Turbo Blower Research Articles

History of blast furnace blowers.

The development of blowers is inextricably linked with the stages of the history of technology and blast furnace production. The amount of blast is one of the main parameters of cast iron production, determining the size and performance of the blast furnace. Consideration of the issues of changing the design and drive of blowers starts from the natural draft and wedged leather bellows. The use of a horse-drawn drive or a water co-scaffold made it possible to increase the amount of air supplied to the furnace. The important event in the development of blowers was the advent of a steam engine, which made it possible to ensure industrial steel production in the middle of the XIX century. A fundamental change in the design of blowers occurred during the transition from reciprocating machines to centrifugal machines ‒ turboblowers powered by a steam turbine drive. Various design solutions of blowers of the transition period of the beginning of the XX century are considered, on the example of the technical equipment of the blower station of the Donetsk Metallurgical Plant (the plant of the Novorossiysk Society). Modern blower machine designs and characteristics are shown. It is noted that the cessation of the increase in the volume of created blast furnaces is associated with the achievement of the capacity limit of blowers. It is noted that in a number of cases, on the basis of technical and economic calculations, the possibility of obtaining a higher level of energy efficiency of the process of supplying blast to a blast furnace is substantiated when gas-tubine installations operating on blast-furnace gas are used to drive a turboblower. Some increase in the efficiency of the blast furnace process can be obtained, by considering the operation of a complex of devices: a turbo blower, an air heater, an air piping system.

Количественная оценка параметров турбинного генератора потока на основе требований к респираторным системам

The article considers the experience of designing a turbine-type flow generator (also known as "turbine", "blower", "centrifugal fan", etc.) for artificial respirators. The system requirements for such a device have been transformed into the geometric and mechanical parameters of the blower in the form adopted in turbomachinery world. These requirements affect not only the pressure and performance indicators, but also the acceleration time (reaching the required operating mode) and the sound pressure level. Special attention is paid to the choice of aerodynamic parameters of the turbo blower, as well as to the specifics of its operation considering the effect of the electric motor torque on its characteristics. The concept of monitoring the residual life of the motor by a vibration sensor and a resistance thermometer, allowing introducing emergency settings in the algorithm controlling the ventilator, is considered. All this will make it possible more reasonable interpretation of the solutions and products presented currently on the market, as well as more detailed considering the specifics of a particular device when developing technical requirement for a blower.

Experiment of the Influence of Dynamic Balancing Precision on Rotor Dynamic Behavior of 75KW Oil-free Turbo Blower

The principle and structure of the 75kW oil-free turbo blower is briefly introduced and the performance of gas foil bearings (GFBs) is tested. According to the test results, the lift-off speed of the gas foil journal bearings (GFJBs) using in 75kW oil-free turbo blower is about 4000rpm, and the gas foil thrust bearings (GFTBs) can provide at least 140N and 200N load capacity at 7200rpm and 9000rpm, respectively. The rotordynamics behavior of oil-free turbo blower is studied. Two proximity probes and speed sensor are installed to monitor the horizontal vibration displacement, vertical vibration displacement and shaft speed, respectively. And the vibration spectrum and the rotor axis orbit are analyzed. It was found that the maximum vibration amplitude of the rotor with dynamic balancing precision of G-1 was only 3.5 μm, and no other low frequency other than low frequency caused by signal interference. The fundamental frequency vibration amplitude of the rotor with dynamic balancing precision of G-2.5 is larger when running stably, but there is no low frequency and high frequency vibration with higher amplitude. Shaft couldn’t lift-off with dynamic balancing precision of G-6.3 In general, oil-free turbo blower with two kinds of dynamic balancing precision rotors can operate well.

New Type Turbo Blower Saves Energy & Stable Operation With IoT

New Type Turbo Blower Saves Energy & Stable Operation With IoT

Operational anomalies identification of the turbo blowers using statistical analysis of the experimental data

In this paper is presented a method for anomalies identification that may occur in equipments operation because of the large variations, above the limits, of the process parameters. The method is developed by using statistical approach and visualization tools of the processed data. The scientific visual method is generally used to control, monitor and improve processes by removing special cause variation. The statistical process control (SPC) has an advantage over other methods, because it can be applied to any process with its emphasis on early detection and prevention of problems. The objective for this paper is to present the technique used to control and monitor the Turbo Blower equipment, from steel industry. The purpose of statistical analysis is to ensure that all processes function as accurately as possible within the tolerance limits.

