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CII Green Cementech 2010
Energy Efficient Turbo Blowers Energy Efficient Turbo Blowers
for Cement Industry for Cement Industry
Green Cementech 2010
Let Lets make Indian Cement Plants s make Indian Cement Plants
World Class in Green! World Class in Green!
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Types of Air Blowers Types of Air Blowers
Positive Displacement type
Twin Lobe, Tri Lobe blowers (Roots blowers) with belt driven
induction motors
Applications: For constant flow& variable pressure
Flow rate: From 5m
3
/hr to 57,117m
3
/hr
Pressure: Up to 0.2 kg/cm
2
with single stage & up to 1. 8 kg/cm
2
with double stage
Vacuum: Up to 0.5kg/cm
2
Centrifugal (Turbo) type
With belt driven or direct driven induction motors
Application: conventional Centrif ugals provide variable f low&
constant pressure
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Conventional Positive Displacement type, Conventional Positive Displacement type,
Twin Lobe Air Blower Twin Lobe Air Blower
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Centrif ugal Blowers: Practically there is thin line
differentiating Centrifugal Fans & Centrifugal Blowers
K TurboBlowers arevery different fromconventional centrifugal /
turbo blowersas their performancecurveiscontrolled & adjustable
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(Twin Lobe Positive Displacement)
Improving Energy Efficiency Improving Energy Efficiency
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Turbo Blowers from K Turbo Inc., S. Korea
2
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Core Components & Salient Features
Permanent Magnet Motor: a) Power required only to rotate & not
for magnetizing of rotor; b) Can be started & stopped any number
of times; c) High Eff iciency even at part load
No Gear Box: No transmission loss due to direct drive & no
lubrication required.
Variable Speed Drive for achieving high speed, smooth starts
(reduced starting current) & energy eff icient capacity control as
part of the Blower package.
Air Foil bearing for high speed operation (used in J et engines)
Oil Free air
LowNoise: 80 dB against 100 dB of PD blowers
Entire range is air-cooled & no need of water for cooling.
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Comparison with PD blowers Comparison with PD blowers
Below80 dB 95-110 dB Noise Level
Smaller Large Foot Print
Semi-
permanent
5 Years Life
Air Filters Overhaul Maintenance
Below5% 250% Starting Current compared 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+Invertor)
77% 55% Aero Efficiency
KTurbo
Blower
PD Blower Parameter
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APPLICATIONS OF KTURBO BLOWERS APPLICATIONS OF KTURBO BLOWERS
Air (gas) conveying of powder (Cement factory,
Chemical factor y, Food & Beverage factory, Power
station etc.)
Aeration for water treatment (municipal sewage
disposal plant, water treatment systems in factories
etc.)
Agriculture and food processing (drying, processing,
conveying etc.)
