Plant & Works Engineering September 2022 Issue

A eration systems are among the biggest energy consumers in a wastewater treatment facility and they can be a maintenance challenge too. To keep costs under control, plant operators have a choice of designs to upgrade to blowers that run efficiently and reliably under all expected operating conditions. Modern diffused aeration systems have transformed the design of wastewater treatment facilities. Capable of operating in deep tanks, these systems allow operators to process more water in less space. They can run for multiple years with minimal maintenance, and, with the right control systems, they can manage the highly variable demand experienced by many municipal and larger industrial sites. To deliver these benefits, every system requires a reliable, efficient supply of air. The blower systems used to supply the air occupy a niche place in the spectrum of industrial and commercial air handling equipment. They operate at higher pressures than the fans used in HVAC applications but must deliver larger volumes of air than typical industrial compressors. At the same time, in order not to risk breaching regulations and permit requirements they need to offer high levels of availability. They need to work efficiently while also being quiet and easy to control. Volumetric blowers Some blower designs operate using volumetric principles. Air is drawn into a chamber which is then reduced in size, squeezing the air to boost its pressure before releasing into the outlet pipework. Rotary lobe blowers, also known as Roots blowers, achieve this with two interlocking rotors that spin in opposite directions. Roots blower technology was introduced in the 1800s. It remains largely unchanged to this day and is still widely used in wastewater applications, especially in Europe. These blowers are simple, reliable and require little maintenance. Their efficiency is limited by not having a reducing chamber built-in, but rather pushing the air into the discharge. In addition, as all volumetric designs’ efficiency is held back by the need for small gaps between the parts, some air will escape back into the inlet, some of it will leak to the outside through seals and some of the already pressurised air may leak to a less pressurized part. The design also produces pulses of air, making these blowers noisy in operation and creating vibration in the discharge pipework and its components. Another volumetric compression approach that has become popular in recent years is the rotary screw blower. This uses interlocking male and female helical rotors that rotate to decrease the available volume between them. At the start of the compression cycle, the inlet air fills the flute space and becomes trapped. The air is then continually compressed as the male and female components rotate with each revolution until the air is pushed through the discharge outlet. Compared with traditional lobe blowers, the way air is internally compressed in rotary screw blowers reduces energy consumption by 30%. Screw blower noise levels are typically lower than conventional tri-lobe Roots blowers. The pipework noise is somewhat reduced because the output is continual rather than pulsed. Kinetic blowers Compression can also be achieved by changing the velocity of the air rather than its volume. Centrifugal blowers do this using a rapidly spinning impeller. Air is drawn in close to the centre of the impeller, turned through 90 degrees and accelerated as it is thrown outwards by the rotating blades. Multi-stage centrifugal blowers, commonly used in U.S. wastewater treatment plants, mount several impellers on the same shaft, with air moving from one to the other, increasing its pressure as it goes. The output of a single stage centrifugal blower depends upon the size of the impellers and their rotational speed. To avoid large, heavy, and expensive impellers, this type of blower often includes a gearbox to speed up the rotation of the motor. That has downsides, however, including friction losses, a larger number of wearing parts and the need for additional maintenance and overhauls. An alternative to mechanical gearboxes is the use of a variable frequency drive (VFD) and a high-speed motor to run a small impeller at very high rotational speeds. “Turbo blower” designs, such as Sulzer’s HST, are mechanically optimised and highly efficient, with a design that utilises specialized bearings to cope with the elevated speeds. The magnetic bearings used in Sulzer HST turbo blowers ensure there is no metal-to-metal contact between the shaft and the Process, Controls & Plant Focus on: Compressed Air More than blowing bubbles 24 | Plant & Works Engineering www.pwemag.co.uk Septembe r 2022 PWE looks at different blower technologies and how to improve the reliability and efficiency of legacy plants.