Why the magnetic levitation centrifugal blower can perfectly replace the RAETTS blower
In the sewage treatment industry, magnetic levitation centrifugal blower have been increasingly used. Compared with traditional two-blade and three-blade RAETTS blowers, multi-stage and single-stage centrifugal blower, rotary blower, etc., the advantages of magnetic levitation blower are particularly obvious. , which has also become the first choice product for many sewage treatment companies to improve their standards and receive good market feedback.
The main advantages of magnetic floating blowers are:
1. Power advantage
The maximum power of the magnetic levitation blower can reach 300kW or even higher. It is suitable for many large and medium-sized external sewage treatment plants. The efficiency of the magnetic levitation blower is high. In the past, several low-power traditional blower were needed, but now only one magnetic levitation blower is needed to achieve the flow rate. Parameter requirements are met, saving money and space.
2. Save electricity and reduce consumption
With traditional mechanical bearing blower, mechanical friction will occur during operation of the equipment, and the speed will be low, the noise will be loud, there will be many faults, and even the life will be short. Because the magnetic levitation blower uses magnetic levitation bearings, it has no mechanical friction and high transmission efficiency, and can save more than 30% of electrical energy. The maintenance cost of the magnetic levitation blower is very low. It only needs to replace the filter element and cotton regularly. At the same time, the working conditions of the on-site operation can be remotely controlled, saving manpower.| Turbo blower factory
3. Long service life
The service life of traditional RAETTS blowers is only 5-8 years, and maintenance costs will be more expensive in the later period. The magnetic levitation blower is directly driven, has no friction, and does not require lubricating oil. The service life of the equipment can be as long as 25 years. This greatly saves additional purchase and maintenance costs for the company, and indirectly generates revenue for the company.| turbo blower supplier
4. Fast return on investment
RAETTS blowers, multi-stage centrifugal blower and other blower have low working efficiency. At present, sewage treatment plants mostly use magnetic levitation blowers or air levitation blowers. The latter two have obvious advantages, which has been verified by customers.
Magnetic levitation blowers also have the advantages of simple installation, remote control, low noise, environmental protection, and unattended operation. They are the preferred blower type for sewage treatment and other industries in the dual-carbon era.
A new revolution in the industrial blower industry—suspended centrifugal blower
We know that the blower is a universal equipment with strong versatility and wide range of uses. It is a machine that converts input mechanical energy into pressure potential energy and transports gas by increasing the gas pressure. High-pressure blower are used in many industries, including environmentally friendly sewage treatment aeration, to meet the oxygen requirements of aerobic microorganisms in activated sludge and the conditions for full contact and mixing of sewage and activated sludge, thereby degrading various substances in the water. Organic matter can achieve the purpose of sewage purification and can also play a role in stirring. There are also electroplating bath liquid stirring and aquaculture, which all play the same role. | turbo blower manufacturers
Modern blower can be divided into three types: centrifugal, axial and rotary based on the direction of gas flow. The structure of the axial flow blower is relatively simple and is generally only used in ventilation and ventilation places. The exhaust air pressure is low, and it can generally be regarded as an incompressible fluid when calculating efficiency, and no modification is generally required. RAETTS blower is a rotary blower, also called a volumetric blower. It is currently the main target of energy-saving renovation in a large number of factories and enterprises. RAETTS blower technology originated in the 1980s. It is large in size, noisy, takes up a lot of space, and has high maintenance costs. After about three years of operation, high maintenance costs have become a major expenditure pain point for enterprises. Under the pressure of “double carbon”, a large number of RAETTS blowers have become the main transformation target.| Turbo Blower Manufacturer from China
The air suspension blower and magnetic suspension centrifugal blower produced by Retz are centrifugal high-pressure blower. They adopt German energy-saving blower technology and achieve energy saving and noise reduction from hardware to software. They are currently the first choice for the upgrade and transformation of a large number of RAETTS blowers. Specifically, the motor of the Leitz blower adopts an ultra-efficient permanent magnet synchronous motor with an efficiency of more than 96%; the impeller adopts a ternary flow technology impeller to achieve a higher energy efficiency ratio; the air suspension bearing and the magnetic suspension bearing have no friction and do not require lubrication. With continuous transmission, the efficiency is higher; the whole machine realizes unmanned management, and the maintenance cost is very low.
Judging from the development history of blower, energy efficiency is getting higher and higher, energy saving and noise reduction are getting stronger and stronger, and low-carbon and environmental protection are the general trends. In this regard, Leitz blowers have been practicing. Judging from the actual use results, the noise, intelligence level, and use environment will be qualitatively improved after the transformation.
The cement raw meal homogenization warehouse uses magnetic levitation blowers to save energy and reduce consumption.
Judging from the current situation, during the “14th Five-Year Plan” period, the cement industry will face many more challenges than during the “13th Five-Year Plan”, specifically including “three highs and two”, namely high resource costs, high reduction costs, high environmental costs, and low reduction costs. The platoon tasks are heavy and the surplus is serious. Against this background, increasing energy conservation and emission reduction has become an arduous and urgent task facing the cement industry. During the energy-saving transformation of a large number of cement plants, cutting-edge magnetic levitation blowers are used to significantly save energy and reduce consumption during the homogenization process of the cement raw material homogenization warehouse. This is a phenomenon worthy of attention in the industry.
Homogenization refers to the process of reducing the fluctuation amplitude of the chemical composition of the material and making the chemical composition of the material uniform by adopting certain technological measures. The homogenization of cement raw meal refers to the process in which the ingredients of the ground raw meal tend to be uniform through reasonable mixing or pneumatic mixing. The purpose of using the homogenization warehouse for homogenization is to ensure the clinker quality, output and reduce consumption as a basic measure and prerequisite. It is also an important way to stabilize the quality of cement delivered from the factory. The blowers in the traditional homogenization process generally use RAETTS blowers and multi-stage centrifugal blowers. The disadvantages are outdated technology, low efficiency, high power consumption, loud product noise, and high maintenance costs. A large number of cement plants give priority to magnetic levitation blowers when upgrading and upgrading their standards, and the results are very good.| high-speed turbo blower manufacturers
The magnetic levitation blower is a high-speed centrifugal blower driven by magnetic levitation bearings. Its main features are that the bearings have no mechanical friction, suspended rotation, and low losses. It is also equipped with a ternary flow turbine, a high-speed permanent magnet synchronous motor, a high-speed frequency converter, an intelligent controller, etc. The core technology is to float first and then rotate when starting. The turbine and rotor are directly connected, with zero transmission loss. The efficiency can reach more than 97% and the noise is less than 80dB, which meets the expected upgrade effect.
Retz is based in China and serves the world. By continuously introducing international advanced technology and equipment, Leitz develops more energy-saving, smarter and more empowering blower products, providing customers with the advantages of low energy consumption, low operating costs, simple installation, and convenient maintenance. , the majority of cement companies have benefited a lot from the upgrading of RAETTS blowers to Leitz blowers.
