaulMaintenanceBelow 5%250%Starting Cur rent com pared to Rated Current

67%22.5%Total Efficiency at 50% Load

70%45%Total Efficiency at 100% Load

92%82%Drive Eff iciency (Motor+Coupling+Inve rtor )

77%55%Aero Efficiency

KTurbo Blower

PD BlowerParameter

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Energy Effic

iency

Certi fie

d by Korea

Energy Managem

ent Corp

oration

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APPLICATIONS OF KTURBO BLOWERSAPPLICATIONS OF KTURBO BLOWERS

• Air (gas) conve ying of powder (Cement factory, Chemical factor y, Food & Beverage fa ctory, Power station etc.)

• Aeration for water treatmen t (municipal sewage disposal plant, wa ter treatment systems in factories

etc.)

• Agriculture and food processing (drying, processing, conve ying etc.)

• Biotechnology (Oil free air supply)

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Sam ple C ase Studies of Energy Saving AchievedApplication With Roots Bl ower With K Turbo Blow er Since Saving

Nisshinbo(textil e)

Indust rial WWT

75HP: 2 uni ts, 1 00HP : 1 unit

(5000 mm Aq, 144 m3/ min)

185 kW

75HP: 2 uni ts(6000 mm Aq, 102 m3/min)

112 kW4 Ye ars 40%

POSCO(steel)

Process Ai r(Revers e Washing)

75.7 kW118dB

43.5 kW80dB

4 Ye ars 42.5%

SungshinCement

Mate rial Handlin g

150HP : 2 u nits(4300 mm Aq, 37. 5*2= 75 m

3/min) 125.6 kW

150HP : 1 u nit(4300 mm Aq, 93 m3/min)

78.0 kW4 Ye ars 38%

Lafarge Hall a

(cement)

Mate rial Handlin g

150HP : 1 u nit(4700 mm Aq, 35 m3/min)

62.4 kW

75HP: 1 uni t(4700 mm Aq, 35 m3/min)

40.5 kW5 Ye ars 35%

DAESANG(food)

Indust rial WWT

75HP: 3u nits

200HP : 1 uni t(4500 mm Aq, 204 m3/min)

319 kW

75HP: 4 uni ts(4500 mm Aq, 204 m3/min)

204 kW6 Ye ars 35%

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Ø Case Studies of Appl ications in Cement Industr ies:

1. Air Lift Blower

2. Conveying Blower fo r coal

3. Aeration Blower for si lo

4. Conveying Blower fo r alte rnated fue l

5. Main burner Blowe r for a ir injection

Ø Results of Instal lat ion

Ø Pictures of instal lat ion

Installations at Cement industriesInstallations at Cement industries

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PD Blower & K Turbo Blower

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CII Green Cementech 20101-1. Air Lift blower1-1. Air Lift blower

1. Application : Conveying crushed material from raw mill to silo

2. Using pressure : 0.1bar~1.5bar

3. Using air flow delivery : 50 /min~200 /min4. Application Area : Sung-shin cement (Using from early 2004)

- Raw Mill#1,2 Air Lift Blower (TB150 -0.8S*3set)

- Raw Mill#4 Air Lift Blower (TB200-0.6T*2set)- Raw Mill#3,5 Air Lift Blower (TB200 -0.6T*3set)

- Raw Mill#7 Air Lift Blower (TB200-0.6T*3set)

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1. Application : Conveying main material to pre-Heater of kiln

2. Using pressure : 0.1bar~1.0bar

3. Using air flow delivery : 75 /min~200 /min

4. Application area : Ssung-Shin cement Inc, (Using from early 2004)

Kiln#1,2,3 (TB150-0.8S*6set, TB200-0.6T*2set)

Kiln K,C-Line: Air Lift Blower

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1. Application : Conveying the cement produced from cement Mill