New Type Turbo Blower Saves Energy & Stable Operation With IoT

New Type Turbo Blower Saves Energy & Stable Operation With IoT

Reducing Energy Consumption in a WWTP. Case study: Constanta Nord WWTP

The 21st century society is faced with a serious issue that is worsening day by day: water scarcity. The lack of fresh water resources that fail to meet the increasing demand of the population led to 844 million people living without access to safe water, 2.3 billion people living without access to improved sanitation and 1 million people killed by water, sanitation and hygiene-related disease each year. One of the possible solutions to tackle this problem, would be the construction of wastewater treatment plants. But looking more in-depth at the issues, we can definitely say that wastewater treatment is a very capital-intensive process, especially due to its high energy consumption. This paper presents two solutions to decrease the energy consumption in a wastewater treatment plant, following the case of the turbo blowers in Constanta Nord WWTP.

Small-scale and high-speed centrifugal turbo blower for air-cooled lithium ion battery packs in electric vehicles

This study investigates a high-speed centrifugal turbo blower with an impeller diameter of 33 mm. The turbo blower is applied to the lithium-ion battery cooling systems of electric vehicles, and is advantageous because of its high flow rate. The blower is an axial flow centrifugal blower that changes the radial kinetic energy of the impeller to axial kinetic energy. The high-speed turbulent flow inside the turbo blower is numerically simulated with a compressible k-ω turbulence model. To predict blower performance, the static pressure and flow rate are calculated for 50,000, 80,000, 110,000, 140,000 and 170,000 RPM. We present a turbo blower operated at 110,000 RPM with 67.6% efficiency that can be applied to a 2 kW air-cooled lithium-ion battery pack.

Implementation of Condition Based Diagnosis as Maintenance Improvement Strategy in Turbo Blower Assembly

In the present work, a test rig resembling to the section of the turbo blower motor assembly used in heavy manufacturing industries is developed. The purpose is to reveal significant increase in a machine's vibration level to warn about the developing problems due to the deteriorating health of bearings which can be easily identified using condition based monitoring. Vibration spectrum analysis, a predominant CBM technique is used in this study because vibration signature reveals a lot of important information about the fault generation within them. This paper discusses vibration severity causing potential failures in turbo blower thus applying condition monitoring to avoid premature failure thus, improving productivity.

Rigid Mode Vibration Control and Dynamic Behavior of Hybrid Foil–Magnetic Bearing Turbo Blower

In this study, experimental and analytical analyses of the vibration stability of a 225 kW class turbo blower with a hybrid foil–magnetic bearing (HFMB) were performed. First, critical speed and unbalance vibration responses were examined as part of the rotordynamic research. Its shaft diameter was 71.5 mm, its total length was 693 mm, and the weight of the rotor was 17.8 kg. The air foil bearing (AFB) utilized was 50 mm long and had a 0.7 aspect ratio. In the experiments conducted, excessive vibration and rotor motion instability occurred in the range 12,000–15,000 rpm, which resulted from insufficient dynamic pressure caused by the length of the foil bearing being too short. Consequently, as the rotor speed increased, excessive rotor motion attributable to aerodynamic and bearing instability became evident. This study therefore focused on improving rotordynamic performance by rectifying rigid mode unstable vibration at low speed, 20,000 rpm, and asynchronous vibration due to aerodynamic instability by using HFMB with vibration control. The experimental results obtained were compared for each bearing type (AFB and HFMB) to improve the performance of the vibration in the low-speed region. The experimental results show that the HFMB technology results in superior vibration stability for unbalance vibration and aerodynamic instability in the range 12,000–15,000 rpm (200–250 Hz). The remarkable vibration reduction achieved from vibration control of the HFMB–rotor system shows that oil-free turbomachinery can achieve excellent performance.

