Currently, the internationally adopted method for waste disposal is landfill. A large amount of landfill waste generates significant secondary pollutants—leachate. Leachate is a type of high-concentration organic wastewater with a complex composition. If discharged directly into the environment without treatment, it causes severe environmental pollution, seriously affecting urban living conditions. This presents a recognized challenge in the water treatment industry.
The primary methods for treating leachate are a combination of aerobic and anaerobic biological treatments, where the main operating costs are electricity and chemical fees. Electricity accounts for about 40%-50% of the wastewater treatment costs, and the electricity consumption of blowers in aeration tanks accounts for more than 60% of the total electricity cost of the wastewater treatment plant.
Before the upgrade, the treatment plant used Roots blowers, which had high noise levels, high energy consumption, and high maintenance costs. Additionally, as the blowers aged and their parts wore out, the airflow would gradually decrease, making it increasingly difficult to meet operational needs. Since its establishment, Marwell Environment’s magnetic bearing blowers have been efficiently used in numerous industries such as wastewater treatment, metal oxidation, bio-fermentation, material transport, and flue gas desulfurization. More and more enterprises are opting to upgrade traditional high-energy-consuming blowers. Therefore, this project chose Marwell magnetic bearing blowers for the technical upgrade to reduce the operating costs of leachate treatment, improve system stability, and mitigate noise pollution affecting both operators and the surrounding environment.
Upgrade Situation:
Before the technical upgrade, the on-site aeration system used two 90kW Roots blowers and one 45kW Roots blower. After the upgrade, two 105kW Marwell magnetic bearing blowers were installed as replacements.
Comparison of Blower Parameters Before and After the Upgrade:
Blower Type | Roots Blower | Roots Blower | Marwell Magnetic bearing Blower |
|---|---|---|---|
Number of Operating Units | 2 | 1 | 2 |
Single Blower Flow Rate (m³/min) | 44 | 16.7 | 60 |
Total Air Flow Rate (m³/min) | 88 | 16.7 | 120 |
Outlet Pressure (kPa) | 80 | 100 | 90 |
Single Blower Power (kW) | 90 | 45 | 105 |
Blower Power (kW) | 180 | 90 | 210 |
Energy Saving Rate (%) | - | - | 29% |
(Project Site)
(Project Magnetic Bearing Blower Operating Status Interface)
(Measured Operating Power)
Operating Conditions:
The comparison of operating conditions between Marwell bearing blowers and the original Roots blowers after the technical upgrade is shown in the table below:
Blower Type | Flow Rate% | 80 |
|---|---|---|
Marwell Magnetic bearing Blower | Screen Display Power (kW) | 84.9 |
Measured Power (kW) | 81.33 | |
Instantaneous Flow Rate (Nm³/h) | 60.78 | |
Unit Power Consumption (kW) | 1.34 | |
Root blower | Frequency Converter Frequency (Hz) | 50 |
Measured Power (kW) | 87.4 | |
Instantaneous Flow Rate (Nm³/h) | 42.25 | |
Unit Power Consumption (kW) | 2.07 |
Based on measurement data, the unit power consumption of the blowers (measured power/instantaneous flow = unit power consumption) shows that the Marwell magnetic bearing blowers have an energy-saving rate of 35.26% compared to the Roots blowers.
Project Summary:
From the on-site operation of the blowers, it is clear that the performance of the Marwell magnetic bearing blowers far exceeds that of the original Roots blowers. The main advantages are:
Low Energy Consumption: About 35% more energy-efficient than the original Roots blowers.
Low Noise: The blower noise has decreased from the original 110dB to ≤80dB.
Easy Maintenance: Maintenance has shifted from regularly adding lubricating oil and replacing filter cotton to only replacing the filter cotton filter.
Easy Operation: Start/stop and airflow adjustment can be performed via a touchscreen interface.
Features of the Marwell magnetic bearing blowers Operation Interface:
Digital Display: Operating modules, inlet temperature, speed, outlet pressure, bus voltage, motor temperature, power, radiator temperature, etc., are all digitally displayed, saving manual temperature measurement operations.
Historical Data: 24-hour historical data is accessible.
Operator Login: Operators log in with a password, and the speed of the permanent magnet motor can be controlled by touch-screen frequency adjustment, thereby controlling the blower's flow rate.
High-Frequency Monitoring: High-frequency monitoring of the magnetic levitation bearing motion trajectory ensures high-precision rotation.
Integrated Control System: The motor control system, magnetic levitation control system, and the entire machine control system are integrated.
Remote Control: Equipped with the "
Marwell
" remote control system, it can be controlled from the central control room and allows for remote maintenance and debugging.
Marwell magnetic bearing blowers have been efficiently used in nearly 100 domestic and international leachate projects. To date, thousands of magnetic bearing blowers have been applied in various regions around the world, consistently helping customers in various industries reduce costs and improve efficiency. Due to their approximately 30% energy savings compared to traditional blowers, oil-free operation, no mechanical maintenance, low vibration and noise, easy installation and maintenance, and "Marwell" remote operation and maintenance capabilities, they have received unanimous praise from users and industry experts.
