Wastewater Treatment Plant Upgrade

Sewage Industry

Retrofitting Requirements

The customer's sewage system originally used Roots blowers, which have experienced reduced operational efficiency and can no longer meet the increased production demand. The existing equipment needs to be retrofitted to fulfill production requirements with additional capacity, while achieving noise reduction, high efficiency, and easier maintenance.

Energy-Saving Solution

Through on-site technical discussions with the customer, the plan involves retrofitting three Roots blowers by removing them and installing air suspension centrifugal blowers in their original locations. This upgrade achieves 30% energy savings and reduces noise to below 80 dB.

Retrofitting Advantages

• High Efficiency – Utilizes permanent magnet high-speed motors with 97% efficiency and a rotational speed of 40,000 rpm
• Energy & Cost Savings – Saves 2.45 million kWh of electricity annually, reducing monthly electricity costs by $130,000
• Safe & Easy Maintenance – Oil-free bearing system eliminates lubrication needs and associated hazards. Only filter cotton replacement is required, taking just 10 seconds
• Reduced Labor Costs – Intelligent control enables easy operation and maintenance, with multi-layer protection ensuring efficient performance

Annual savings of approx. $120,000, with an electricity saving rate of up to 32%.

Energy-Saving Comparison: Replacing Roots Blowers with Air Suspension Centrifugal Blowers

Replacing one 255kW Roots blower with a 185kW air suspension centrifugal blower results in an annual electricity savings of:

2,233,800 kWh - 1,620,600 kWh = 613,200 kWh

At an electricity rate of $0.008/kWh, the annual cost savings per unit is approximately $5000

By replacing three units of the same model in the sewage system, the total annual savings amount to $131,400.