Power saving analysis of suspended blowers in cement plants
The cement industry has always been a large energy consumer, and blowers are often used as the “electric tiger” of cement plants. They are commonly used in systems such as material transportation, stabilizing kiln grinding conditions, dust removal, desulfurization and denitrification. The energy consumption of blowers in cement plants accounts for about 10% of production. It can be said that the efficiency of blowers directly determines the energy saving, consumption reduction and low-carbon development of the industry. A large number of cement plants are looking for high-performance blower equipment to replace traditional RAETTS blowers and multi-purpose blower equipment when upgrading and upgrading standards. Stage centrifugal blower.
In recent years, the sudden emergence of air suspension centrifugal blowers and magnetic suspension centrifugal blowers have become popular in the cement industry. They have won the favor of customers for their energy saving, consumption reduction, low noise and environmental protection, low maintenance costs and long life.
We know that objects on the earth are affected by gravity and cannot float unless there is an external force, such as an airplane. Another situation is that when two magnetic objects are close to each other, they will repel each other with the same poles and attract each other with the opposite poles. The working principle of magnetic levitation equipment is to use the technical principle that like poles of a magnetic field repel each other. By controlling the size and direction of the repulsive force, the repulsive force and gravity are equal to each other, so that the magnet above is suspended in the air. Another type of equipment is air suspension equipment, which uses Bernoulli’s principle, which is the pressure exerted by the flowing air on a plane that is at right angles to its direction of movement, just like a hair dryer can make a table tennis ball hover vertically.
blowers developed using air suspension technology and magnetic suspension technology are called air suspension centrifugal blowers and magnetic suspension centrifugal blowers. Their common feature is that there is no physical contact between the bearings and the mechanical surface, so there is zero friction, zero wear, no lubricating oil, and high overall machine efficiency. It is higher than 86% and the noise is as low as below 80dB. It is the first choice for a large number of RAETTS blowers to be upgraded and upgraded.| turbo blower distributors
In a 5000t/d production line of a cement company in the north, the original design of the kiln head primary blower and the head and tail coal conveying blowers are RAETTS blowers. RAETTS blowers have the disadvantages of high energy consumption, high noise, and high maintenance costs. After inspection and demonstration by technical personnel of the cement company, it was determined to change to Leitz-Magnetic Levitation blower. After the transformation was completed, the production operation was stable, the power saving and noise reduction effect was very obvious, and at the same time, the kiln input amount, coal feeding amount, and pipeline pressure were basically the same. Under the condition, the average operating power of three RAETTS blowers was 390kW. After being transformed into three magnetic levitation blowers, the average operating power was 250kW, and the average power saving rate was 33.1%.
In addition, the maintenance of the magnetic levitation blower is simple and convenient. It only needs to be regularly cleaned or replaced with imported filter cotton. No lubricating oil is required. After the modification, the noise in the blower room has been reduced from more than 105dB to less than 80dB, and the noise reduction effect is obvious.| Blower Systems Suppliers
Comparison before and after using magnetic levitation blowers in water plant pretreatment process
When the sand content, color, algae, organic matter, mutagenic precursors, etc. in the raw water are high and the odor is obvious, and the purified water after the conventional treatment process cannot meet the water quality target, pretreatment should be added on the basis of the conventional treatment process. To address contaminated drinking water source water treatment. Pretreatment facilities include continuous operation, intermittent operation and emergency treatment devices. The blower in the pretreatment process is a large power consumer, and it is urgent to replace it with a low-energy blower during the standard upgrade.
Let’s take the use of magnetic levitation centrifugal blowers to save energy in the pretreatment process of a water plant in Guangdong Province as an example to see the advantages of pretreatment replacement blowers – magnetic levitation blowers:
The situation of the relevant blowers before the factory’s standard upgrade and transformation is as follows:
There are four biological contact oxidation tanks in a water source plant in Guangdong Province. A duckbill-shaped aeration head is arranged at the bottom of the tank with built-in polypropylene suspended balls with a diameter of 50 mm and a relative density of 0.95. The pool is evenly aerated by RAETTS blowers through 4 main pipes and 8 branch pipes 24 hours a day. The air volume of the RAETTS blower is 101 m3/min (50 Hz). In recent years, two RAETTS blowers have been used normally. The actual air volume of a single unit is 80 m3/min (40 Hz), and the total power of the two units is about 210 kW. The annual electricity consumption is about 184 × 104 kW·h, and the electricity consumption of the blower room increases by about 2% year by year. The average power consumption of the blower room per thousand tons from 2017 to 2021 is about 11. 38 kW·h. The noise generated by a single RAETTS blower is about 90 to 95 dB when working, and the noise generated by two units working at the same time is about 105 to 110 dB.| eration blower manufacturer
According to the “Design Code for Noise Control in Industrial Enterprises” (GB/T 50087-2013), when working in a production workshop for a long time, the noise shall not be higher than 85 dB. The temperature in the blower room is high (it can reach the highest temperature of 50℃ in summer) and working there for a long time can easily cause occupational hazards to workers. In addition, the RAETTS blower began to have bearing and spindle wear problems after 4 years of use. Up to now, 90% of the wind turbines have had their bearings replaced, and each wind turbine has to replace its bearings about 1.9 times on average. Each time the bearings are returned to the factory for maintenance, multiple employees are required to disassemble and assemble them, and the gear oil and engine oil of the RAETTS blower need to be replaced every six months, making maintenance time-consuming and laborious.
After comprehensive investigation, according to the operating air volume of two RAETTS blowers (160 m3/min), one magnetic levitation blower with a rated operating power of 175kW can be selected instead, with a rated air volume of 170m3/min and a rated wind pressure of 0.6bar. In actual operation, the air volume of two RAETTS blowers or one magnetic levitation blower supplies four biological pools. The operating efficiency of the magnetic levitation blower (75% ~ 81%) is higher than that of the RAETTS blower (55% ~ 61%). At the actual operating air volume of 160 m3/min, the operating efficiency of one magnetic levitation blower is about 25% higher than that of two RAETTS blowers, which means that the magnetic levitation blower saves more energy when doing the same work. The high-efficiency operation area of the magnetic levitation blower is also relatively wide (100~170 m3/min), which can effectively reduce the operating cost of the enterprise.
Features and structure of Leitz magnetic levitation centrifugal blower
As a new equipment that has emerged in recent years, magnetic levitation centrifugal blower are composed of core technologies such as magnetic levitation bearings, high-speed permanent magnet synchronous motors, high-efficiency centrifugal impellers, high-efficiency inverters and intelligent controllers. Compared with traditional RAETTS blowers and multi-stage centrifugal blower, they are more energy-saving and consumption-reducing. It is obvious, simple to install and easy to maintain. At present, magnetic levitation blower have been used in sewage treatment, cement, papermaking, printing and dyeing, petroleum, chemical and other industries.
