Xylem Guide To Blowers

Guide to Blowers
ADVANTAGES & DISADVANTAGES

OF AVAILABLE BLOWER TECHNOLOGIES
Blower Expense
In a typical wastewater treatment plant, the blowers account for only 10%
of the capital expenditure, while the operating expenses account for up to
90% of the lifecycle cost. This means that blowers can account for 40-80%
of the energy used at a treatment plant.
When determining which blower is best for your application needs, you should
consider not only the blower’s efficiency, but also how it will perform over time,
including both its turn-down capability and maintenance requirements.
Building
Pumping
8%
15%
23%
Other
treatment 54%
Aeration/
Blowers
Blower Criteria
On the pages that follow you’ll find an overview of the advantages and
disadvantages of different blower technologies and ratings for each technology’s
efficiency, turn-down capability, and repair and maintenance requirements.
EFFICIENCY
Gauge of how the blower transfers the energy power
into air power
(scale = Excellent; Good; Fair; Poor)
TURN-DOWN CAPABILITY
Gauge of how a blower (or group of blowers) is able to
satisfy the change in future air demand
(scale = Excellent; Good; Fair; Poor)
REPAIR & MAINTENANCE

How easy and how often repair and maintenance is
required and how economical it is to repair the blower
(scale = Minimal; Moderate; Considerable)
Positive Displacement (PD) Lobe Blowers
Lobe type blowers are simple and have been widely used in
aerating wastewater for over 100 years. Positive displacement (PD)
blowers, specifically in this case rotary lobe blowers, are the most
used technology for blower applications, especially for medium to
small flows.
Lobe type blower efficiency is poor due to no internal compression
during the 360 degree rotation cycle. It also loses efficiency with
increased pressure. However, the technology is reliable and meets the
turn down requirements well if sized correctly.
Very often the internal losses of these blowers are not taken into
account and the inlet flow is given as the flow value – giving the
technology better performance on paper than in reality. Other losses
that should be accounted for in these types of blowers include:
transmission losses (often from the belt drive), motor losses, gear losses,
and, if variable speed is used, losses from the variable frequency drive.
These blowers also result in high noise and vibration caused by
pulsations. Recent models have been released on the market with
slightly higher efficiency using twisted lobes with a prolonged sealing
line resulting in slightly less pulsation.
EFFICIENCY TURN-DOWN REPAIR &

CAPABILITY MAINTENANCE
POOR EXCELLENT MODERATE TO

CONSIDERABLE
Positive Displacement (PD) Screw Blowers
Screw blowers, engineered using high pressure screw blower

technology, are very often used in high pressure compressor
applications and medium to small flows. These blowers have
been adapted to suite the pressure requirements used in
blower applications usually lower then 1bar.
Screw blowers are characterized by a pair of intermeshing screws
that progressively reduces the volume of air as it moves along
the length of the screw elements. These blowers have both low
leakage and parasitic losses. The technology is reliable and meets
the turn down requirements very well if sized correctly.
When compared to lobe blowers, screw blowers are slightly more
efficient thanks to the accrued internal compression within the
screw elements.
Similar to positive displacement lobe type blowers, this technology
can experience considerable losses. Belt drive or gears are often
used for power transmission resulting in additional losses in the
motor and variable frequency drive. While some manufacturers use
a coating on the screws in an attempt to obtain better efficiencies,
that coating is lost over time. The pulsations in screw blowers are
lower than lobe type blowers, however, they still create high noise
and vibration. This technology also loses efficiency with increased
pressure but not as much as lobe type blowers.

MODERATE EXCELLENT MODERATE TO

CONSIDERABLE
Integral Gear Type Centrifugal Blowers
Integral gear type centrifugal blowers have been used for many
years when higher flows are required. While the compression
efficiency is good, these blowers operate on fixed speed. That
means that, when designed, these blowers have to account for
maximum pressure that may not be experienced for several years
and should include future pressure loss assumptions. This could
negatively impact the efficiency of the blower from the beginning
when it is first commissioned.
Integral gear blowers include a flow inlet guide vane (IGV) and variable
diffuser (VD). These components are seen as complicated because they
utilize many mechanical parts that require maintenance and the control
system required for their operation is complex and expensive.
While the compression efficiency of integral gear blowers can be
one of the highest, the gain from the compression efficiency is lost in
the complex power transfer, pressurized oil lubrication system, water
cooling and motor and bearing losses.
A sound enclosure is an additional accessory that does not come
standard with these types of blowers. The enclosure, however, limits
accessibility for blower service and increases the space required for
installation. In addition, this technology emits a lot of heat and therefore
requires good ventilation.

