Turbosuflante cu lagăre magnetice KAESER KOMPRESSOREN PillAerator
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Magnetic Bearing Turbo Blowers
150 kW and 300 kW
Flow rate up to 267 m³/min, 16,000 m³/h, Pressure differential 0.3 to 1.3 bar
www.kaeser.com
Magnetic Bearing KAESER Turbo Blowers
High performance – Efficient process air
Featuring a high-speed motor, the PillAerator from KAESER is a directly coupled, oil-free compression turbo blower that provides exceptional efficiency, reliability and flexibility. The turbo impeller and motor shaft start, stop and rotate with zero wear,
or the need for any need for lubrication, thanks to magnetic bearing technology. This future-forward turbo blower design is
used in the low pressure range and is especially useful for applications with high flow rate and performance demands where
maximum energy efficiency and process air availability are of key importance.
Energy efficient
0 1 5 0, 0
kWh
Direct power transmission between the motor and impeller, combined with speed-controlled flow rate regulation, ensure remarka
ble efficiency. In addition, the wear-free
magnetic bearing allows almost unlimited start/stop operation for intermittent aeration
processes.
Future-forward
The motor and frequency converter are cooled by a sophisticated cooling concept, like
that used in e-vehicles. The closed cooling water circuit not only protects both core
components from environmental influences, but also makes their exhaust heat available
for reuse.
Reliable
The magnetic bearing’s intelligent sensors ensure ideal shaft position at all times.
Should drastic pressure changes or voltage losses occur, the machine shuts down
independently of the power supply for its own protection, so that no damage can occur.
Low noise and pulsation
With a maximum sound pressure level of 76 dB(A), the PillAerator is one of the quietest
process air generators available. As turbo machines, they do not generate any pressure
pulsations in the connected pipework.
Ready-to-run
The turbo blowers are designed for immediate operation
wi
th minimal installation effort. The intake air filter is already integrated and the accessories for its installation are
pre-assembled. This reduces the effort required for piping
and installation of ventilation ducts - especially when using
the water-cooling option already included as standard.
2
TANK
AERATION
YEAST
FERMENTATION
Water management
Food and pharmaceutical industry
► Aeration, flotation
► Fermentation, dispersion
Efficient
Reliable
Low maintenance
AIR KNIFE
Montage uses images from: © Valenty, navintar, industrieblick - stock.adobe.com
Applications – Flexible and versatile
Industry
► Cooling air, combustion air
Flue gas desulphurisation
Always the first choice for an efficient and reliable
compressed air supply
Whether for use in water treatment applications, yeast
production, bioreactors, for air knife applications in the
steel industry, or for the purposes of flotation, turbo blowers from KAESER impress with their reliability, efficiency
and excep
tional ease of maintenance. Since they are
completely oil-free, they are the ideal choice for sensitive
processes – such as those in the food industry.
3
Turbo blower technology
© KEBA Industrial Automation Germany GmbH, Simone Schuldis - Fotolia
Turbo blowers work on the principle of dynamic compression. The impeller of the radially-acting turbo compressor accelerates intake air in the circumferential direction, thereby increasing flow speed and, as a consequence, energy. Part of this
energy is converted into an increase in static pressure in the downstream diffuser. With few moving components in this turbo
machine, an increase in pressure with continuous flow is generated.
Image: Magnetic bearing motor with attached impeller
The high-speed motor
A high efficiency permanent magnet synchronous motor
(PMSM) is responsible for the direct and loss-free generation of impeller speeds up to 30,000 rpm. The motor’s
impressive performance is made possible due to its
canned motor de
sign, whereby the stator and magnetic
bearing are encapsulated from environmental influences - and without a wearing shaft seal. In order to ensure
effective and controlled cooling, the motor is exclusively
water-cooled, which also protects it from ingress of fine
dust.
The motor shaft is levitated by a magnetic bearing that
not only enables the high motor speeds to be achieved
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with zero contact or wear, but also permits virtually unlimited
motor starting frequency.
Furthermore, the active magnetic bearing immediately detects and compensates for deflections to keep the motor
shaft safely in its rotational orbit. The magnetic bearing
control device is protected against power supply failure
by regenerative motor operation. In the event of unexpected, drastic pressure surges, safety bearings
provide further protection for the motor shaft so
that it can be brought to a controlled stop without
damage.