2. Using pressure : 0.1bar ~ 1.0bar

3. Using air flow delivery : 75 /min ~ 200 /min

4. Application area : Sang-Yong Cement (Using from 2004) Mill# 4,5

(TB150-0.8S*2set)

Cement Mill Air Lift Blower

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CII Green Cementech 20102. Conveying blower for coal2. Conveying blower for coal

1. Applica tio n : Conve ying coal fo r fi rin g

2. Using p ressu re : 0 .1b ar ~ 1 .5b ar

3. Using ai r fl ow d elive ry : 1 5 /min ~ 1 00 / min

4. Applica tio n A re a :

L afa rg e-Halla ce men t Inc, Kiln# 1,2 ,3,4 F or dose d Coal (TB 75-0.6 S*6s et, T B10 0-0.8 S*1se t)

(Using fr om late 2 003) Co al Mill# 2,3 ,4 F or Coal (T B75 -0 .6S *1se t, TB 150 -1. 5S* 2set)

Kiln# 4 F or Co al (T B15 0-1.5 S*1se t)

S ung -S hin c em ent Inc, Coal Mill# 3,4 : Fo r Coal (TB7 5-1.5 S*2s et) , Kiln #5 1,2 s tep : F or Co al (TB15 0-0.8 S*2se t)

(Using fr om late 20 04) Kil n#6 Main B urn er : Fo r Coal (TB 150 -0 .8S *2set)

Ot he rs : Ss ang -Y ong ce men t, Hy un -Dai ce me nt, Han -I l cem ent usin g lik e u ppe r d ata

Conveying blower for milled coal, Dosed c oal and Main Coal

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CII Green Cementech 20103. Aeration blower for Silo3. Aeration blower for Silo

Aeration for cement silo

1. Application : Take down cement easily from main silo to forwarding silo or BCT ( Bulk cement Trailer)


3. Using air flow delivery : 15 /min ~ 50 /min

4. Application Area :

Lafarge-Halla cement Inc, Cement Silo#1 Aeration & transportation (TB50-0.6S*2set, TB150-0.8SP*1set)

Su ng-Shin cement Inc, Cement Silo#8 Aeration (T B200-0.72SP*3set)

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CII Green Cementech 20104. Conveying Blower for alt. fuel4. Conveying Blower for alt. fuel

Conveying alternative fuel to ki ln

1. Application : Conveying alternative fuel to Kiln



4. Application area : Sung-S hin Cement, Kiln#6 Conveying baked scrap tire to kiln (TB200-0.72S *1set)Ssang-Yong cement, Conveying scrap plastic sheet to kiln (TB75-0.6S*3 set, TB1500.8S*2set)

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CII Green Cementech 20105. Main Burner Blower for air injection5. Main Burner Blower for air injection

1. Application : Compressed air for combustion2. Using pressure : 0.1bar ~ 0.5bar


4. Application area : Lafarge-Halla Inc, Kiln#2,3 Main Burner (T B75-0.6S*set, TB150-0.8S*2 set)

(Using from late 2003)

Ssang-Yong cement Inc, Kiln#3 Main Bu rner (T B75-0.6SP*1set, TB20 0-0.72SP *2set)

Kiln#7 Main Burner (TB100- 0.6SP*1set) (Using from late 2004)

Injecting compressed air to main burner

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With Roots Blower

• 56-m3/min at 1.76 bar

• Power drawn = 204 kW

• Energy consumption

= 1,762,560 kWh/ year

•Energy Savings = 388,800 kWh/year (22%)

Case Study: Case Study: Se men Gre sik Se men Gre sik Cement,Cement, IndonesiaIndonesiaApplication: Coal Conveying

With KTurbo Blower

• 56-m3/min at 1.76 bar

• Power drawn = 159 kW

• Energy consumption

= 1,373,760 kWh/ year

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CII Green Cementech 20106-1. Results of installations6-1. Results of installations

