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Application of High-Speed Turbocompressors at Municipal WWTPs in Michigan

Application of High-Speed Turbocompressors at Municipal WWTPs in Michigan. Jim Flamming, P.E. , Senior Process Engineer, Fishbeck, Thompson, Carr & Huber, Inc. Aeration Blowers. Aeration consumes 40-70% of energy used in activated sludge plants (WEF MOP OM-9)

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Application of High-Speed Turbocompressors at Municipal WWTPs in Michigan

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  1. Application of High-Speed Turbocompressors at Municipal WWTPs in Michigan Jim Flamming, P.E. , Senior Process Engineer, Fishbeck, Thompson, Carr & Huber, Inc.

  2. Aeration Blowers • Aeration consumes 40-70% of energy used in activated sludge plants (WEF MOP OM-9) • For supplying diffused aeration grids, 2 types: • Positive Displacement • Approx. 60% efficient • Typically smaller (<100 hp) • Output varies with speed,not pressure • Factory or OEM packages available • Widely applied, low capital costs

  3. Aeration Blowers • Multistage Centrifugal: • Approx. 65-75% efficient • Wide range of sizes, typ. >50 hp • Output varies with pressure • Widely applied for over 100 yrs. • Can be more expensive initially than positive displacement • PD and multistage blowers are the workhorses of the industry.

  4. But Times Are Changing! • With renewed emphasis on energy efficiency, new styles of blowers are starting to be applied. • High speed turbocompressorsoffer several potential advantages over traditional blowers: • Higher efficiencies • Lower maintenance costs • Variable output • Quiet operation

  5. High Speed Turbocompressors • Operate at very high speeds:25,000 to 45,000 rpm • No contact bearing surface: magnetic or airfoil bearings • No contact = no friction = no wear parts • Oil free operation; no lubrication requiredor bearings to service • Very low maintenance

  6. High Speed Turbocompressors • 10-20% improvement in efficiency • Operate on VFDs; maintaining best efficiency at turndowns of up to 50% of max output • No contact – very low vibrations – low noise (<70 dB at operating speed) • Factory supplied package units with controls • Typically small footprints

  7. High Speed Turbocompressors • Different styles from different manufacturers • Magnetic Bearings – ABS/HST, Hoffman Revolution, Atlas Copco ZB-VSD; Spencer AyrJet • Air Foil Bearings – HIS HT; K-Turbo; APG-Neuros; Turblex • Magnetic bearings prevent any contact during operation, but typically cost more upfront • Most are direct drive units; Turblex also providesa separately geared unit with additional control capability

  8. ABS/HST • Of the direct drive units, so far ABS/HST has the most installations in the U.S. at municipal WWTPs (61 units at 21 WWTPs, and 1300 units worldwide) • Built in Sweden • Only one with direct drive installations so far in Michigan, at three sites, which we will review as case studies

  9. ABS/HST • Five models • 93-536 HP • 600-10,400 scfm • 5.5 – 18.2 psig discharge pressure

  10. ABS/HST

  11. Case StudiesMichigan WWTPs

  12. Marquette WWTP • Replaced RBCs with three plug flow 500,000-gallon nitr. basins; plus one 500,000-gallon WAS tank • 1 50-hp and 1 75-hp blower to three 200-hp turbocompressors (ABS HST SP6000-1-L-5) each 4,337 scfm at 8 psig • Start up July 2008

  13. Coldwater WWTP • Trickling filter-solids contact plant • NH3 violations, May 2007 • Installed new IFAS, which required added aeration (presented in Session 1) • Existing plant had two75-hp, 900-scfm blowers

  14. Coldwater WWTP • Installed two 93-hp ABS/HST S2500-2-A-5; each 1,257 scfm at 8 psig • Placed in new building; existing blowers remain as backup units • City doesn’t have historical flow and hp draw data for blowers; difficult to compare

  15. Reed City WWTP • Three basin SBR plant • Industrial/municipal WW • Utilized three 150-hp PD blowers which had HIGH rates of failure • Replaced units with four111-hp HST S2500-1-H-5;each 1,969-scfm at 8 psig innew blower building

  16. Reed City WWTP

  17. Reed City WWTP • After installation, plant measured output: • Old blowers rated for 3,000 scfm withtwo blowers running • New HSTs – 3,600 scfm at 80 hp • DO’s higher in SBRs • Low noise • Virtually no vibration • Still in start-up; addressing electrical issues at site

  18. Some Things To Consider… • HSTs may not be suitable for every plant • Relatively high initial capital costs; need to do a life cycle cost analysis; magnetic vs. air-foil • Not cost-effective at lower HP requirements • Would not want to parallel with PD blowers • Sophisticated electronics, need to review existing electrical service and power quality • Faults happen during start-up

  19. Conclusions • The world of wastewater treatment is changing • New PLC-based controls open up the possibility for new kinds of technologies • Offer better efficiencies and less maintenance • While not for every application, HSTs offer some intriguing advantages that are worth consideration .

  20. Thank you Any Questions?

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