What makes the KAESER
turbo blower so special?
Rather than using conventional aviati
on-based air bearing technology for its turbo blowers, KAESER uses smart astronautic
magnetic bearing technology to assure uncompromising long-term availability, as is especially expected of machines in the
water industry, for example.
Moreover, the PillAerator offers significant additional advantages over other magnetic bearing blowers.
kW/(m³/min)
Image: KAESER PillAerator HP 4000 turbo blower and impeller
(m³/min)
Efficiency and control range
Cooling concept
Different impeller versions (L, M, H) enable efficient
coverage of the power and pressure range required by the
specific application at hand. As shown in the graph, power
consumption can therefore be reduced to a minimum
(yellow line) for the required flow rate. The particular aerodynamics, which have been refined using complex flow
simulations, provide a wide flow rate control range.
As with modern e-vehicles, the motor and frequency converter are water-cooled and are therefore independently
encapsulated from outside a
ir. The water can be recooled
either with ambient air, or with an external secondary water
circuit, meaning that the heat contained in the cooling fluid
can be subsequently recovered and reused.
5
The turbo unit – The heart of the system
The compact heart of system comprises the impeller, the turbo blower housing, the
directly coupled motor, as well as the inlet nozzle and the blow-off valve. The recooling
system for the motor and frequency converter cooling water is just as easily accessible
and consists of air/water and water/water heat exchangers, a circulation pump and a
control valve.
In order to keep sound emissions at the air inlet to an absolute minimum, the turbo
blower draws in air through an integrated silencer and filter.
Dynamic drive
Image: © KEBA Industrial Automation Germany GmbH
Made from aerospace grade aluminium alloy, the turbo
impeller is seated directly on the shaft of the slim rotor.
Consequently, the motor not only allows high speed
operation, but also
has exceptional control dynamics.
For example, speeds of 20,000 rpm are achieved 5 in
seconds.
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Intelligent magnetic bearing technology
Cooler motor
There is more to KAESER’s magnetic bearing technology than meets the eye. The bearings are preloaded by
a permanent magnetic component, which relieves their
active, electromagnetic component. This consequently
leads to lower winding currents and therefore to reduced
heat generation.
With its clever cooling concept - which is independent from
ambient air conditions - and canned design, the motor
not only ensures consistent cooling performance, but is
also encapsulated against environmental influences. As a
result, there is no need for a wear seal between the blower
stage and the motor shaft.
Image: Machine layout
True flow rate
Always clean
With the KAESER PillAerator, flow rate is measured in
real-time at the machine inlet. The air inlet is therefore designed as a nozzle equipped with corresponding pressure
and temperature sen
sors, to enable greater precision in
delivering the required flow rate.
The intake filter provides reliable protection against
upstream influences such as filter breakthroughs and
contaminated intake air ducts. The process air is filtered
both when it is drawn in from the ambient surroundings
and when it is drawn in from ducts. To ensure low life
cycle costs, all filters are designed as inserts that can be
changed quickly and easily.
7
Future-forward cooling concept
Cooling and use of exhaust heat
In a closed circuit, a pump circulates the cooling fluid via the motor and frequency converter, as well as via water/air and
water/water heat exchangers. Up to a certain ambient temperature, it is possible to select either automatically or directly
whether air or external cooling water should be used as the primary cooling medium. Water is the best choice for higher
ambient temperatures, or for heat recovery purposes.
Cooling system
1.
Magnetic bearing motor, water-cooled
2.
Water-coo
led frequency converter
3.
Controllable water/air heat exchanger
4.
Water/water heat exchanger
5.
Maintenance-free circulation pump
6.
Cooling water inlet and outlet with possibility for use of
exhaust heat
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Water/air heat exchanger
Water/water heat exchanger
The heat exchanger fan operates automatically depending
on ambient conditions and cooling requirement. The controller also decides when the water/water heat exchanger
is activated to provide additional support if necessary. It is
also possible to select which option is used as the primary
cooling system.
This heat exchanger can be used to provide additional
support at high ambient temperatures, or can be selected
as the primary cooling system. It is designed as a hybrid
heat exchanger, so that exhaust heat from the motor and
frequency converter can be transferred as effectively as
possible should heat recovery be required.