Energy cost saving (1 year): USD13,000

Reduce Noise:over 15 dBReduce vibration:Over 19mm/s

Energy cost (per year)Total: about USD22,000Cal) 40kW * 330day * 24hour/day * 0.07USD/day = USD 22,176Noise level : under 80dB

Vibration : under 1mm/s

Energy cost (per year)Total: about USD35,000Cal) 63kW * 330day * 24hour/day * 0.07USD/day = USD34,927Noise level : Over 95dB

Vibration : over 20 mm/s

Details of Energy saving

/

Noise & Vibration

Energy save: 35%

Equipments:KTurbo Blower: 75HP * 1setOperating data

Dis. pressure: 0.47 barDelivery: 35 m3/minPower consumption: 40 kW

Equipments:Roots Blower: 150HP * 1setOperating data

Dis. pressure: 0.47 barDelivery: 35 m3/minPower consumption: 63 kW

Measured Results

REMARKSAFTER

(at same conditions)BEFORE

Ex: Lafarge-Halla cement Inc, (Mode: Constant Volumetric Flow)

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CII Green Cementech 20106-2. Results of installations 6-2. Results of installations

Energy cost saving (1 year): USD27,000Reduce Noise:Over 15 dBReduce vibration:Over 19mm/s

Energy cost (per year)Total: about USD43,000Cal) 78kW * 330day * 24hour/day * 0.07USD/kWh = USD 43,243Noise level : under 80dBVibration : under 1mm/s

Energy cost (per year)Total: about USD70,000Cal) 126kW * 330day * 24hour/day * 0.07USD/kWh = USD69,854Noise level: Over 95dBVibration: over 20 mm/s

Details about Energy saving

/Noise & Vibration

Energy save: 48kW (39%)& Conveying more material

Equipments:

KTurbo Blower: 150HP * 1set

Operating data Dis. pressure: 0.43 barDelivery: 93 m3/minPower consumption: 78 kW

Equipments:Roots Blower: 150HP * 2set

Operating data Dis. pressure: 0.43 barDelivery: 75 m3/minPower consumption: 126kW

Measured Results

REMARKSAFTER

(more diff icult condition)BEFORE

• Ex: Sung-Shin cement Inc, (Mode: Constant Volumetric Flow)

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K Turbo Blowers installations in Cem ent Industry

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Installation (Cement Factory)

Hanil Cement

Hyundai Cement

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Installation (Cement Factory)

Lafarge Halla Cement

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KTurbo: The Ultimate Rotating Machine

Construction of K Turbo BlowersConstruction of K Turbo Blowers

Variable Speed

+Direct Drive (No Gear B ox)

+No Bear ing Lubricat ion

Oil-free Turbo Air B lower

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InverterPower InControls

Intake Silencer

BOV Silencer

Construction of Single & Twin Turbo Blo wers

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PM Motor & Impellers2 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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Why KTurbo ?

1) Ful ly Opt imized Aero/Mot or/ Invert er component

• Optimum specific speed selection

• Long life time inverter, stable operation

• Long life / life time air-foil bearing

2) Best Efficiency, Many Refe rences

3) Small Foot Print & Low N oise

4) Stain less Stee l Cast Impe ller

5) Oil-fr ee Blower / Com pressor

6) No effect of power supply fr equency var iation

Continued…

6

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7) Starting cur rent = Full Load curr ent (good for DG Sets)

8) Built-in Flow-meter

9) Most Advanced Surge De tection Dev ice

• Instant flow r ate measurement / flow instab ility monit oring.

10) Full line up

• 25-600hp (air cooled)

Why KTurbo ? Continued…

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Core Tec hnologies

(1) Air foil bearings(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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•The working principle of foil bearing is same as hydrodynamic oil bearing like a tilting pad oil bearing which is used for classical gear increasing high speed machines.

•Because foil bearing use surrounding air instead of oil to support shaft, it needs larger diameter and length and special damping mechanism.

