Waste water technology

Reduce energy consumption and increase air volume!

Startseite Industries & Applications Wastewater treatment Increased energy efficiency with screw blowers

Blowers for oxygen input into the aeration basins

Electrical energy consumption was reduced by more than 20 percent. This was achieved by modernizing an existing air compressor system with a new blower station from KAESER Kompressoren SE.

Challenge

The central blower station had to be modernized at a wastewater treatment plant used for 85,000 inhabitants. Here, four older frequency-controlled rotary blowers generated the compressed air, which was distributed to the individual activated sludge zones via a manifold with orifice regulating gates. In the case of a new plant, the requirement was to reduce the electrical energy demand considerably and thus to better adapt the compressed air generators running in the interconnected system to the air demand, which fluctuates strongly seasonally e.g. as a result of the grape harvest. Half of all cascades are ventilated intermittently. The new systems must undergo a performance test in accordance with ISO 1217 Annex C or E before delivery.

Solution statement

The intensive analysis of the time-related air demand and operating pressure as well as the applications of the many years of experience in compressed air technology resulted in a solution that allows each demand point to be approached with the least possible use of machine and lossy frequency conversion.
Two KAESER screw blowers type EB 380S-SFC (55 kW each, frequency controlled), one KAESER EB 380 S-STC (37 kW, Y/D starter) and one KAESER BB 89C-STC rotary piston blower (11 kW, Y/D starter).
A control range for the compressed air produced of 315 to 5515 Nm³/h (approx. 1:17) was achieved.
The KAESER SIGMA AIR MANAGER interconnected control system combines the most effective machines for the current demand. The control system also manages backup capacities in case a machine fails or requires maintenance.
The KAESER SIGMA AIR MANAGER communicates with the process control system via data bus, exchanges operating and status data and simultaneously performs pressure control.

Customer value

Expenditure for energy generation could be reduced by at least 23 percent
As an inside, the compressor station ventilated with ambient air in the machine room remained completely unaffected by the German temperature record of over 40 °C set in 2015, as KAESER screw blowers are designed for ambient temperatures of up to 45 °C as standard anyway.

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