The main features of Leitz magnetic levitation blower include:
(1) Energy saving and high efficiency: The magnetic levitation centrifugal blower adopts many advanced technologies such as high-efficiency centrifugal impeller, high-speed permanent magnet synchronous motor and active magnetic levitation bearing, and the energy saving rate is higher than 30%;
(2) Low noise and environmental protection: there is no mechanical contact between the rotating parts and the stationary parts in the blower, no friction, low noise, and no need for lubricating oil;
(3) Easy maintenance: There are no gearboxes, lubrication systems and other components in the system, so no mechanical maintenance is required. Daily maintenance only requires replacement of the filter element and cotton.
(4) Small size and light weight: The whole machine is designed in an integrated manner, with fluid components, motors, frequency converters and other components integrated inside. The whole machine has a compact structure and light weight. No equipment foundation is required, and no large lifting equipment is required for lifting.
(5) Remote monitoring possible: The magnetic levitation centrifugal blower is equipped with a remote monitoring system to monitor the operating status of the blower online and achieve unmanned duty.
Leitz magnetic levitation centrifugal blower structure:
The whole structure of the magnetic levitation centrifugal blower adopts an integrated design. The whole machine has an upper and lower structure. The upper part is the main machine (including the motor and fluid components), with a built-in muffler, and the lower part is the electronic control system. The impeller and rotor of the main machine adopt a direct-coupled structure. The magnetic bearing realizes the stable suspension of the rotor. Driven by the frequency converter, the permanent magnet synchronous motor drives the impeller to rotate at high speed. Air is sucked in from the upper part. After being compressed by the diffuser, it is discharged from the volute outlet. bulging out.
Hard core analysis of Leitz magnetic levitation centrifugal blower hardware
(1) Impeller: The impeller is a semi-open centrifugal impeller, which is directly driven by the motor shaft. The impeller is designed using the three-dimensional flow theory, using aviation forged aluminum, and is precision machined by a Hammer five-coordinate machine tool. The efficiency of the centrifugal impeller working within the range of ±20% of the rated volume flow rate is not less than 85%.
(2) Volute: Made of integrally cast aluminum alloy, the suction side is horizontal and the discharge side is vertical.
(3) Motor: equipped with a high-speed permanent magnet synchronous motor (PMSM). The motor is driven by a special frequency converter, and the actual power under different working conditions is different. The motor winding adopts 180 (H) grade insulation. The motor is allowed to be overloaded by 10%. Within the entire design operating range of the blower, the motor efficiency is not less than 95%.
(4) Rotor: The rotor directly connected to the impeller is made of high-temperature alloy.
(5) Magnetic bearings: When the blower is running, the magnetic bearings generate electromagnetic force to support the stable suspension of the rotor. There is no mechanical friction with the surroundings. It has the characteristics of low vibration, low noise, no lubrication and easy maintenance. The magnetic pole winding of the magnetic bearing adopts 180 (H) Grade insulation (see Table 1 for protection parameters), after 1 hour of continuous and stable operation, the temperature rise does not exceed 60°C, and the operating temperature does not exceed 110°C.
(6) Frequency converter: The starting current of the blower is about 10A, which has no impact on the power grid. During the operation of the blower, the motor speed is adjusted through the frequency converter to ensure that the blower flow rate is continuously adjustable within the designed working range.
(7) Vent valve: The blower has a built-in low-pressure pneumatic vent valve controlled by a solenoid valve. The opening pressure of the vent valve is about 5kPa. The air outlet pressure of the blower is used to open the pneumatic vent valve.
(8) Cooling: The entire blower adopts air cooling or water cooling for heat dissipation. The electronic control part uses centrifugal blower blowing for heat dissipation, and the motor part uses the rotor’s own axial flow blower for heat dissipation.
(9) Local control panel (touch screen): The magnetic suspension centrifugal blower cabinet is equipped with a local control panel (touch screen), which is used to display the blower operating parameters, display the historical curves and real-time curves of each parameter, and display blower failure alarm information. Adjust the blower operating conditions, etc. The parameters displayed on the touch screen include: inlet flow, motor speed, outlet pressure, outlet temperature, inlet temperature, motor temperature, input power, bus voltage, radiator temperature and filter status, etc. Users can adjust the blower flow rate by adjusting the percentage of the required air volume through the touch screen, and can set alarm values for parameters such as flow rate, outlet temperature, outlet pressure, etc. according to process requirements.
(10) Instruments: In order to accurately and effectively obtain the working status and working parameters of each part of the blower, the following instruments and sensors are set up in the blower, including displacement sensor, inlet pressure sensor, outlet pressure sensor, chassis differential pressure sensor, inlet Temperature sensor, outlet temperature sensor, motor temperature sensor, frequency converter temperature sensor, etc.;
(11) Cabinet: The magnetic suspension centrifugal blower cabinet is made of cold-rolled steel plates, and the surface is spray-coated for anti-corrosion treatment.
Smart city sewage treatment plant blower, air suspension centrifugal blower are the first choice
Before the 1980s, due to the lack of domestic blowing equipment, many companies used RAETTS blowers for blowing and aeration. By the mid-1990s, the single-stage high-speed turbine centrifugal blower became the mainstream blowing equipment for sewage treatment. This machine has high speed and relatively stable wind pressure at a certain speed, which is better than RAETTS blower and multi-stage centrifugal blower. In recent years, magnetic levitation blowers and air levitation blowers have been gradually adopted by sewage treatment plants due to their low energy consumption, low maintenance and high efficiency, and are suitable for various treatment processes, and are widely used in new sewage plants or upgrades.
Air suspension centrifugal blower is a type of single-stage high-speed centrifugal blower. It is equipped with air suspension bearings and ultra-efficient permanent magnet synchronous motors, and adopts core high-end technologies such as high-precision single-stage centrifugal impellers. It has no gear speed increase device, no mechanical contact, no lubrication system, variable frequency speed regulation to adjust air volume, and is environmentally friendly and low-noise. and low maintenance costs, which make air suspension blower very popular in the market.
With the increasing urban population and the continuous development of industry and agriculture, environmental pollution has become more and more serious, especially water pollution. It is now known as the three major pollutions in nature along with noise pollution and air pollution. Among them Urban sewage is a serious form of water pollution.
In smart urban sewage treatment, it is necessary to support multi-protocol and multi-type device access, conduct unified video intelligent analysis and video big data management in the cloud, complete full-terminal and full-platform coverage and distribution, and realize the integration of “cloud, edge, and terminal” Chemical collaboration. This requires high precision and intelligent operation of the blower, which requires regular and quantitative blowing and aeration to meet the needs of precise operation. The air-suspended high-efficiency frequency converter and PLC control system can accurately control pressure, flow, temperature and other parameters, realize remote control and unmanned duty, and provide the hardware and software foundation for smart water operations.
