How to Save 2.5 Million kW·h of Electricity Annually?
The textile industry is one of the high energy-consuming, high water-consuming, and high pollution industries. It is one of the manufacturing industries with high energy consumption, and also uses a lot of water, generates a large amount of wastewater, and significantly impacts environmental quality. Conducting in-depth energy conservation and emission reduction work in the textile industry is of great importance to the country, the industry, and enterprises. In recent years, many textile enterprises have updated their wastewater treatment equipment and rapidly developed towards energy-saving and environmental protection, actively utilizing new energy-saving production equipment for technological transformation.
To reduce the energy consumption of the blowers, the impact of noise on the environment, and the frequency of blower failures, this wastewater treatment plant has undergone two rounds of technological upgrades for its blowers.
Before the technological upgrades, the wastewater treatment system operated with four 250 kW centrifugal blowers. The nameplate and measured parameters of the blowers are shown in the table below.
Centrifugal Blower Nameplate Parameters
Centrifugal Blower | Nameplate Pressure (kPa) | Nameplate Flow (m³/min) | Rated Power (kW) |
Blower #1 | 68.6 | 150 | 250 |
Blower #2 | 68.6 | 150 | 250 |
Blower #3 | 68.6 | 150 | 250 |
Blower #4 | 68.6 | 150 | 250 |
Actual Operating Parameters of Centrifugal Blowers
Centrifugal Blower | Measured Pressure (kPa) | Measured Flow (m³/min) | Operating Power (kW) |
Measured Blower #1 | 68.6 | 105 | 230 |
Measured Blower #2 | 68.6 | 105 | 235 |
Measured Blower #3 | 68.6 | 105 | 240 |
Measured Blower #4 | 68.6 | 105 | 240 |
Total Flow: 420 m³/min Pressure: 68.6 kPa Total Power: 945 kW | |||
Based on the actual production situation, the original four centrifugal blowers were replaced with three Marwelll MBT-400 magnetic bearing blowers. magnetic bearing blowers are easy to install, requiring only a flat surface for installation without the need for large cranes or other auxiliary equipment.
Through practical operation tests, these blowers have proven to have high efficiency, low noise, and stable operation. The blower outlet flow can be adjusted via frequency conversion according to process requirements, significantly saving power consumption and achieving the goals of energy saving, noise reduction, and environmentally friendly operation.
（Project Site）
Operating Conditions
（1) Comparison of Operating Conditions between Marwelll magnetic bearing blowers and Original Centrifugal Blowers After Technical Upgrade:
Blower | Number | Flow (m³/min) | Pressure (kPa) | Power (kW) |
Before Upgrade | 4 units | 420 | 68.6 | 945 |
After Upgrade | 3 units | 423 | 72 | 500 |
Under similar operating conditions, the original centrifugal blowers consumed approximately 945 kW·h per hour, while the Marwelll magnetic bearing blowers now consume about 500 kW·h per hour. This results in an hourly power saving of 445 kW·h, achieving a 47% energy-saving rate. Monthly power savings are approximately 320,400 kW·h, and annual power savings are around 3,844,800 kW·h, which translates to annual electricity cost savings of about USD3,580,00 .
Technical Specifications:
Rated Flow: 140 m³/min
Outlet Pressure: ~72 kPa
Rated Speed: 17,000 r/min
On-Site Noise: ≤80 dB
Flow Regulation Range: 40% - 100%
Installation: Compact size, simple installation
Control: High-precision adjustment of outlet flow via inverter regulating motor speed, and visualization of operations
(Noise Test)
(3) Features of Marwelll Magnetic bearing Blower Interface:
1. Digital Display: Running module, inlet temperature, speed, outlet pressure, bus voltage, motor temperature, power, and radiator temperature are all digitally displayed, saving manual temperature measurement operations.
2. Historical Data: 24-hour historical data can be queried.
3.User Login: Operator login with a password; frequency adjustment via touch screen to control the speed of the permanent magnet motor and thus control the blower's flow.
4.High-Frequency Monitoring: High-precision monitoring of the Magnetic bearing bearing motion trajectory.
5.Integrated Systems: Motor control system, Magnetic bearing control system, and overall machine control system are integrated.
6.Remote Control: Equipped with Marwelll ’s remote control system, allowing control from the central control room and remote maintenance and debugging.
Project Summary
From the on-site operation, the application of magnetic bearing blowers far exceeds the performance of the original centrifugal blowers, with key advantages including:
Low Energy Consumption: 47% more energy-efficient than the original centrifugal blowers, exceeding the expected contract requirements.
Low Noise: Reduced noise from 110 dB to ≤80 dB.
Ease of Maintenance: Transitioned from periodic lubrication and filter cotton replacement to only needing to replace filter cotton and filters.
Ease of Operation: Intelligent operation via touchscreen for startup, shutdown, and flow adjustment.
Marwelll magnetic bearing blowers have been effectively used in nearly a hundred textile enterprises. To date, thousands of magnetic bearing blowers have been applied domestically and internationally. Their superior features, such as approximately 30% energy savings compared to traditional blowers, oil-free and maintenance-free operation, low vibration and noise, easy installation and maintenance, remote operation and maintenance with "Marwelll ," and dual protection with self-power generation, continuously help customers in various industries reduce costs and improve efficiency. These characteristics have received unanimous praise from users and industry experts.