Biotechnology (Oil free air supply)
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Sample Case Studies of Energy Saving Achieved
Application With RootsBl ower With K Turbo Blow er Since Saving
Nisshinbo
(textil e)
I ndustrial
WWT
75HP: 2 uni ts, 100HP: 1
unit
(5000mmAq, 144m3/ min)
185kW
75HP: 2 uni ts
(6000mmAq, 102m3/ min)
112kW
4Years 40%
POSCO
(steel)
Process Ai r
(Revers e
Washing)
75.7 kW
118dB
43.5 kW
80dB
4Years 42.5%
Sungshin
Cement
Material
Handling
150HP: 2 units
(4300mmAq, 37. 5*2=75m
3/ min) 125.6kW
150HP: 1 unit
(4300mmAq, 93m3/ min)
78.0kW
4Years 38%
Lafarge
Hall a
(cement)
Material
Handling
150HP: 1 unit
(4700mmAq, 35m3/ min)
62.4 kW
75HP: 1 uni t
(4700mmAq, 35m3/ min)
40.5kW
5Years 35%
DAESANG
(food)
I ndustrial
WWT
75HP: 3units
200HP: 1uni t
(4500mmAq, 204m3/ min)
319kW
75HP: 4 uni ts
(4500mmAq, 204m3/ min)
204kW
6Years 35%
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Case Studies of Applications in Cement Industries:
1. Air Lift Blower
2. Conveying Blower for coal
3. Aeration Blower for silo
4. Conveying Blower for alternated fuel
5. Main burner Blower for air injection
Results of Installation
Pictures of installation
I nstallations at Cement industries
I nstallations at Cement industries
3
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PD Blower & KTurbo Blower
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1-1. Air Lift blower
1-1. 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 / min
4. 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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1-2. Air Lift blower
1-2. Air Lift blower
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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1-3. Air Lift blower
1-3. Air Lift blower
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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2. Conveying blower for coal
2. Conveying blower for coal
1. Application: Conveying coal forfi ring
2. Using pressure : 0.1bar ~1.5bar
3. Using ai rfl owdelivery : 15 / min ~100 / min
4. ApplicationArea:
L afarge-Halla cementI nc, Kiln#1,2,3,4 F or dosed Coal (TB75- 0.6S*6s et, TB100- 0.8S*1set)
(Using from late 2003) Coal Mill#2,3,4F or Coal (TB75-0.6S*1set, TB150-1. 5S* 2set)
Kiln#4F or Coal (TB150- 1.5S*1set)
Sung-Shinc ement I nc, Coal Mill#3,4 : For Coal (TB75- 1.5S*2s et), Kiln#5 1,2s tep : F or Coal
(TB150- 0.8S*2set)
(Using from late 2004) Kil n#6 Main Burner : For Coal (TB150-0.8S*2set)
Others : Ss ang-Yong cement, Hyun-Dai cement, Han-I l cement usinglikeupperdata
Conveying blower for milled coal, Dosed coal and Main Coal
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3. Aeration blower for Silo
3. 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)
2. Using pressure : 0.7bar ~ 1.5bar
3. Using air flow delivery : 15 / min ~ 50 / min
4. Application Area :
Lafarge-Hallacement Inc, Cement Silo#1 Aeration & transportation
(TB50-0.6S*2set, TB150-0.8SP*1set)
Sung-Shin cement Inc, Cement Silo#8 Aeration (TB200-0.72SP*3set)
4
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4. Conveying Blower for alt. fuel
4. Conveying Blower for alt. fuel
Conveying alternativefuel toki ln
1. Application : Conveying alternative fuel to Kiln
2. Using pressure : 0.7bar ~ 1.5bar
3. Using air flow delivery : 50 / min~150 / min
4. Application area :
Sung-Shin 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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5. Main Bur ner Blower for air injection
5. Main Bur ner Blower for air injection
1. Application : Compressed air for combustion
2. Using pressure : 0.1bar ~ 0.5bar
3. Using air flow delivery : 70 / min~200 / min
4. Application area :
Lafarge-HallaInc, Kiln#2,3 Main Burner (TB75-0.6S*set, TB150-0.8S*2 set)
(Using from late 2003)
Ssang-Yong cement Inc, Kiln#3 Main Burner (TB75-0.6SP*1set, TB200-0.72SP
*2set)
Kiln#7 Main Burner (TB100- 0.6SP*1set) (Using from late
2004)
I njecting compressed air tomain 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: Semen Gresik Semen Gresik Cement, Cement, Indonesia Indonesia
Application: 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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6-1. Results of installations
