50%+ Energy Savings Aeration Achieved by Replacing Roots Blowers with Maglev Technology at a Municipal WWTP, RAETTS Maglev Blower Retrofit Project in Jiaozuo, Henan
As energy prices continue to rise and wastewater treatment plants face increasing pressure to reduce operating costs, aeration system upgrades have become one of the most effective paths toward energy optimization. Aeration typically accounts for 40–60% of total electricity consumption in a wastewater treatment plant, making blower selection a critical decision for both operators and plant owners.
In a recent municipal wastewater treatment project in Jiaozuo, Henan, RAETTS successfully completed the installation and commissioning of three 150kW maglev turbo blowers, delivering outstanding energy-saving results and stable aeration performance.
Project Background: High Energy Consumption from Roots Blowers
The original aeration system relied on traditional Roots blowers, a common solution in older wastewater treatment facilities. While Roots blowers are robust, they often suffer from low efficiency, high noise, and heavy maintenance requirements—especially under partial-load operation.
Original configuration:
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Two Roots blowers serving the same aeration process
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Rated power: 216kW per unit
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High electricity consumption and frequent maintenance
This setup resulted in significant operating costs and limited flexibility in airflow control.
Upgrade Solution: RAETTS Maglev Turbo Blowers
To improve energy efficiency and operational stability, the plant upgraded to RAETTS maglev turbo blower technology.
New configuration:
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3 × 150kW maglev turbo blowers
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One blower supplies air to two aeration tanks
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Actual operating power: approximately 84kW per blower
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Stable airflow and dissolved oxygen (DO) control achieved after commissioning
The results were immediate and measurable.
Measured Results: Real Energy Savings After Commissioning
Compared with the original Roots blower system, the maglev retrofit delivered:
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More than 50% reduction in power consumption
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Approximately 600,000 RMB annual electricity cost savings
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Significantly lower noise and vibration levels
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Reduced maintenance workload for plant operators
These figures are based on real operating conditions, not theoretical calculations or laboratory data.
Why Maglev Blowers Deliver Superior Performance in WWTP Aeration
1. High-Efficiency PMSM Drive System
RAETTS maglev blowers utilize Permanent Magnet Synchronous Motors (PMSM) with efficiency levels up to 96%. Unlike traditional asynchronous motors used in Roots blowers, PMSM maintains high efficiency across a wide operating range, particularly under part-load conditions common in wastewater treatment.
2. Advanced Aerodynamic Impeller Design
The high-speed turbo blower is equipped with a three-dimensional aerodynamic impeller, optimized for maximum air delivery efficiency. This design enables the blower to deliver required airflow with significantly lower shaft power, making it ideal for continuous aeration processes.
3. Oil-Free Magnetic Bearing Technology
Maglev bearings completely eliminate mechanical contact during operation. This means:
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No lubricating oil system
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No bearing wear
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No transmission losses
For wastewater treatment plants, this translates into near-zero routine maintenance and reduced risk of unplanned downtime.
4. Wide Operating Range and Stable Aeration Control
Wastewater influent flow and organic load fluctuate throughout the day. RAETTS maglev blowers offer a wide turndown ratio and precise speed control, ensuring stable aeration and consistent DO levels even during frequent load changes.
5. Improved Working Environment
Thanks to non-contact bearings and precise dynamic balancing, maglev blowers operate with much lower noise and vibration compared with Roots blowers. This improves the working environment for operators and reduces the need for additional soundproofing measures.
A Growing Trend in Municipal Wastewater Projects
Based on recent retrofit and new-build projects, more wastewater treatment plants are directly specifying maglev turbo blowers during project planning and tendering stages. The focus is shifting from initial equipment cost to life-cycle cost, energy efficiency, and operational reliability.
In many cases, the payback period for maglev blower retrofits is as short as one to two years, driven primarily by electricity cost savings.
Conclusion: A Proven Path to Lower Operating Costs
The successful installation of 3 × 110kW RAETTS maglev turbo blowers at the Jiaozuo wastewater treatment plant demonstrates how modern aeration technology can dramatically reduce energy consumption while improving operational stability.
For wastewater treatment plants considering blower replacement or energy-saving upgrades, maglev turbo blowers offer a future-ready solution that aligns with today’s energy, environmental, and operational challenges.
👉 Contact RAETTS to receive blower selection support, energy-saving analysis, and customized aeration solutions for municipal and industrial wastewater treatment projects.
E-mail: sales@raettsgroup.com
WhatsApp: +86 137 1270 2424
