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Energy Efficient Turbo Blowers

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  1 www.kturbo.com CII Green Cementech 2010 Energy Efficient Turbo BlowersEnergy Efficient Turbo Blowersfor Cement Industryfor Cement Industry Green Cementech 2010 LetLet’ ’ s make Indian Cement Plantss make Indian Cement Plants World Class in Green!World Class in Green!   www.kturbo.com CII Green Cementech 2010 Types of Air BlowersTypes of Air Blowers Positive Displacement type Twin Lobe, Tri Lobe blowers (Roots blowers) with belt driveninduction motors Applications: For constant flow & variable pressureFlow rate: From 5m 3  /hr to 57,117m 3  /hrPressure: 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 Centrifugals provide variable flow & constant pressure   www.kturbo.com CII Green Cementech 2010 Conventional Positive Displacement type,Conventional Positive Displacement type,Twin Lobe Air BlowerTwin Lobe Air Blower   www.kturbo.com CII Green Cementech 2010 Centrifugal Blowers: Practically there is thin linedifferentiating Centrifugal Fans & Centrifugal Blowers K Turbo Blowers are very different from conventional centrifugal/turbo blowers as their performance curve is controlled & adjustable www.kturbo.com CII Green Cementech 2010 (Twin Lobe Positive Displacement) Improving Energy EfficiencyImproving Energy Efficiency   www.kturbo.com CII Green Cementech 2010 Turbo Blowers from K Turbo Inc., S. Korea  2 www.kturbo.com CII Green Cementech 2010 Core Components & Salient Features Permanent Magnet Motor: a) Power required only to rotate & notfor magnetizing of rotor; b) Can be started & stopped any numberof times; c) High Efficiency even at part loadNo Gear Box: No transmission loss due to direct drive & nolubrication required.Variable Speed Drive for achieving high speed, smooth starts(reduced starting current) & energy efficient capacity control aspart of the Blower package.Air Foil bearing for high speed operation (used in Jet engines)Oil Free airLow Noise: 80 dB against 100 dB of PD blowersEntire range is air-cooled & no need of water for cooling.   www.kturbo.com CII Green Cementech 2010 Comparison with PD blowersComparison with PD blowers Below 80 dB95-110 dBNoise LevelSmallerLargeFoot PrintSemi-permanent5 YearsLife Air FiltersOverhaulMaintenanceBelow 5%250%Starting Current compared to Rated Current   67%22.5%Total Efficiency at 50% Load70%45%Total Efficiency at 100% Load92%82%Drive Efficiency (Motor+Coupling+Invertor)77%55% Aero Efficiency KTurboBlowerPD BlowerParameter www.kturbo.com CII Green Cementech 2010  E n e r g y  E f f  i c  i e n c y C e r t  i f  i e d   b y  K  o r e a  E n e r g y  M a n a g e m e n t  C o r p o r a t  i o n www.kturbo.com CII Green Cementech 2010  APPLICATIONS OF KTURBO BLOWERS APPLICATIONS OF KTURBO BLOWERS Air (gas) conveying of powder (Cement factory,Chemical factory, Food & Beverage factory, Powerstation etc.)Aeration for water treatment (municipal sewagedisposal plant, water treatment systems in factoriesetc.)Agriculture and food processing (drying, processing,conveying etc.)Biotechnology (Oil free air supply) www.kturbo.com CII Green Cementech 2010 Sample Case Studies of Energy Saving Achieved  ApplicationWith Roots BlowerWith K Turbo BlowerSinceSavingNisshinbo(textile) IndustrialWWT75HP: 2 units, 100HP: 1unit(5000mmAq,144m3/min) 185 kW 75HP: 2 units(6000mmAq,102m 3  /min) 112 kW 4 Years40% POSCO(steel) Process Air(ReverseWashing) 75.7 kW118dB43.5 kW80dB 4 Years42.5% SungshinCement MaterialHandling150HP: 2 units(4300mmAq,37.5*2=75m 3  /min) 125.6 kW 150HP: 1 unit(4300mmAq,93m 3  /min) 78.0 kW 4 Years38% LafargeHalla(cement) MaterialHandling150HP: 1 unit(4700mmAq,35m 3  /min) 62.4 kW 75HP: 1 unit(4700mmAq,35m 3  /min) 40.5 kW 5 Years35% DAESANG(food) IndustrialWWT75HP: 3units200HP: 1unit(4500mmAq,204m 3  /min) 319 kW 75HP: 4 units(4500mmAq,204m 3  /min) 204 kW 6 Years35% www.kturbo.com CII Green Cementech 2010 Ø Case Studies of Applications in Cement Industries:1. Air Lift Blower2. Conveying Blower for coal3. Aeration Blower for silo4. Conveying Blower for alternated fuel5. Main burner Blower for air injection Ø Results of Installation Ø Pictures of installation Installations at Cement industries   Installations at Cement industries  3 www.kturbo.com CII Green Cementech 2010 PD Blower & KTurbo Blower www.kturbo.com CII Green Cementech 2010 1-1. Air Lift blower   1-1. Air Lift blower 1. Application : Conveying crushed material from raw mill to silo2. Using pressure : 0.1bar~1.5bar3. Using air flow delivery : 50    /min~200    /min4. Application Area : Sung-shin cement (Using from early 2004)-Raw Mill#1,2 Air Lift Blower (TB150-0.8S*3set)-Raw Mill#4 Air Lift Blower (TB200-0.6T*2set)-Raw Mill#3,5 Air Lift Blower (TB200-0.6T*3set)-Raw Mill#7 Air Lift Blower (TB200-0.6T*3set) www.kturbo.com CII Green Cementech 2010 1-2. Air Lift blower   1-2. Air Lift blower 1. Application : Conveying main material to pre-Heater of kiln2. Using pressure : 0.1bar~1.0bar3. Using air flow delivery : 75    /min~200    /min4. 