6-1. Results of installations
Energy cost saving
(1 year):
USD13,000
Reduce Noise:
over 15 dB
Reduce vibration:
Over 19mm/s
Energy cost (per year)
Total: about USD22,000
Cal) 40kW * 330day *
24hour/day * 0.07USD/day
= USD 22,176
Noise level : under 80dB
Vibration: under 1mm/s
Energy cost (per year)
Total: about USD35,000
Cal) 63kW * 330day *
24hour/day * 0.07USD/day
= USD34,927
Noise level : Over 95dB
Vibration: over 20mm/s
Details of
Energy
saving
/
Noise &
Vibration
Energy save: 35%
Equipments:
KTurbo Blower: 75HP * 1set
Operatingdata
Dis. pressure: 0.47 bar
Delivery: 35m3/min
Power consumption: 40kW
Equipments:
Roots Blower: 150HP * 1set
Operatingdata
Dis. pressure: 0.47 bar
Delivery: 35m3/min
Power consumption: 63kW
Measured
Results
REMARKS
AFTER
(at same conditions)
BEFORE
Ex:Lafarge-Hallacement I nc, (Mode: Constant Volumetric Flow)
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6-2. Results of installations
6-2. Results of installations
Energy cost
saving (1year):
USD27,000
Reduce Noise:
Over 15 dB
Reduce
vibration:
Over 19mm/s
Energy cost (per year)
Total: about USD43,000
Cal) 78kW * 330day *
24hour/day * 0.07USD/kWh
= USD 43,243
Noise level : under 80dB
Vibration: under 1mm/s
Energy cost (per year)
Total: about USD70,000
Cal) 126kW* 330day *
24hour/day * 0.07USD/kWh
= USD69,854
Noise level: Over 95dB
Vibration: over 20 mm/s
Details
about
Energy
saving
/
Noise &
Vibration
Energy save:
48kW (39%)
&Conveying
more material
Equipments:
KTurbo Blower: 150HP *
1set
Operatingdata
Dis. pressure: 0.43bar
Delivery: 93m3/min
Power consumption: 78kW
Equipments:
Roots Blower: 150HP * 2set
Operatingdata
Dis. pressure: 0.43 bar
Delivery: 75m3/min
Power consumption: 126kW
Measured
Results
REMARKS
AFTER
(more difficult condition)
BEFORE
Ex:Sung-Shincement I nc, (Mode:Constant VolumetricFlow)
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K Turbo Blowers installations in Cement I ndustry
5
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I nstallation (Cement Factory)
Hanil Cement
Hyundai Cement
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I nstallation (Cement Factory)
Lafarge HallaCement
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27
KTurbo: The Ultimate Rotating Machine
Construction of K Turbo Blowers Construction of K Turbo Blowers
Variable Speed
+
Direct Drive ( No Gear Box)
+
No Bear ing Lubricat ion
Oil-fr ee Tur bo Air Blower
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I nverter Power I n
Controls
I ntake
Silencer
BOV
Silencer
Construction of Single & Twin Turbo Blowers
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29
PM Motor & Impellers
2 Polepermanent magnet
(SmCo) with high strength
retaining ring
High performance
electriccore H ClassI nsulation
winding
Radial airfoil
bearing
Radial airfoil
bearing Thrust disk&
Thrust bearing
Stainlesssteel
casted I mpeller
Scroll
I ntake
Discharge
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30
Why KTurbo ?
1) Fully Optimized Aero/Motor/ Inverter component
Optimum specific speed selection
Long life time inverter, stable operation
Long life / life time air-foil bearing
2) Best Efficiency, Many References
3) Small Foot Print & LowNoise
4) Stainless Steel Cast Impeller
5) Oil-free Blower / Compressor
6) No effect of power supply frequency variation
Continued
6
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7) Starting current =Full Load current (good for DG Sets)
8) Built-in Flow- meter
9) Most Advanced Surge Detection Device
Instant flowrate measurement / flowinstability
monitoring.
10) Full line up
25-600hp (air cooled)
Why KTurbo ?
Continued
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Core Technologies
(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 ORcircumferential compliance characteristics
The third generation
Foil support in axial, circumferential ANDradial direction
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The workingprincipl e of foil bearingis same as hydrodynamic oil bearing like a tiltingpad
oil bearingwhich is used for classical gear increasinghigh speedmachines.
Because foil bearing use surroundingair insteadof oil to support shaft, it needs larger
diameter andlengthand special damping mechanism.