Exhaust heat utilisation
Save money with heat recovery
The state-of-the-art cooling circuit
design is the same as that used in today’s advanced e-vehicles. It protects the core components, ensures their effective cooling and enables utilisation of recyclable exhaust heat. In a closed circuit, cooling fluid
circulates via the motor and frequency converter, as well as via water/air and water/water heat exchangers. Whether used for
higher ambient temperatures or with heat recovery in mind, water is the primary coolant.
Cooling mode selection explained:
Primary coolant mode: Air = Direct space heating using warm air flow. Primary coolant mode: Water = Heat
transfer via the medium of water with temperatures up to
approx. 40 °C.
Advantage: The heat from the drive section is always
available – with the same temperature level, regardless of
the season (in contrast to heat exchangers in the pressure
line).
Directly usable heat – guaranteed!
Potential heat use:
On average, approx. 6 % heat output occurs in modern
turbo blowers in the drive section, comprising the motor
and i
ts control technology. With good use of the machine,
this equates to between 6 and 12 kW for medium-sized
turbo blowers (150 kW series) and 15 to 20 kW for large
turbo blowers (300 kW series).
•
Usable for processes: Heating biology or bioreactors,
sludge conditioning and drying.
•
Usable for buildings: Low-temperature surface heating
or support for the heating circuit, feed into a heat
pump to achieve a higher temperature level (service
water or similar).
When multiplied by the number of blowers in operation,
this results in an impressive amount of potentially directly
usable heat energy.
Equivalence to familiar energy sources and CO2 emissions
Approx. 6 %
Machine
Drive power
Process
Heat capacity
Montage uses image from: © jokatoons - stock.adobe.com
The exhaust heat from the drive trains of three turbo blowers (each with a power consumption of 160 kW) corresponds to
a heating value of 15,000 to 25,000 litres of heating oil per year, depending on load. That consequentl
y translates into an
annual CO2 emission of 44 to 73 tons – these figures are doubled for 300 kW series machines.
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Importance of the coolant for air-conditioning
AIRcooled operation
Air-cooled blower station operation
When selecting the preferred coolant – air
or water, or both in combination – it is
important to consider the compressed air
system as a whole.
This especially applies to exclusively aircooled turbo stations with process air intake
via supply air ducting, and supply and exhaust air openings for machine room ventilation. The lower the temperature difference
between the outside environment and the
inside of the machine room, the stronger
the room ventilation needs to be, which can
often present a challenge, particularly in
existing buildings.
In such cases, water offers an attractive
alternative as the cooling medium.
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WATERcooled operation
Water-cooled blower station
operation
In water-cooled operation, the effort required for room ventilation and cooling i
s
significantly lower, both in terms of supply
air and exhaust air. Exhaust air ducting
can even be omitted entirely, since most of
the exhaust heat from the machine can be
removed from the room using water. The
water piping shown below the pressure
pipework is sufficient to achieve this.
Since the preferred cooling medium can be
switched over via the KAESER turbo blower, warm exhaust air can be used in winter,
for example, to provide room heating or to
preheat the intake process air via bypass
flaps.
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Electronics
12
User interface (HMI)
Data centre
All performance and operating states can be displayed
on the 9” colour touch panel and users can choose from
over 20 selectable interface languages. If remote control
capability is not available from the control centre, or if an
associated fault occurs, the machine can be operated
with manual setpoint input (flow rate, pressure or external
process variables).
All other systems, such as the frequency converter, are
coordinated vi
a the powerful central processing unit connected to the HMI. This bundles the flow of information via
the HMI and the programmable controller.
Image: Elements, electronics side
STOP
EMERGENCY
ON
OFF
How it works
M
(1)
Power supply
(2)
Transformer
(3)
Fusing
(4)
Main contactor
(5)
Mains filter
(6)
Commutation throttle
(7)
Frequency converter
(8)
Condenser, intermediate
circuit
(9)
Sinusoidal filter
(10)
Motor
(11)
Magnetic bearing
electronics
(12)
Controller
(13)
Control panel
Frequency conversion
Safety concept
The speeds required for the high-speed motor are generated via a powerful frequency converter, which enables
variable-speed operation and therefore continuous flow
rate adjustment to meet actual demand. The closed water
cooling circuit ensures consistent frequency converter
performance.
In the event of a power failure, the machine is shut down
and comes to a controlled stop. Meanwhile, the power
supply for the magnetic bearing control unit is
generated
by the motor and frequency converter. This eliminates the
need for batteries or UPS packages and their associated
maintenance.
