An optimal low pressure screw blower for cement plants
Do you know why it is important to run compressed air and blower systems at the right pressure?
It directly affects how much energy they use. Learn why a low-pressure screw blower is an effective choice.
As you may know, the right equipment plays a critical role in cement plants, as it is essential for various processes. This involves several processes. These include:
- Pneumatic conveying
- Unloading bulkers
- Conveying fly ash
- Firing kilns
- Fluidizing silos
- Bypassing chlorine for plants that use alternative fuels
Installing the best solution to meet your facility's needs is important. Read on below to learn more about how such equipment impacts operations.
Current practice: Lobe (roots) blowers
Lobe blowers, also known as roots blowers, have been around since the mid-19th century. Their principle of operation involves isochoric compression. Air enters the compression chamber, and the volume remains constant as identical rotors rotate.
However, external compression leads to low efficiency and high noise levels. These limitations confine lobe technology to low-pressure applications.
The game changer: Screw blowers
Enter the screw blower, a modern marvel. Here’s why it shines:
- Isentropic compression
Unlike lobe blowers, screw blowers operate on isentropic compression. The magic lies in their screw compression element—male and female rotors rotating in opposite directions.
- Efficiency unleashed
Screw elements maintain a fixed, built-in pressure ratio, eliminating mechanical forces causing imbalance. This allows them to work at high shaft speeds, combining a large flow rate with compact dimensions.
- Energy savings
For the same pressure, a screw blower consumes significantly less power than a lobe blower.
Imagine an ambient temperature of 35°C: Roots blower: 61 kW with an air outlet temperature of 125°C. Screw blower: 43 kW with an air outlet temperature of 94°C. That’s 30% less energy.
- Optimized airflow
Screw blowers fine-tune internal airflow paths, minimizing pressure drops and turbulence.
Why correct pressure matters
Energy efficiency: Operating compressors and blowers at the optimal pressure ensures energy efficiency. When systems are oversized, they consume more power during operation, leading to higher electricity bills. By choosing the right size, we can significantly reduce energy consumption.
Initial investment costs: Oversized compressors not only consume more energy but also require a larger initial investment. Properly sized equipment strikes a balance between performance and cost-effectiveness.
Reduced carbon footprint: Lower energy consumption can translate to a smaller carbon footprint. As the cement industry increasingly focuses on sustainability, minimizing energy usage becomes paramount.
Selecting the right solution
How to choose the optimal compressors and blowers for your cement plant? Here are some practical steps for you.
Understand your compressed air needs: Calculate your compressed air requirements based on the specific processes in your plant. Consider factors like air volume, pressure, and flow rates.
Correct type of compressors and blowers: Different working pressures and flow rates call for different technologies. Screw blowers with over 300 mbarg working pressures are exceptionally energy efficient. However, below 300 mbarg, the savings are not as great compared to traditional lobe blowers.
Avoid oversizing: Oversized equipment leads to wasted energy. Choose the right capacity based on actual demand.
An efficient low pressure screw compressor
Investing in a rotary screw blower that provides low pressure compressed air can save a lot of energy. With this, there's some advantages to consider.
- Energy savings: Matching the right technology to your application can save up to 35% on energy consumption.
- Lower Total Cost of Ownership (TCO): Properly sized compressors and blowers reduce both initial investment costs and long-term operational expenses.
- Safety and reliability: Well-designed systems ensure safe and reliable production.
In conclusion, running compressors and blowers at the correct pressure is not just about efficiency. It’s about sustainability, cost savings, and responsible resource utilization. By making informed choices, cement plants can contribute to a greener future while optimizing their operations.