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 www.kturbo.com CII Green Cementech 2010 1-3. Air Lift blower   1-3. Air Lift blower 1. Application : Conveying the cement produced from cement Mill2. Using pressure : 0.1bar ~ 1.0bar3. Using air flow delivery : 75    /min ~ 200    /min4. Application area : Sang-Yong Cement (Using from 2004) Mill# 4,5(TB150-0.8S*2set) Cement Mill Air Lift Blower www.kturbo.com CII Green Cementech 2010 2. Conveying blower for coal   2. Conveying blower for coal 1. Application : Conveying coal for firing2. Using pressure : 0.1bar ~ 1.5bar3. Using air flow delivery : 15    /min ~ 100    /min4. Application Area :Lafarge-Hallacement Inc   , Kiln#1,2,3,4 For dosed Coal (TB75-0.6S*6set, TB100-0.8S*1set)(Using from late 2003) Coal Mill#2,3,4 For Coal (TB75-0.6S*1set, TB150-1.5S*2set)Kiln#4 For Coal (TB150-1.5S*1set)Sung-Shin cement Inc   , Coal Mill#3,4 : For Coal (TB75-1.5S*2set), Kiln#5 1,2 step : For Coal(TB150-0.8S*2set)(Using from late 2004) Kiln#6 Main Burner : For Coal(TB150-0.8S*2set)Others : Ssang-Yong cement, Hyun-Dai cement, Han-Il cement using like upper data   Conveying blower for milled coal, Dosed coal and Main Coal www.kturbo.com CII Green Cementech 2010 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 orBCT (Bulk cement Trailer)2. Using pressure : 0.7bar ~ 1.5bar3. Using air flow delivery : 15    /min ~ 50    /min4. 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 www.kturbo.com CII Green Cementech 2010 4. Conveying Blower for alt. fuel   4. Conveying Blower for alt. fuel Conveying alternative fuel to kiln 1. Application : Conveying alternative fuel to Kiln2. Using pressure : 0.7bar ~ 1.5bar3. Using air flow delivery : 50    /min~150    /min4. 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) www.kturbo.com CII Green Cementech 2010 5. Main Burner Blower for air injection   5. Main Burner Blower for air injection 1. Application : Compressed air for combustion2. Using pressure : 0.1bar ~ 0.5bar3. Using air flow delivery : 70    /min~200    /min4. 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 late2004)   Injecting compressed air to main burner www.kturbo.com CII Green Cementech 2010 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 GresikSemen GresikCement,Cement,IndonesiaIndonesia  Application: Coal Conveying With KTurbo Blower 56-m3/min at 1.76 barPower drawn = 159 kWEnergy consumption=1,373,760 kWh/year   www.kturbo.com CII Green Cementech 2010 6-1. Results of installations   6-1. Results of installations E nergy cost saving(1 year):USD13,000 R  educe Noise:over 15 dB R  educe vibration:Over 19mm/s E nergy cost (per year)Total: about USD22,000 Cal) 40kW * 330day *24hour/day * 0.07USD/day= USD 22,176 N oise level : under 80dB  V ibration : under 1mm/s E nergy cost (per year)Total: about USD35,000 Cal) 63kW * 330day *24hour/day * 0.07USD/day= USD34,927 N oise level : Over 95dB  V ibration : over 20 mm/s Details of  E nergysaving / N oise &   V ibration E nergy save: 35% E quipments:KTurbo Blower: 75HP * 1set O perating dataDis. pressure: 0.47 barDelivery: 35 m3/minPower consumption: 40 kW E quipments:Roots Blower: 150HP * 1set O perating dataDis. pressure: 0.47 barDelivery: 35 m3/minPower consumption: 63 kW MeasuredResults   REMARKS AFTER (at same conditions)BEFORE Ex: Lafarge-Hallacement Inc, (Mode: Constant Volumetric Flow) www.kturbo.com CII Green Cementech 2010 6-2. Results of installations   6-2. Results of installations E nergy costsaving (1 year):USD27,000 R  educe Noise:Over 15 dB R  educevibration:Over 19mm/s E nergy cost (per year)Total: about USD43,000 Cal) 78kW * 330day *24hour/day * 0.07USD/kWh= USD 43,243 N oise level : under 80dB  V ibration : under 1mm/s E nergy cost (per year)Total: about USD70,000 Cal) 126kW * 330day *24hour/day * 0.07USD/kWh= USD69,854 N oise level: Over 95dB  V ibration: over 20 mm/s Detailsabout E nergysaving / N oise &   V ibration E nergy save:48kW (39%)& Conveyingmore material E quipments:KTurbo Blower: 150HP *1set O perating dataDis. pressure: 0.43 barDelivery: 93 m3/minPower consumption: 78 kW E quipments:Roots Blower: 150HP * 2set O perating dataDis. pressure: 0.43 barDelivery: 75 m3/minPower consumption: 126kW MeasuredResults   REMARKS AFTER (more difficult condition)BEFORE ã Ex: Sung-Shin cement Inc, (Mode: Constant Volumetric Flow) www.kturbo.com CII Green Cementech 2010 K Turbo Blowers installations in Cement Industry