Numerical study on performance improvement when strong vortex occurs on the shroud of vaneless diffuser in turbo blower

This research is about improving the performance of a turbo blower when a strong vortex occurs on the shroud of a vaneless diffuser. The design parameters for a vaneless diffuser in a turbo blower were analyzed, and the optimum design conditions for a vaneless diffuser were derived. Among these parameters, the independent ones were outer radius of the diffuser (Rd), cross-sectional area ratio of the diffuser (Ad/Ai), and generation method for the shroud curve in the diffuser. The dependent parameter was fan static efficiency in the CFD; moreover, the purpose of this study was to maximize this efficiency. The influence of the design parameters was analyzed using Computational fluid dynamics (CFD) and Design of experiments (DOE). The reliability of CFD results was verified by comparing the experimental and CFD results obtained using a preliminary model. For DOE, a full factorial design and the response surface methodology were employed, and a regression equation was used for deriving the optimum design conditions. The DOE results revealed that as Rd increased and Ad/Ai increased accordingly, the fan static efficiency in the CFD also increased. Furthermore, as Rd increased, the high-value range of the fan static efficiency in the CFD increased. In general, the performance of the turbo blower was enhanced when the vortex region in the vaneless diffuser decreased in area. In addition, the cross-sectional area of the vaneless diffuser was designed to achieve recovery of static pressure.

200 마력급 터보 블로워 적용을 위한 자기베어링 설계

Recently, the development trend of turbomachinery is high capacity and high efficiency. Most of turbomachinery in the market are adopting ball bearings or air foil bearings. However, ball bearings have a limit for high speed product over 2.0×10SUP6/SUP DN(product of the inner diameter of the bearing in mm (D) and the maximum speed in rpm (N)). Air foil bearings have a limit for high axial load for high power products over 200~300 HP(horse power). Magnetic bearing is one of the solutions to overcome the limits of high speed and high axial load. Because magnetic bearings have no friction between the rotor and the bearings, they can reduce the load of the motor and make it possible to increase the rotating speed up to 5.0×10SUP6/SUP DN. Moreover, they can have high axial load capacity, because the axial load capacity of magnetic bearing depends on the capacity of the designed electromagnet. In this study, the radial and thrust magnetic bearings are designed to be applied to the 200 HP class turbo blower, and their performance was evaluated by the experiment. Based on the tests up to 26,400 rpm and 21,000 rpm under the no-load and load condition, respectively, it was verified that the magnetic bearings are stably support the rotor of the turbo blower.

Study on the Optimal Rotor Retaining Sleeve Structure for the Reduction of Eddy-Current Loss in High-Speed SPMSM

In the case of designing high-speed surface-mounted permanent magnet synchronous motor (SPMSM), the rotor retaining sleeve is inserted into the rotor to prevent the permanent magnet’s damage. It is quite an efficient way to consider manufacturability, but the sleeve becomes the major source of ohm loss in high-speed operation. In this paper, the high-speed motor for a turbo blower at the rating of 100 kW, 20000 r/min was introduced. To improve its efficiency, the retaining sleeve’s optimal design was needed. For this, parametric analysis on the shape of the retaining sleeve was carried out in a different type of motor. Within a range that meets the mechanical safety, sleeve designs have been changed. The effect of changing design variables of the sleeve was studied. This paper presents the optimized sleeve’s advantages in electrical efficiency from the results of the electromagnetic finite element analysis software. Finally, it suggests the optimal sleeve design to reduce eddy-current loss, which is related to motor shape.