MODERATE MODERATE CONSIDERABLE

Direct Drive Turbo Blowers
Direct drive turbo blowers are engineered using more

recent motor and variable frequency drive (VFD) technology.
Based on well known turbo technology that requires high
speed in order to function, these types of blowers use a
VFD to transform 50 or 60 Hz of supplied power into high
frequencies, achieving high rotating speed directly to the
motor and impeller.
The power for direct drive turbo blowers range from 15kW up
to 600kW and pressures up to 1,5bar. Not many manufacturers
are able to offer the full flow and pressure range due to the
shaft weight and rotating speeds in their selected bearing
technologies. Turbo blowers are available utilizing two different
types of technologies – either the magnetic bearing principle or
the newer airfoil bearing technology.
With turbo blowers, the turbo impeller is connected directly to the
shaft, which makes it possible to eliminate all transmission losses,
resulting in excellent efficiency.
Regarding turndown, not all turbo blowers have a wide turndown
and will vary based on the blower manufacturer.
Other factors that should be considered when selecting turbo
blowers are addressing the heat emitted by the motors and how
the internal functions will be monitored and controlled, which can
be achieved either through simple VFD programming or by using
a PLC with a touchscreen HMI. Operators have a range of options
available with these types of blowers.

EXCELLENT MODERATE MINIMAL

Non-Contact Magnetic Bearing Blowers
UPS
Battery Power to magnets
Backup Bearing
Controller from bearing controller Motor shaft
Several position
sensors communicate Emergency
with bearing controller landing bearing
When direct drive turbo blowers were first introduced to the

market they incorporated the magnetic bearing principle. Magnetic
bearing technology uses active magnets to position the motor rotor
in the right position during both operation and at standstill.
In order to govern the magnetic force in the blower there needs to be
a controller and sensors in place to constantly measure the position of
the rotor. Constant monitoring means that this technology is sensitive
to power failures. In order to account for possible power failures,
battery backups are often needed. Backup bearings with limited crash
landings capabilities should also be installed in the motor as well. Some
manufactures also use the variable frequency drive charge to power the
bearings during power failures.
Overall, this technology is susceptible to higher temperatures and
requires several backup systems and control functions. All of this
increases possible failure points.

GOOD GOOD MODERATE

Non-Contact Air Bearing Blowers
Airfoil bearing technology is nothing new – it’s been around for

years and is used in non-contact air bearing blowers. In these
blowers an air cushion is created when the motor shaft rotates
allowing the shaft to rotate freely without making contact with any
other parts. This eliminates the energy transfer loss or frictional loss
that is inevitable with other types of blowers.
Weight is crucial in air bearing blowers. Light-weight shafts using
Air cushion created
titanium are preferred and an aluminum machined impeller is
by rotational speed recommended so as not to limit the start and stops of the bearings.
lifting the rotor
Air bearing blowers continue to evolve. For example, new coatings like
triple Nano silver coatings have made it possible to extend the bearing
lifetime 3-4 times that of blowers using a traditional Teflon coating.
These types of blowers do not require any additional backup systems
and are not negatively impacted by power failures and are 100% self
controlled with no need for any safety devices to protect the bearing.
With these latest developments bearing lifetime has become a non
issue comparing to the magnetic bearing considering aging of
electrical components.

GOOD GOOD MINIMAL

Blower Comparison

MODERATE TO
Positive Displacement Lobe Blowers POOR EXCELLENT
CONSIDERABLE
MODERATE TO
Positive Displacement Screw Blowers MODERATE EXCELLENT
CONSIDERABLE
Centrifugal Blowers MODERATE MODERATE CONSIDERABLE
Non-Contact Magnetic Bearing Blowers GOOD GOOD* MODERATE
Non-Contact Air Bearing Blowers GOOD GOOD* MINIMAL*
*Dependent on manufacturer’s technical solution

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Guide to Blowers

ADVANTAGES & DISADVANTAGES

REPAIR & MAINTENANCE

EFFICIENCY TURN-DOWN REPAIR &

POOR EXCELLENT MODERATE TO

Screw blowers, engineered using high pressure screw blower

EFFICIENCY TURN-DOWN REPAIR &

MODERATE EXCELLENT MODERATE TO

EFFICIENCY TURN-DOWN REPAIR &

MODERATE MODERATE CONSIDERABLE

Direct drive turbo blowers are engineered using more

EFFICIENCY TURN-DOWN REPAIR &

EXCELLENT MODERATE MINIMAL

When direct drive turbo blowers were first introduced to the

EFFICIENCY TURN-DOWN REPAIR &

GOOD GOOD MODERATE

Airfoil bearing technology is nothing new – it’s been around for

EFFICIENCY TURN-DOWN REPAIR &

GOOD GOOD MINIMAL

EFFICIENCY TURN-DOWN REPAIR &

Centrifugal Blowers MODERATE MODERATE CONSIDERABLE

Non-Contact Magnetic Bearing Blowers GOOD GOOD* MODERATE

Non-Contact Air Bearing Blowers GOOD GOOD* MINIMAL*

*Dependent on manufacturer’s technical solution

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