•To provide maximum support force, foil bearing adopts entire bearing surface and spring backup. Bearing surface configuration and spring characteristics define bearing behavior.

•During start/stop, direct contact between shaft and bearing surface occurs. To protect bearing surface during start/stop, dry lubricant coating is applied on the bearing surface and 30,000 time on/off is available.

Principles of Hydrodynamic Pressure Generation

Hydrodynamic Pressure Generation

Principles of Foil Bearings

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History of Foil Bearings

Simple BumpSimple Bump

Reversed MultiReversed Multi--LayerLayer

MultiMulti--Leaf Leaf

MultiMulti--Pad BumpPad Bump

Third Generation BumpThird Generation Bump(KTurbo)(KTurbo)

•• Radial variationRadial variation•• Circumferential Circumferential variationvariation•• Axial s plit/variationAxial s plit/variation

•• MiT iMiT i ha ve m ade ma jor r es earchha ve m ade ma jor r es earch

•• KTurbo ha s > 1000 units experi enc esKTurbo ha s > 1000 units experi enc es

TeflonTeflon--SS

MoS2MoS2

High Temp Solid High Temp Solid LubricantLubricant--PS304 ; NASAPS304 ; NASA--KOROLO N1350F ; KOROLO N1350F ; MiTiMiTi

High Capacity, High Speed, High Damping, High TemperatureHigh Capacity, High Speed, High Damping, High Temperature

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Life time KTurbo air f oil bearings

Ø K Turbo foil bear ings were proved through

Ø 6 years ope ration (over 1300 units )

Ø On 400hp 60kg & 600hp ro tor system

Ø extreme mac hines of 2 stage 7 bar com pressor.

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Comparison of bearings

5010050A/S COST

Complexity (Pump, Filter, Reduce pressure system, pressure sensor, etc.)

Complexity (Pump, Filter, Reduce pressure system, pressure sensor, etc.)

SimpleSystem

1520Reliability

Change bearing every 3 yearsCheck by 5 yearsNoMaintenance

Change bearing every 3 yearsSemi-permanentSemi-permanentLife Span

UsedUsedNot usedLubrication oil

Ball BearingTilting Pad BearingAir Foil BearingClassification

7

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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%)

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Why PM m otor ?

Ø No magnetizing power is necessary

Ø Lower heat generation means less cooling loss.

Ø Smaller rotor means less friction loss

Ø No slip means high efficiency even at part load condition.

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Efficiency of PM motor & Induction Motor

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Induction Mot ors Induction Mot ors v/sv/s PM Mot or PM Mot or

Very high: 95–98%Medium: 88–94%High: 85–97%Electric Efficiency

Medium: 75–85%

15%- 20%

High

Very Low: 0.65

High Speed Induction

Very high: 95-97%High: 88–95%Total Efficiency

1%-3%2-3%Cooling Loss

LowNormalRotor Temperature

Low: 0.8

Low Speed Induction

High: 0.9Power Factor

PMClassification

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1.1. Stain less Stee lStain less Stee l•• SUS630, 17SUS630, 17--4PH4PH

2.2. Optim um Specific SpeedOptim um Specific Speed•• Maximum efficiencyMaximum efficiency

3.3. Optim um back sweep angleOptim um back sweep angle•• Maximum efficiencyMaximum efficiency•• High Rise to surgeHigh Rise to surge•• Wide operating rangeWide operating range

4.4. Spl itter BladeSpl itter Blade•• Larger flow capacityLarger flow capacity•• Higher efficiencyHigher efficiency

5.5. LeaningLeaning•• Higher structural strengthHigher structural strength

(3) Features of K Turbo Im peller

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(4) B ui lt-in Flow Meter

Bell m out h is m uch more accurat e t han Orifice, because it needs only one sensor.