Experimental study of small-size air turbo blower supported by externally pressurized conical gas bearings

This paper describes a several ten thousand rpm class small-size air turbo blower. This has been newly developed using externally pressurized conical gas bearings and blower impeller with centrifugal suction blades on both faces. This bearing can reduce the number of machine parts since it is possible to support the thrust and radial load components in both directions. Calculations of the characteristics were conducted and investigated using the manufactured test bearings. A test rig was manufactured, and the characteristics were experimentally verified. These bearings have a conical bearing surface with diameters of 10mm and 8mm and a length of 15mm. A pair of length is 30mm. The actual bearing clearances are 0.012mm and 0.014mm, respectively. The measured bearing characteristics agreed with the designed values. It was clarified that the proposed calculation method is useful for predicting the characteristics in a relatively simple way. The air turbo blower impeller has a 15mm diameter and a 3mm thickness with centrifugal suction blades on both faces that were made by precision machining. The measured rotational frequency of the rotor exceeds 350Hz (21,000rpm) in the test. The rotor vibration was verified as a forward whirl with a conical mode. The blower characteristics were also investigated. The maximum discharge air flow rate and the pressure were 19.2×10−5m3/s and 1.77kPa, respectively, at the maximum rotational frequency of 350Hz. This may be used as a small-size air supply blower.

CFD를 이용한 소형 2단 터보블로워의 공력해석

터보블로워는 상대적으로 적은 체적유량에서 높은 압력이 요구되는 곳에 사용되는 대표적인 유체기계로서 다양한 산업에 응용되어 사용된다. 본 연구에서는 고속으로 회전하는 소형 2단 터보블로워의 정압상승 메커니즘을 이해하기위해, 1단 임펠러 영역과 터보블로워 전체 영역에 대해서 상용툴인 ANSYS 14.5를 이용하여 CFD해석을 수행하였다. CFD 해석과정에는 역압력 구배에 의한 유동박리 예측에 적합한 k-<TEX>${\omega}$</TEX> SST 난류 모델을 적용하였다. 터보블로워의 전산해석 결과는 KS B 6311 및 KS A 0612에 따른 성능시험방법을 통하여 해석기법이 타당함을 검증하였다. CFD 해석결과 터보블로워의 압력상승은 선형적으로 나타나지 않으며, 안내깃에서의 손실과 케이싱과 임펠러 간극에서 손실이 발생하는 것으로 분석되었다. 소형 2단 터보블로워를 공력성능을 예측하기 위해서는 전체 유동영역에 대한 전산 해석이 필요하며, 실험과 전산해석의 오차에 대해 고려된 전산해석 결과가 선정되어야 한다. Aerodynamic characteristics of the small two-stage turbo blower were investigated using commercial CFD tool(ANSYS CFX Ver. 14.5) in this paper. Turbo blower, which is a centrifugal type of turbomachinery, is used in various industries. It is used for application that required high static pressure rising at relatively small volumetric flow rate. In order to understand the mechanism of static pressure rising, the aerodynamic characteristics of the small two-stage turbo blower are analyzed at high rotating speed in this study. The k-<TEX>${\omega}$</TEX> SST turbulence model, which is good at prediction of adverse pressure gradient flows, was applied. The CFD results of the turbo blower are validated by performance test. The static pressure rising of the turbo blower is nonlinearly increased over the first stage and the second stage. The secondary flow occurred at guide vanes, between the casing and the first impeller shroud, and the bottom of the impeller disk. As a result, It is required that whole fluid area is analyzed to predict aerodynamic characteristics of small two-stage turbo blower. and the result should be selected with considering for error from experiment and CFD.

Preliminary thermodynamic study for an efficient turbo-blower external combustion Rankine cycle

This research paper presents a preliminary thermodynamic study of an innovative power plant operating under a Rankine cycle fed by an external combustion system with turbo-blower (TB). The power plant comprises an external combustion system for natural gas, where the combustion gases yield their thermal energy, through a heat exchanger, to a carbon dioxide Rankine cycle operating under supercritical conditions and with quasi-critical condensation. The TB exploits the energy from the pressurised exhaust gases for compressing the combustion air. The study is focused on the comparison of the combustion system’s conventional technology with that of the proposed. An energy analysis is carried out and the effect of the flue gas pressure on the efficiency and on the heat transfer in the heat exchanger is studied. The coupling of the TB results in an increase in efficiency and of the convection coefficient of the flue gas with pressure, favouring a reduced volume of the heat exchanger. The proposed innovative system achieves increases in efficiency of around 12 % as well as a decrease in the heat exchanger volume of 3/5 compared with the conventional technology without TB.