To provide maximumsupport force, foil bearing adoptsentire bearingsurface and spring
backup. Bearingsurface configurationand springcharacteristics define bearing behavior.
During start/stop, direct contact betweenshaft andbearing surface occurs. To protect
bearing surface during start/stop, dry lubricant coating isappliedonthe bearingsurface and
30,000time on/off isavailable.
Principlesof Hydrodynami c Pressure
Generation
Hydrodynamic Pressure Generation
Principles of Foil Bearings
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History of Foil Bearings
SimpleBump SimpleBump
Reversed Multi Reversed Multi--Layer Layer
Multi Multi--Leaf Leaf
Multi Multi--Pad Bump Pad Bump
Third Generation Bump Third Generation Bump
(KTurbo) (KTurbo)
Radial variation Radial variation
Circumferential Circumferential
variation variation
Axial split/variation Axial split/variation
MiTi MiTi havemade major r esearch havemade major r esearch
KTurbohas> 1000 unitsexperi ences KTurbohas> 1000 unitsexperi ences
Teflon Teflon--SS
MoS2 MoS2
High Temp Solid High Temp Solid
Lubricant Lubricant
--PS304 ; NASA PS304 ; NASA
--KOROLON1350F ; KOROLON1350F ; MiTi MiTi
High Capacity, High Speed, High Damping, High Temperature
High Capacity, High Speed, High Damping, High Temperature
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Life time KTurbo air f oil bearings
K Turbo foil bearings were proved through
6 years operation (over 1300 units)
On 400hp 60kg & 600hp rotor system
extreme machines of 2 stage 7 bar compressor.
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Comparison of bearings
50 100 50 A/S COST
Complexity (Pump, Filter,
Reduce pressure system,
pressure sensor, etc.)
Complexity (Pump, Filter,
Reduce pressure system,
pressure sensor, etc.)
Simple System
1 5 20 Reliability
Change bearingevery3
years
Check by 5years No Maintenance
Change bearingevery3
years
Semi-permanent Semi-permanent Life Span
Used Used Not used Lubricationoil
Ball Bearing Tilting PadBearing Air Foil Bearing Classification
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)
Highefficiency (> 95%)
Sensor-lessI nverters
Cost-effective
Highefficiency (> 97%)
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Why PM motor ?
No magnetizing power is necessary
Lower heat generation means less cooling loss.
Smaller rotor means less friction loss
No slip means high efficiencyeven at part load condition.
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Efficiency of PM motor &I nduction Motor
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Induction Motors Induction Motors v/ s v/ s PM Motor PM Motor
Very high: 9598% Medium: 8894% High: 8597%
Electric
Efficiency
Medium: 7585%
15%- 20%
High
Very Low: 0.65
High Speed
Induction
Very high: 95-97% High: 8895% Total Efficiency
1%-3% 2-3% Cooling Loss
Low Normal
Rotor
Temperature
Low: 0.8
Low Speed
Induction
High: 0.9 Power Factor
PM Classification
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41
1. 1. Stainless Steel Stainless Steel
SUS630, 17 SUS630, 17--4PH 4PH
2. 2. Optimum Specific Speed Optimum Specific Speed
Maximumefficiency Maximumefficiency
3. 3. Optimum back sweep angle Optimum back sweep angle
Maximumefficiency Maximumefficiency
High Rise to surge High Rise to surge
Wide operatingrange Wide operatingrange
4. 4. Splitter Blade Splitter Blade
Larger flow capacity Larger flow capacity
Higher efficiency Higher efficiency
5. 5. Leaning Leaning
Higher structural strength Higher structural strength
(3) Features of KTurbo Impeller
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42
(4) Built-in Flow Meter
Bell mouth is much more
accurate than Orifice,
because it needs only
one sensor.