Analysis of core hardware of Leitz air suspension blower
1. Ultra-efficient permanent magnet synchronous motor. The permanent magnet brushless ultra-high-speed motor is the latest type of motor in the world that has emerged with the development of permanent magnet material technology, semiconductor technology and control technology. During operation, the rotary shaft operates at a high speed of 20,000 to 200,000 revolutions. The engine’s The efficiency can reach 97%.
2. Air suspension bearing. Air suspension bearings mainly include radial bearings, thrust bearings and other components. This kind of bearing is different from traditional mechanical bearings and ball bearings. There is no physical contact point between the rotary shaft and the bearing during operation, no lubricating oil is required, extremely low energy loss, extremely high efficiency, and is suitable for a variety of working environments.
3. Single-stage centrifugal three-dimensional flow impeller. The impeller is made of high-strength aviation aluminum, Ti, SUS and other materials, which has excellent wear resistance and deformation resistance, and has a service life of more than 30 years. The impeller and the motor are directly connected, and the power transmission efficiency reaches more than 90%.
4. Cooling system. The air suspension blower adopts oil-free air strong cooling and water cooling combined technology.
5. Noise reduction technology and built-in vent valve. The internal air outlet bypass pipe of the blower is equipped with a vent valve and a silencer. Its shell is made of carbon steel and has sound-absorbing materials inside. The blower adopts a pneumatic vent valve in the body to ensure that the blower can be shut down safely without any impact in case of power outage or abnormal conditions. Directly connected to the blower through elastic pipes to reduce pressure loss and noise from the inlet pipeline. The filter and silencer are steel casings with silencer material inside. A square or rectangular replaceable filter element is installed at the air inlet, and an integral imported muffler made of a sheet-like structure made of good sound-absorbing materials is installed between the air inlet and the filter in the blower body to reduce imported noise. Using high-tech air suspension bearing technology, mechanical friction and vibration are completely avoided. Noise level <80dB.
6. High-efficiency frequency converter and control system. The air suspension centrifugal blower itself has integrated local control and frequency conversion system, eliminating the need to set up separate frequency conversion cabinets and operation cabinets. Through the control panel of the blower itself, you can set various functions and query parameters such as fluid temperature, motor revolutions, air outlet pressure, air volume, power consumption, etc. The system also supports digital remote control and monitoring functions and can be controlled from the central control room.
Analysis of technical characteristics of Leitz magnetic levitation blower
Magnetic levitation centrifugal blower is an emerging high-speed centrifugal blower equipment in recent years. It adopts an integrated structure of high-speed motor + frequency converter + magnetic levitation bearing. The motor output shaft is directly connected to the impeller, eliminating the need for intermediate mechanical speed-increasing devices such as gears and couplings. Frequency conversion automatically adjusts and controls output parameters such as air volume and wind pressure. Leitz magnetic levitation blower are in a leading position in the industry. They have the world’s most advanced technology integration and nationwide service capabilities, and have become the first choice for many traditional blower to upgrade and transform.
The standard configuration of Leitz magnetic levitation blower includes ultra-efficient permanent magnet synchronous high-speed motors, high-efficiency inverters, oil-free magnetic levitation bearings, vent valves, local controllers, safety monitoring systems and muffler covers. All components are integrated and installed on a common base. , no special fixed foundation is required.
The magnetic levitation centrifugal blower is a type of single-stage high-speed centrifugal blower. Its core is magnetic levitation bearing and permanent magnet motor technology. The key component is the magnetic bearing, which uses the principle of constant conduction magnetic attraction to achieve high-speed, stable and frictionless operation of the rotating shaft through electromagnetic attraction. It uses position sensors, power amplifiers and PI operators to realize real-time status detection, adjustment and fault diagnosis of the motor rotating shaft. Its active control capability can effectively suppress the unbalanced vibration of the rotating shaft, and it has complete and strict UPS power-off protection measures.
Leitz magnetic levitation centrifugal blower use magnetic levitation bearings, which have no contact loss and mechanical loss, and realize high-speed stepless variable speed adjustment, so that the operating efficiency of the whole blower can be as high as about 86%. All components of the blower (high-speed motor, frequency converter, magnetic bearings) are integrated and installed on a common base without the need for a special fixed foundation. The equipment is small in size, light in weight, easy to install and operate, and has low noise and no vibration during operation.
System integration is high. High-efficiency filters, cooling systems, fully automatic anti-surge systems, power outage and fault protection systems, and real-time touch screens bring convenience to operators and reduce the occurrence of operating accidents.
Maintenance is simple and low cost. The magnetic levitation single-stage centrifugal blower motor is directly connected to the impeller. There is no gear speed increase device, no mechanical contact, no lubricating oil system, no wear and energy loss, and low maintenance costs. The frequency converter is used to regulate the air volume, which is more energy-saving than a throttle valve, and the air volume adjustment range is wide, generally 45% to 100%.
High cooling efficiency. The cooling system adopts a combination of air cooling and water cooling, which can effectively protect the motor and enable the blower to start and stop at any time.
remote control. PLC+GPRS is adopted. Not only can it be controlled by the central control room, but if the blower fails, remote maintenance and debugging can also be implemented.
Leitz blowers help water projects “build competitive products and create brands”
At present, in order to achieve the goal of “building high-quality products and creating brands”, a large number of water projects must not only optimize the process design, but also optimize the selection of water treatment equipment, and further explore the specific energy-saving space of high-power equipment in sewage treatment plants. Target.
When domestic water companies select blowers, the general construction department, together with various electric centrifugal blower equipment suppliers, conducts many technical exchanges and discussions on the performance of imported multi-stage low-speed centrifugal blowers, single-stage high-speed air suspension blowers and magnetic suspension blowers for sewage plants. During the on-site inspection, technical and economic analyzes of various types of wind turbines were conducted. At present, when the majority of water companies are upgrading and transforming, for blast and aeration equipment, Retz air suspension blower and magnetic suspension blower are the first choice, and they have received good market feedback.
Leitz air suspension blower and magnetic suspension blower are the two main blower. They are respectively equipped with the world’s leading air suspension bearings and magnetic suspension bearings. They have the characteristics of zero wear, low loss and no vibration. The product energy saving rate is more than 30%, low noise and environmental protection. , suitable for use in various complex working conditions.
According to a large number of customer feedback, under the same air volume conditions of centrifugal blower and Leitz air/magnetic levitation blower, when the air volume changes between 110 and 160m3/min, the maglev blower saves 31.2% in power compared with the centrifugal blower, and as the air volume increases increases, the energy-saving effect decreases more.
Calculated based on the daily operation load of a water company with a load of 100,000 tons, the incoming water quality is relatively stable. Since the second phase of operation, in order to achieve the purpose of further saving energy, reducing consumption and cost while ensuring that the outlet water quality is stable and up to standard, the magnetic levitation blower has saved energy consumption by about 31.2% compared with the centrifugal blower, and the total power saving is about 120KW. The unit price of electricity It is 0.76 yuan/kWh, saving 65,664 yuan per month. It operates 360 days a year, and the annual cost savings is about 788,000 yuan. The energy saving effect is obvious.