Risk and hazard analysis of machines through reliability-based condition monitoring

With the passage of time, any processing machine develops degraded effectiveness, marked by reduced mean time between failure (MTBF) and the reduction in the value of reliability. Even periodic preventive maintenance is not enough to restore reliability to its original value. Many a times even predictive preventive maintenance may require changed system of condition monitoring. Based on failure modes effect and criticality analysis (FMECA) and risk priority number (RPN) and comparing the thresholding value of the each component, it is possible to classify the critical components in regard to risk and hazards and losses involved in case of repair and maintenance. This requires determining the likelihood coefficient (LC) of each failure mode and the same for threshold values. In this paper, the author like to discuss and critically analyse the system, taking a case from the industry involving reliability based condition monitoring of Turbo Blower.

유전자 알고리즘을 이용한 최대 강성을 갖는 자기베어링-회전체 최적설계에 관한 연구

High speed rotor systems with magnetic bearings have been the subject of much research in recent years due to the potential for active vibration control. In this thesis, optimal design was conducted for an 8-pole heteropolar magnetic bearing used in the flexible rotor of a turbo blower. In connection with bearing stiffness, this optimal design process was conducted using a genetic algorithm(GA), which is based on natural selection and genetics. The maximum stiffness of the magnetic bearing-rotor was found by considering the critical speeds of the flexible rotor. As a result, the magnetic bearings were optimized to have maximum stiffness.

터보불로워 용 회전체 주축 소재의 마찰, 마모 및 부식 저항 향상을 위한 WC-metal 분말의 초고속화염용사코팅

High velocity oxy-fuel (HVOF) spray coating of WC-metal powder (powder) was carried out to improve the resistances of friction, wear and corrosion of magnetic bearing shaft material Inconel718 (In718) of turbo blower. A micron sized WC-metal powder (86.5% WC, 9.5% Co 4% Cr) was coated onto In718 surface using HVOF thermal spraying. During the spraying, the binder metals and alloy such as Co, Cr and Co-Cr alloy were molten and a small portion of WC particles were partially decomposed to <TEX>$W_2C$</TEX> and free carbon at above its decomposition temperature of <TEX>$1250^{\circ}C$</TEX>. The free carbon and excessively sprayed oxygen formed carbon oxide gases, resulting a porous coating of porosity of <TEX>$2.2{\pm}0.3%$</TEX>. The surface hardness of substrate increased approximately three times from 400 Hv of In718 to <TEX>$1260{\pm}30Hv$</TEX> of the coating The friction coefficients of the coating were approximately <TEX>$0.33{\pm}0.03$</TEX> at <TEX>$25^{\circ}C$</TEX> and <TEX>$0.26{\pm}0.03$</TEX> at <TEX>$450^{\circ}C$</TEX>. These values were smaller than those of In718 substrate at both temperatures due to the lubrication from the free carbon and the cobalt oxide debris. The corrosion resistance of the coating was higher than that of In718 both in salt water of 3.5% NaCl and acid of 1 M HCl solutions, on the contrary, it was lower in base solution of 1 M NaOH. According to this study, the HVOF WC-metal powder coating is recommended for the durability improvement of magnetic bearing shaft of turbo blower.

High-Speed Bearing Technologies for Wastewater Treatment Applications

High-Speed Bearing Technologies for Wastewater Treatment ApplicationsReview of High-Speed magnetic and airfoil bearings history and development is presented. Principles of operation of each technology are then explained in detail. A discussion on application of both technologies to the wastewater treatment blowers follows. Airfoil bearings offer a low cost but higher risk high-speed bearing solution for turbo blowers, whereas magnetic bearings offer dynamic...Author(s)Aleksandra IrvingJoseph IbetsSourceProceedings of the Water Environment FederationDocument typeConference PaperPublisherWater Environment FederationPrint publication date Oct, 2013ISSN1938-6478DOI10.2175/193864713813667458Volume / Issue2013 / 20Content sourceWEFTECCopyright2013Word count91