] 99 . 0 min, / m Pa, sec, K, [m, 1
1
2 60
3
1
/ 1

1
1
]
1

,
_

,
_

,
_

d
k
k
k
d C
P
p P
k
k
T R
P
p P
A c Q
8
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DischargeDuct
Blow-off Valve
Silencer
Blower core
I nverter
Dischargepressure: P
DischargeTemp : T2
Suction Flow ratedP :dP3
Suction Temp :T1
Filter PressureDrop :dP1
Air Flow measuring
Airin
Airout
I mpeller
I nletReducer
T1 dP3 [ Differential pressure]
+ -
< Air Flow calculation, Q>
Q Q (T1, Po, dP3)
Measurement System
Control
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(5) LOAD/ UNLOAD
NoAir From
BOV
Discharge
LOAD
Air From
BOV
NoDischarge
UNLOAD
* BOV closed
* Normal
operation
(high rpm)
* BOV open
* Standbywith idling
(low rpm)
* ~ 1 kWpower level
BOV BOV
Toggle by
manual/ remote/ MCP
Responsetime
From LOAD toUNLOAD : ~10 sec
From UNLOAD to full LOAD :~30 sec
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45
Response to pressure change
Current Set inner loop
Stable i nitial response
Speed Set I nner loop
Unstableinitial response
SurgeOccurs
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Performance curves of turboblowers
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(6) HMI with touch screen
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48
HMI: Main Screen
9
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HMI: Operating Curves display
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CF memoryis applied
Dataloggingevery1sec, 1min, 1hour
All eventrecording
HMI: Data Logged every second
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CFmemory i s ap plied
Data logging every 1 sec, 1 min, 1hour
All event recording
HMI: Event Logged every second
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CF memoryis applied
Dataloggingevery1sec, 1min, 1hour
All eventrecording
HMI: On-line trend display
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53
CCR
(Central Control Room)
SCADAorDCSorPLC
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-2 Anchor bolting case-1 Concretepad
10
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Leveling
Up &down of foot
(for easyleveling of
themachine)
Leveling check-2
Leveling check-1
Sometimesneed shims
duetopoor level ing of
surface
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Discharge side components
arrangement order
Check valve flexibl e silencer stopval ve
safety valve (whenapplicable) .
Need suitable pipe supporter prior
to free from the piping systems
and/ or plant unexpected vibration
influence to the machine.
Inspect the check valve flow
direction mark on it
After discharge check valve, the
pipe should be go straight
minimum three diameter of the
pipe. (important)
Piping-discharge
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Air Filters
Pre
85%@10
4-8 weeks
Final
99%@10 or 68%@2
5-12months
P 21-44mmWTR
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References: J une 2009
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Clients
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Clients
11
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KTurbo Direct driven Turbo Blowers&Compressors
Energys aving
(over 35%)
Energys aving
(over 35%)
- ROI :under 1.5 years
- I mportant for Carbon
CreditsBusiness
- ROI :under 1.5 years
- I mportant for Carbon
CreditsBusiness
Lownoise& N o
vibration
Small & Light
Lownoise& N o
vibration
Small & Light
- I mproveenvironment at sites
- Reduceinstallation cost
- Reduceproduct cost
- I mproveenvironment at sites
- Reduceinstallation cost
- Reduceproduct cost
Nooil i nsystem
Nooil i nsystem
- I mproveenvironment at sites
- NOneed of lubrication Oil
- 100% Oil-freeAir
- I mproveenvironment at sites
- NOneed of lubrication Oil
- 100% Oil-freeAir
Benefits with K Turbo
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Thank You! Thank You!
Godrej & Boyce Mfg Co Ltd
Compressed Air Solutions
Godrej | Electrical & Electronics
Pirojshanagar, Vikhroli, Mumbai 400079. I ndia
Tel.: +91- 22- 67962251 to 2255
Fax: +91-22-67961410 / 67961525
E-mails: kcp@godrej.com; jayraj@godrej.com; roshe@godrej.com;
www.godrej-airsolutions.com
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