Advantages of using Leitz magnetic levitation blower in the sewage treatment industry
In recent years, my country has upgraded a large number of old water plants and built new sewage treatment plants on a large scale to meet my country’s sewage treatment needs. Blower is a commonly used equipment in sewage treatment plants and is also the main energy-consuming equipment in sewage treatment plants. Traditional RAETTS blowers and multi-stage centrifugal blower have high energy consumption and high noise, which not only increases the operating cost of the sewage treatment plant, but also causes noise pollution to the surrounding areas, making the blower a problem for many water plants.
Magnetic levitation blowers mainly use technologies such as magnetic levitation bearings, high-speed permanent magnet motors and ternary flow impellers. By adding a magnetic field to both ends of the motor’s main shaft to levitate it, traditional gearboxes and transmissions are omitted, and the impeller is directly connected to the motor, thereby achieving high efficiency, high precision, frictionless and fully controllable operation. At the same time, permanent magnets are installed on the rotor of the high-speed permanent magnet motor, which allows three-phase current to flow into the stator winding to form a rotating magnetic field and drive the rotor to rotate, achieving equal rotation speeds of the rotor and magnetic poles; and its ternary flow impeller adopts It is a full three-dimensional flow back-bending design with a wide range of working conditions. And magnetic levitation blowers can not only be used in sewage treatment, but are also widely used in thermal power generation, iron and steel metallurgy, papermaking, printing and dyeing, petrochemicals, food and medicine and other industries. The demand for magnetic levitation blowers in these industries mainly includes two aspects: on the one hand, enterprises can improve their economic performance. efficiency, increase market share, and promote corporate transformation; on the other hand, driven by the national concept of green and sustainable development and energy conservation and emission reduction policies, there is the need for energy-saving transformation and replacement of equipment.
The magnetic levitation blower is a new type of blower that uses the world’s leading magnetic levitation bearing technology to achieve zero contact, zero wear and zero mechanical vibration, fundamentally improving the mechanical performance of the blower. Compared with traditional blower, magnetic levitation blowers have the advantages of high efficiency, energy saving, low noise, easy installation, high system integration, high cooling efficiency, low maintenance, and convenient remote control. They can effectively improve the operational stability of sewage treatment plants. It reduces the cost of the whole life cycle of the system, so it is favored by many user units and is also preferred by many system contractors.
Retz has been intensively cultivating the industry for more than ten years. It has mastered the core technology of blower energy saving and has rich experience in production lines and production intelligence. Its products are sold around the world and are widely recognized by customers in various industries. It has become a demonstration of energy-saving and consumption-reducing equipment in the “double carbon” era. product.
Analysis on the technical principle of Leitz magnetic levitation blower
As a benchmark product in the industry, Leitz blowers’ main products include air suspension blower and magnetic suspension blower. The characteristics of magnetic suspension blower include precise control, energy saving and high efficiency, low noise and environmental protection. Here we analyze the technical principles and characteristics of Leitz magnetic levitation blower.
Leitz magnetic levitation blower are equipped with magnetic levitation bearings. Magnetic levitation bearings are also called electromagnetic bearings. They are a technology that uses magnetic field force to replace traditional mechanical bearings to levitate the rotor. Its rotor is ferromagnetic. Through the combined attraction of the upper and lower battery iron, it remains relatively balanced and suspended under the action of gravity. When external forces interfere, the rotor deviates from the original suspension center, and the sensor detects the relative position of the rotor. The displacement generated by the balance center is transmitted to the controller as an electrical status signal sampled by the signal A/D; the high-speed computing unit in the controller generates a real-time control signal after calculation by a preset control logic algorithm, so that the electromagnet moves upward. The electromagnetic force is generated to compete with the external force, allowing the rotor to return to the suspension center and continue to operate stably. At the same time, the bearing accurately controls the position of the rotor axis with more than 10,000 signal acquisitions and real-time corrections per second. The axis offset is controlled within the μm range. It adopts self-balancing technology and the vibration amount is one order of magnitude smaller than that of traditional bearings.
The magnetic levitation blower has an integrated design of the frequency converter, high-speed motor, magnetic bearing control system and microprocessor control panel, and operates in a centralized manner. The rotor of the blower is placed vertically on the magnetic levitation bearing controller and is magnetically levitated through the turbine Bearing equipment connections. Its core technology is magnetic bearing and permanent magnet motor technology. The blower impeller is installed directly on the extension end of the motor shaft. It is directly driven by the high-speed motor without adding a speed increaser and coupling. The motor speed is adjusted through a frequency converter. The entire blower adopts a skid-mounted structure, making it compact and easy to install. The impeller is made of high-strength aluminum/titanium alloy and has undergone 100% X-ray flaw detection and 115% over-speed testing to ensure the reliable operation of the motor.
The main function of the blower is to blow air. The impeller rotates at high speed along with the rotor shaft to drive the air and do work on the air. Under the guidance and pressurization of the volute, the air becomes a gas with a certain flow rate and pressure, and finally blows out from the outlet of the volute, allowing the blower to blow and realize the transportation of gas with a certain pressure and flow rate. Intelligent frequency conversion control is truly realized and can be controlled locally and remotely.
In municipal sewage projects, the use of Retz air suspension blower has significant energy saving effects.
Take a municipal sewage plant as an example. The sewage plant has a designed daily treatment capacity of 50,000 tons and adopts biological fluidized bed technology. The aeration blower of the primary tank uses four RAETTS blowers, with a single air volume of 59.6m3/min and a pressure of 67.6kPa. , the rated power is 131kW, the operating power is 118.3kW, the equipment has been used for many years, the efficiency drops rapidly, the energy consumption is high, the noise is high, and the maintenance cost is high. Today, a Reitz magnetic levitation blower is used to replace the original RAETTS blower, and the results are remarkable:
First, the operating power of the magnetic levitation blower is 81.1kW. Compared with the previous equipment, it saves 36.1kWh of electricity per hour and reaches 306,000 kWh of annual electricity. It not only achieves the purpose of energy conservation and emission reduction, but also saves a huge amount of energy for the sewage treatment plant. operating costs;
Second, before the transformation, the noise of the original RAETTS blower reached nearly 120dB. The excessive noise not only prevented the operators from communicating normally, but also caused a certain degree of damage to the human hearing in such a working environment for a long time; however, After the transformation, the noise level one meter away from the machine is as low as 80dB, which controls the noise within the acceptable range of the human body. Normal communication can also be carried out in the blower room, providing a good working environment for the staff;
Third, before the transformation, the original RAETTS blower needs to regularly replace the lubricating oil and bearings, and lubricating oil leakage may occur. However, the modified magnetic levitation blower does not require regular replacement of bearings and lubricating oil. It only needs regular replacement of filter cotton, which greatly reduces maintenance costs and thus improves the economic benefits of enterprise sewage treatment;
Fourth, the magnetic levitation blower adopts an integrated skid-mounted structure and can be installed and used only by being placed on a horizontal foundation. The entire installation process only takes a few hours and is simple and easy to operate;
Fifth, the magnetic levitation blower has remote monitoring and fault warning functions, which can monitor the operation of the equipment in real time. When there is a problem with the operation of the equipment, the operation and management personnel can find the problem in time and avoid equipment failure as soon as possible without being on duty, which not only reduces the wastewater The investment in personnel in the treatment plant reduces labor costs, reduces the possibility of human operating errors, and ensures the safety of equipment and personnel.