13
EVERY THING AT A
GL ANCE
and under control
Speed and flow rate
Pressures and temperatures
Operating and maintenance hours
System and status data
Warning and fault messages
Communication
14
Operating data
Status data
The operating point is displayed in the turbo blower’s
characteristic map in real-time. Machine utilisation and
distance to operating limits can therefore be immediately
seen at glance. Messages are displayed on the screen,
are accessible at the press of a button and are archived as
a message history. Relevant process data and messages
are also stored to SD card and can be analysed later as
required.
The main components of the turbo blower are shown
clearly and unambiguously as a P+I diagram, from which
their operating and status data can be read immediately.
This includes the components through which the process
air flows, th
ose of the cooling circuit, the motor (rotor position and magnetic bearing temperature) and the frequency
converter (voltage, current and temperature).
~
~
Image: © by-studio - Fotolia
Master controller
Remote control from a control centre
Modbus TCP, EtherNet/IP, Profinet and Profibus DP, each
with a comprehensive process image, are available for
communication and remote control via data bus connection. The machine operating limits are also communicated
via these technologies to safeguard control. Alternatively,
the machine can be controlled via analogue and digital
interfaces.
A master controller is available for connection of up to 10 turbo blowers. In ’Flow
rate’ or ‘Pressure control’ operating mode,
the master controller coordinates efficient
operation of the individual machines within
the blower station, as well as their switching
processes. In addition, the controller's bus
protocol not only delivers the current process data, but also the status data of the
indiv
idual machines to the master control
centre. PROFIBUS, PROFINET, Modbus
TCP and EtherNet/IP are available for
communication.
15
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Your needs – Our solutions
Climate control unit
Diffuser
Compensator
Non-return flap
The add-on parts are available to fit DIN and ANSI flanges, the diffusers are also offered as 90°
versions. Pipe silencers are also available upon request.
16
Control cabinet climate control
Nitrogen variants – Nitrogen version
The optional climate control unit for control cabinet cooling
enable turbo blower operation in ambient temperatures up
to 45°C (300 kW series) and even 55°C (150 kW series),
as long as the drive section is also supplied with sufficient
cooling water. The climate control units are thermally controlled, the cooling air in the control cabinet is decoupled
from the environment.
A special version of the 150 kW turbo blower is available
for conveying of the inert gas nitrogen, e.g. for air knife
applic
ations in the steel industry. With this version, the
suction-side process line can be connected directly. The
turbo blower’s exceptional control dynamics are highly
valued for this purpose.
System solutions from KAESER
Since you generally require complete system solutions to meet your industrial process needs, rather than individual components, KAESER is the perfect partner for you. Our philosophy is to provide reliable and efficient holistic
solutions that go beyond machine and control technology. This starts with expert planning and continues with
customer focus and ready availability of service parts to keep your process running safely and efficiently at all
times.
Technological expertise
Service/After-sales
As a leading manufacturer of rotary lobe, screw and turbo
blowers, KAESER is always able to advise which technology is right for your specific application. Function and efficiency require correct coordination of the process needs
with the properties of the particular blow
er technology.
No machine is 100 % maintenance-free. In order to keep key
processes running smoothly, you
need an efficient partner with a
comprehensive service network.
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Assembly
18
Production
Assembly
Quality assurance
Highest possible vertical integration of mechanical and electrical
components at the KAESER factory
guarantees consistent quality and
seamless interaction of every individual part.
“Made in Germany” represents the
very highest standards with regards
to component manufacture and assembly in accordance with stringent
quality regulations. This not only
includes hardware components, but
also software.
Prior to delivery, each blower is
subjected to an intensive fa
er technology.
No machine is 100 % maintenance-free. In order to keep key
processes running smoothly, you
need an efficient partner with a
comprehensive service network.
gins
tem be
tive sys
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ff
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ient an
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Expert p
17
Assembly
18
Production
Assembly
Quality assurance
Highest possible vertical integration of mechanical and electrical
components at the KAESER factory
guarantees consistent quality and
seamless interaction of every individual part.
“Made in Germany” represents the
very highest standards with regards
to component manufacture and assembly in accordance with stringent
quality regulations. This not only
includes hardware components, but
also software.
Prior to delivery, each blower is
subjected to an intensive fa
... ascunde
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