]99.0min,/m Pa,sec,K,[m, 11

260 3

1/1

=

∆−−⋅

−

⋅⋅⋅⋅

∆−⋅⋅×=

−

d

k

kk

d CP

pPk

kTR

PpP

AcQ

8

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Discharge Duct

Blow-off Valve

Silencer

Blower core

Inverter

Discharge pressure : PDischarge Temp : T2

Suction Flow rate dP : dP3

Suction Temp : T1Filter Pressure Drop : dP1

Air F low m e asuring

Air in

Air out

Impeller

Inlet Reducer

T1 dP3 [ Differential pressure]+ -

< Air Flow calculation, Q >

Q • Q (T1, Po , dP3)

Meas urem ent Syst em

Control

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(5) LOA D/UNLOA D

No Air From BOV

Discharge

LOAD

Air From BOV

No Discharge

UNLOAD

* BOV closed

* Normal operation

(high rpm)

* BOV open

* Standby with id ling

(low rpm)

* ~ 1 kW power level

BOV BOV

Toggle by manual/remote/MCP

Respons e tim e

From LOAD to U NLOA D : ~10 s ec

From UNL OAD to full L OAD : ~30 s ec

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Response to press ure c hange

Current Set in ner lo op

Stable i nitial response

Speed Set Inner loop

Unstable initial response

Surge Occurs

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Performance curves of turbo blowers

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(6) HMI wit h t ouc h screen

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HMI: Main Screen

9

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HMI: Operating C urves display

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ØCF me mory is a pplie d•Data logging every 1 sec, 1 min, 1hour

•All event recording

HMI: Dat a Logged every second

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ØCF m em ory i s ap plied•Data logging every 1 sec, 1 min, 1hour


HMI: Event Logged every sec ond

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ØCF me mory is a pplie d•Data logging every 1 sec, 1 min, 1hour


HMI: On-line trend display

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CCR(Central Control Room)SCADAor 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-2Anchor bolting case-1Concrete pad

10

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Leveling

Up & down of foot (for easy le veling of the machine)

Leve ling check-2

Leve ling check-1

Sometimes need shims due to poor level ing of surface

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Ø Discharge side com ponents arrangement order

• Check valve à flexibl e à silence r à sto p val veàsafety valve (whe n a pplica ble) .

Ø Need suit able pipe supporte r prior to free from t he p iping system’s and/or p lant unexpected v ibrat ion influence t o the mac hine.

Ø Inspect the c heck valv e flow direct ion ma rk on it

Ø After discharge check va lve, the pipe should be go straight minim um three d iamete r of the pipe. ( important)

Piping-discharge

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Air Filters

Pre85%@ 10 4-8 weeks

Final99%@ 10 or 68%@2

5-12 months

•P 21-44mmWTR

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References: J une 2009

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Clients

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Clients

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KTurbo Direct driven Turbo Blowers & Compressors

Ene rgy s aving

(over 35%)

Ene rgy s aving

(over 35%)

- ROI : under 1.5 years- Important for Carbon

Credits Business

- ROI : under 1.5 years- Important for Carbon

Credits Business

Low n oise & N o vibra tion

Small & Lig ht

Low n oise & N o vibra tion

Small & Lig ht

- Improve environment at sites

- Reduce installation cost - Reduce product cost

- Improve environment at sites

- Reduce installation cost - Reduce product cost

No oil i n syst emNo oil i n syst em

-Improve environment at sites

-NO need of lubrication Oil

-100% Oil-free Air

-Improve environment at sites

-NO need of lubrication Oil

-100% Oil-free Air

Benefi ts wit h K Turbo

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Thank You!Thank You!Godrej & Boyce Mfg C o Lt d

Compressed Air SolutionsGodrej | Electr ical & Electr onics

Pirojshanagar, Vikhroli, Mum bai – 400079. Ind iaTel.: +91-22-67962251 to 2255

Fax: +91-22-67961410 / 67961525E-mai ls: [email protected]; [email protected]; [email protected];

www.godrej-ai rsolutions.com

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Documents

Energy Efficient Turbo Blowers