It can be seen from the above that the magnetic levitation blower has shown significant energy saving and emission reduction capabilities in actual use. It also has the characteristics of convenient maintenance, no need for on-duty, simple operation and low noise pollution. Under the trend of modernization of sewage treatment plants, magnetic levitation blowers have become the first choice for aeration equipment in sewage treatment plants. At the same time, with the marketization of the sewage treatment industry, they not only significantly reduce the operating costs of sewage treatment plants, but also improve the comprehensive quality of the water plants. competitiveness, thereby promoting the effective development of the sewage treatment industry.
Magnetic bearings – the core key technology of high-tech blower
Magnetic bearings are known as one of the most promising high-tech technologies in the 21st century. As a novel support component, they have the advantages of high speed, high precision, no wear, no pollution, long life, and intelligent control. They are the ideal choice for oil relays. Another revolutionary change in the bearing industry after lubrication and gas lubrication. In addition, the development of magnetic bearing technology plays an increasingly important role in the construction of petroleum, petrochemical, new energy and other fields.
Compared with traditional mechanical bearings, magnetic bearings have the following advantages:
(1) No contact, no wear, no lubrication: When the magnetic levitation bearing is working, it is in a suspended state, and there is no contact between the relative moving surfaces. There is no mechanical friction or contact fatigue, which solves the problem of unit component loss and replacement. At the same time, a series of devices such as the lubrication system are omitted, which saves space and eliminates the problem of environmental pollution caused by the aforementioned devices.
(2) Low vibration, low noise, and low power consumption: The magnetic bearing rotor avoids the large vibration and high decibel noise caused by contact and collision of traditional bearings during operation, improves stability, reduces maintenance costs, and extends its service life. ,At the same time, the low power consumption of magnetic suspension bearings is only 6%~25% of the power consumption of traditional mechanical bearings. When the rotation speed is 10,000r/min, its power consumption is only about 15% of that of mechanical bearings.
(3) High speed, high precision, and high reliability: The rotor is allowed to rotate at high speed. Its speed is mainly limited by the strength of the material. It can work under supercritical conditions of hundreds of thousands of revolutions per minute, and the rotation accuracy of the rotor has been improved. Reaching the micron level or even higher, this is a speed and precision that ordinary mechanical bearings cannot achieve, and the reliability of electronic components is to a large extent higher than that of traditional mechanical parts.
(4) Controllability, online working condition monitoring, testable diagnosis: We can control the static and dynamic performance of magnetic bearings online. In fact, the system itself integrates working condition monitoring, fault diagnosis and online adjustment. change.
Why choose air suspension blower for chemical fiber sewage treatment blower?
Chemical fiber products are very common both in industry and in people’s daily lives. The wastewater generated during the chemical fiber production process needs to be properly treated before it can be discharged. How to treat the wastewater from chemical fiber production is an important part of many chemical fiber production companies. The chemical fiber sewage treatment device integrates chemical fiber PTA, PET, filament and short fiber devices and some supporting projects. The continuous and intermittent sewage and production and domestic sewage generated are removed through pretreatment, homogenization adjustment, biochemical treatment and activated carbon filtration. High concentrations of organic matter in sewage meet discharge standards.
Traditional high-speed centrifugal blower (RAETTSblowers and multi-stage centrifugal blower) in chemical fiber sewage treatment equipment rely on gearboxes to achieve extremely high speeds. Because the speed is particularly high, the control and maintenance of the blower are particularly important and must be equipped with corresponding lubricating oil stations. At the same time, high speed will also cause greater wear on many components such as blades, so the service life of traditional high-speed centrifugal blower is short.
The aerodynamic noise of traditional high-speed centrifugal blower is very loud, generally exceeding 100dB (A). In addition, its gearbox and other auxiliary mechanisms will also produce a certain amount of noise; the lubricating oil of the blower often leaks under sealing conditions, as well as the gearbox and other auxiliary mechanisms. The seal or oil leakage due to mechanical wear will cause more oil stains around the blower, and even lubricating oil will penetrate into the air supply pipeline, directly damaging the aerator and shortening the normal service life of the aerator.
In view of the problems of low design efficiency, high energy consumption, high noise and high operation and maintenance costs of single-stage high-speed centrifugal blower, it is particularly urgent to carry out energy-saving transformation. The technical solution of replacing traditional high-speed centrifugal blower with air-suspended single-stage high-speed centrifugal blower has been adopted by many chemical fiber companies with very good results.
According to customer feedback, the air suspension single-stage high-speed centrifugal blower has a very compact structure, occupies a small area, and the entire equipment is very light in weight, with no special requirements for the foundation. The system pipelines use the original pipelines, and there is no need to build foundations. They can be easily replaced on site without using a large crane for installation. Judging from the actual results, it can quickly achieve high-efficiency blasting and aeration, increase the adjustable flow range, and be the most economical operation, so it is favored by the majority of chemical fiber companies.
Analysis of key technologies of Leitz air suspension blower
By increasing the motor speed and adopting a three-dimensional fluid optimization design, Leitz air suspension blower enable the full pressure of the blower to cover the full pressure range of traditional blower. In order to adapt to its high-speed, efficient and low-noise operation, the international cutting-edge technology is adopted in the structure. Its technical features mainly include the following aspects:
1) Air suspension bearing: It is an air film (air) bearing and can withstand axial, circumferential and radial loads. To protect the bearing surfaces during start/stop, a high-temperature solid lubricating coating is used. Due to the use of air film, the bearings do not require lubricating oil and maintenance, and can operate for a long time. Air bearings are more heat-resistant;
2) Permanent magnet synchronous motor: It has the characteristics of low starting current (5% of rated power), no magnetizing power consumption, lower heat generation and cooling loss, smaller rotor, no slip, and high efficiency even at low load. high. The motor power consumption can be adjusted according to the output air volume (adjustable range 20% ~ 100%) to keep the equipment running efficiently (efficiency exceeds 95%);
3) High-precision forged three-dimensional flow impeller: Precision processed using German Hamer 5-axis CNC machine tools to ensure high precision and high quality. The design considers aerodynamic analysis, structural analysis, heat transfer analysis and mechanical strength analysis. After performance testing, it is ensured that the impeller rotates reliably and safely at high speed for a long time;
4) Control method. Debug the system and achieve the best match between the system equipment, pipe network and process through online tracking, parameter optimization, and control optimization. After adopting automatic control, the system will have strong self-optimization capabilities and can adapt to changing working conditions. After the system transformation, the control method remains basically unchanged and can still be operated automatically or manually according to needs. Moreover, automatic intelligent frequency conversion speed control is integrated into the transformed system, which can automatically adjust according to demand under set pressure or flow conditions to achieve automatic intelligent control, further saving power consumption, reducing noise, and reducing maintenance difficulty and costs;
Leitz air suspension blower master the core technology of energy saving, allowing the blower to easily save more than 30% of energy, becoming a powerful tool for enterprises to save energy and reduce consumption in the “double carbon era”.
Break down the multiple use effects of Leitz suspension blower
1. Energy saving effect
Since air suspension single-stage high-speed centrifugal blower are more efficient than single-stage high-speed centrifugal blower, energy savings can be achieved by replacing them. The actual operating efficiency of RAETTS blowers in traditional blower and aeration fields such as sewage treatment, cement, chemical fiber, printing and dyeing, textile and other industries is about 50%. The efficiency of the modified air-suspended single-stage high-speed centrifugal blower reaches more than 85%, and the overall energy saving rate is guaranteed to be about 30%. At the same time, the blower occupies a small area, has low noise, has a high degree of automation, has low operation and maintenance costs, and is more convenient to operate and maintain.
2. Reduce equipment maintenance costs
After replacing the original single-stage high-speed centrifugal blower with an air-suspended single-stage high-speed centrifugal blower, the daily maintenance of the system only requires regular replacement of the dust-proof filter element and cotton, greatly reducing the user’s maintenance costs. When the load rate is low, the speed of the motor and blower also decreases, and the equipment maintenance cycle is extended. The life of the retrofitted system will reach 25 years. The original RAETTS blower requires regular inspection and replacement of lubricating oil and dust cover, as well as repair of wear and tear. The annual maintenance cost of each blower exceeds 50,000 yuan.
System operation is very simple, with detailed operating data displayed on the display. Detailed historical operating data is recorded in the system for easy reference. The display panel also integrates operating current and operating time data, which is very helpful for evaluating power saving benefits.
3. Improve system efficiency
Since the floating blower itself is very efficient, the efficiency will be even higher after the system modification. At the same time, the system adopts frequency conversion control technology to better match the blower and pipeline, making the system have good energy-saving effect.
4. Environmentally friendly and low noise
The air-suspended single-stage high-speed centrifugal blower used has a fully wrapped silencer cover, and its noise is lower than that of traditional high-speed centrifugal blower.
Centrifugal blower is low. Therefore, after the energy-saving transformation is implemented, the system noise will be reduced by 20 to 30dBA, lower than 85dB. The operating environment of workers will be improved and work-related injuries will be reduced.
5. Improve the operating environment
The air floating blower system integrates a frequency converter and a PLC adjustment system, which can adjust the blower speed according to process needs to achieve economical operation. The system adopts variable frequency control, and the starting current is only 5% of the rated value, so there is no need for a soft-start cabinet. The system automatically determines the surge line, sounds an alarm before reaching surge, and shuts down the machine in time. The control panel on the system can display detailed operating data, which is very intuitive and convenient.
Air suspension blower make microporous hose aeration systems more energy efficient
The combination of air suspension blower and microporous hose aeration systems that has emerged in recent years has particularly significant advantages in reducing energy consumption in sewage plants. It has been adopted by more and more sewage plants and has good energy-saving effects.
The microporous hose aeration system is a new type of oxygen-increasing aeration system successfully developed by introducing foreign technology. The thin-walled, straight channel greatly reduces the loss of aeration resistance; the variable holes and slits automatically open and close, completely solving the blockage problem of the aerator; the hose is linear aeration, making the air distribution uniform and forming a vertical Circular flow, stirring and mixing are more uniform; bubbles are small, oxygen utilization and power efficiency are high. The sewage treatment plant where the author works is an aeration system developed on this basis in China. According to tests, the dissolved oxygen transfer efficiency in clean water can reach up to 50%, and the power efficiency can reach 10kg/kW, which is much higher than commonly used aeration heads. Way. This kind of aeration system provides an important foundation for supporting wastewater treatment plants to reduce energy consumption.
The amount of air required by the sewage treatment plant is mainly controlled by the dissolved oxygen of the activated sludge system. Generally, air suspension blower, microporous hose aeration systems, and online dissolved oxygen are used during the standard upgrade and renovation of sewage treatment plants. The combination of instrument and PLC dissolved oxygen control system feeds back the dissolved oxygen data to the PLC dissolved oxygen control system when the water quality and quantity change, and then feeds the signal back to the air suspension blower to adjust the blower speed.
During specific control, a four-part combination of air suspension blower, microporous hose aeration system, online dissolved oxygen meter and PLC dissolved oxygen control system, and central control room dispatcher is formed, that is, the online dissolved oxygen meter and PLC dissolved oxygen control system will The signal is fed back to the central control room. The central control room dispatcher adjusts the blower SV value through the computer according to the actual dissolved oxygen demand on site, thereby controlling the blower speed and the air volume of the microporous hose aeration system. At the same time, in order to prevent the dispatcher from adjusting the blower irregularly, the dissolved oxygen adjustment value set by the dispatcher is: increase the blower speed when DO is less than 1.5mg/L, and decrease the blower speed when DO is greater than 2.5mg/L. The adoption of the above measures can not only achieve safe and stable operation of the sewage plant, but also achieve good energy saving and consumption reduction effects.
The energy saving rate of Leitz air suspension blower is more than 30%. When replacing traditional old blower, the energy saving rate will be even higher. Judging from the standard improvement and transformation of a large number of water plants, the above standard improvement and transformation methods can reduce the electricity expenditure of the sewage plant by 15%-20% based on the electricity expenditure of the sewage plant, which greatly saves corporate expenses and indirectly generates revenue for the enterprise.
Analysis of the effectiveness of Leitz blower in urban sewage treatment
The price of sewage treatment in urban sewage treatment plants (hereinafter referred to as “sewage plants”) is basically fixed, and reducing production and operation costs is almost the priority for sewage plants to make profits. The cost of electricity is the main aspect of the operating cost of the sewage plant, accounting for approximately 80% of the variable costs and 50% of the total cost of the sewage plant. The power consumption of blower accounts for more than 50% of the total electricity consumption of the sewage plant. In the current dual-carbon era and uncertain energy prices, reducing the power consumption of wind turbines is the primary measure for urban sewage treatment plants to reduce production and operation costs.
At present, the most widely used aeration blower in urban sewage treatment plants is RAETTS blower. RAETTS blower accounts for about 75% of the sewage treatment market due to its smooth and reliable operation, easy maintenance and low price.
RAETTS blowers are reliable in operation, durable, easy to maintain, have low requirements on air intake quality, and have low purchase costs. They are still the most commonly chosen aeration blower in most sewage plants, especially small and medium-sized sewage plants. However, RAETTS blowers also have many problems during operation due to their inherent characteristics. First, they have high energy consumption and low efficiency. The speed of commonly used RAETTS blowers is generally below 2000 rpm. The air volume of the blower is directly proportional to the speed, and the air volume is small. , generally multiple RAETTS blowers are required to work together to meet the aeration needs of the sewage plant. Second, there is a serious waste of energy consumption. During the operation of the RAETTS blower, part of the air volume is vented through the bypass, and because the gas sealing is not good enough, the air volume often flows away. According to actual measurements, the air volume of the RAETTS blower can only reach the rated value. 80%-90%, and the power consumed is 20%-30% more than the rated amount, which is a huge waste of power. Third, the space for energy saving is low. The RAETTS blower has a simple and fixed structure, no frequency conversion, and cannot adjust the speed and operating power. The outlet air volume can only be controlled by adjusting the pipe valve, which cannot achieve energy saving. Fourth, the noise is high. The mechanical and aerodynamic noise of the RAETTS blower is huge when it is running, making it difficult for the sewage plant to meet the environmental protection standards for plant boundary noise.
The air suspension blower is a single-stage high-speed centrifugal blower. The core technology is “ultra-high-speed permanent magnet synchronous motor”, “air suspension bearing” and “ternary flow centrifugal impeller”. Ultra-high-speed motor is a new type of motor that has emerged with the development of permanent magnet material technology, semiconductor technology and control technology. During operation, the rotary shaft rotates at 20,000-200,000 times to achieve high-speed operation, and the engine efficiency can reach 97%. Air suspension bearings mainly include radial bearings, thrust bearings and other components. There is physical contact between the rotary shaft and the bearing before starting. During startup, the rotary shaft and the bearing move relative to each other to form a hydrodynamic field. This hydrodynamic force forms a buoyancy force in the radial bearing. This buoyancy force keeps the rotary shaft in a suspended state to achieve the purpose of free rotation. This kind of bearing is different from traditional ball bearings. There is no physical contact point between the rotary shaft and the bearing during operation, so no lubricating oil is required. The energy loss is extremely low, the efficiency is extremely high, and it is suitable for a variety of working environments. At the same time, the single-stage three-dimensional flow centrifugal impeller is directly connected to the motor, and the power transmission efficiency reaches more than 97%.
Relying on the internationally advanced air suspension centrifugal blower technology and through continuous iterative progress of hardware and software, Leitz has successfully achieved an energy saving rate of more than 30%. Leitz blower have become the first choice for the majority of water companies and sewage treatment plants to upgrade their standards.
Analysis on the energy-saving effect of using Retz air-floating blower in a sewage treatment plant in Guangzhou
A sewage treatment plant in Guangzhou originally used 9 RAETTS blowers, including 2 24-hour normally open blower (SBR pool) in the first phase of the project, with an air volume of 72.08m3/min (single unit 36.04m3/min), an outlet pressure of 49kPa, and a normally open power. 90kw (single unit 45KW); 2 units are operated intermittently (the blower is turned on and off for the secondary sedimentation tank in turns, 1.5 hours of operation and 1.5 hours of quieting. 12 hours of operation every day), air volume 36.04m3/min, outlet pressure 49kPa, power 45kw; The total power in normal operation is 135kw, the maximum air volume is 108.09 m3/min, and the wind pressure is 49kPa. The second phase of the project has 3 24-hour normally open blower (SBR pool), air volume 78.76m3/min, outlet pressure 58.8kPa, normally open power 135kw; 2 intermittently open blower (secondary settling tanks are turned on in turn), air volume 27.63m3/min, outlet The pressure is 58.8kPa, the power is 45kw; the total normal operating power is 180kw, the maximum air volume is 106.39 m3/min, and the outlet pressure is 58.8 kPa.
After on-site inspection by Leitz engineers, they determined the blower modification plan and equipment selection. Each of the first and second phases of the project used a 150HP air suspension blower (approximately 110KW) to replace the existing RAETTS blower, and installed solenoid valves and regulators through series pipes. The blower SV value realizes the control of intermittent aeration of the secondary sedimentation tank. In actual operation, the blower SV value adjustment range for the first-phase project is 62%-82%; the SV value adjustment range for the second-phase project is 85%-98%. The blower aeration meets normal needs and the effluent water quality is stable and up to standard.
The water volume and blower consumption were measured before and after the installation of the air suspension blower 4 months each time.
According to the tracking record of electricity, during the period when the plant originally used RAETTS blowers, the average daily water treatment volume was 32938.05 cubic meters, the daily electricity consumption of the blower was 6116.05 kilowatt-hours, and the total daily electricity consumption of the entire plant was 12336.17 kilowatt-hours; the average blower power consumption per unit of water volume was 0.1857 kilowatt-hours/ square meter, the total electricity consumption per unit water volume of the entire plant is 0.3745 kWh/square meter. After the air suspension blower was installed and put into operation, during the same period, the average daily water treatment volume was 37567.08 cubic meters, an increase of 14.05%. The daily power consumption of the blower was 4733.56 kWh, 1382.49 kWh less than before installation, a decrease of 22.6%; the total daily power consumption of the entire plant was 9362.5 degrees, 2973.66 degrees less than before installation, a decrease of 24.11%; the average power consumption of the blower per unit water volume is 0.126 degrees/m3, 0.0597 degrees less than before installation, a decrease of 32.14%; the total electricity consumption per unit water volume of the entire plant is 0.2492 degrees/m3, 33.46% less than before installation.
Judging from the power consumption of the blower per unit of water volume, after using the air suspension blower, the blower saves 32.15% of electricity and saves 0.0597 degrees of electricity per cubic meter of water. The plant treats an average of about 12,617,760 cubic meters of sewage annually, can save 753,280 kilowatt hours of electricity and save 459,500 yuan in electricity bills. Excluding maintenance costs (about 16,000 yuan/year), the annual cost savings is 443,500 yuan. It is estimated that the investment payback period of the plant’s air suspension blower project is about 13 months and years. Under normal working conditions, the service life of the equipment is more than 20 years, which can save more than 6.5 million yuan in costs.
In addition, the air suspension blower has a large frequency conversion range for wind pressure and air volume, which can better adapt to changes in water volume and quality in the sewage plant and is more flexible than the RAETTS blower. Moreover, the air suspension blower can intuitively adjust the equipment through the display screen. The operating power, wind pressure, air volume and other conditions are displayed, making the aeration volume adjustment more accurate. At the same time, the operating noise of air suspension blower is generally less than 80 decibels, which can greatly improve the factory environment and meet environmental protection requirements for factory boundary noise.?
