Industrial Utility Efficiency


By using state-of-the-art vacuum technology for degassing mineral water, it has been possible to save an average of 3,000 cubic meters of water per filling plant per year. The solution was to replace the existing liquid ring vacuum pumps with MINK claw vacuum pumps from Busch Vacuum Solutions.

Blower Upgrade Saves Fraser Colorado Wastewater Treatment Plant Energy Costs

When the plant’s original aeration blowers became costly to operate and newer technology offered the promise of energy-savings, Fuqua took decisive action and replaced the older blowers with high-speed turbo blowers. As a result, the plant saves ratepayers approximately $30,000 per year in energy costs and bolsters the plant’s ability to maintain uptime and achieve extremely clean effluent.  

Three Different Sized Wastewater Treatment Plants Save Energy and Maintenance Costs with Aeration Blower Inlet Filter Upgrades

Optimized intake filters can save thousands of dollars annually in energy savings and may not require construction crews, engineering bids, or grant applications. The benefits can also be realized for treatment plants of all sizes. Described below are examples of three wastewater treatment plants that upgraded filters and came out ahead: a small rural operation with positive displacement (PD) blowers, a suburban plant using multi-stage blowers and a large urban plant that had already upgraded to airfoil bearing high-speed turbo blowers.

Madison Utilities Wastewater Treatment Plant Blower Upgrade Saves Energy

One need look no further than the treatment plant’s digester project upgrade to see the value of the plant’s forward-thinking approach at work. The upgrade involved the replacement of five Positive Displacement (PD) blowers with four, high-speed Inovair integrally geared blowers for aerating the digesters. With fewer – and smaller – blowers the plant saves tens of thousands of dollars in energy costs per year. The blowers also offer flexibility to cost-effectively adapt to the need for increased water treatment in the future. 

Positive Displacement Blower and Vacuum Booster Lubricants

You have your equipment, everything is set up and ready to run, but what about your lubricants? Too often, lubricants receive little attention with respect to their use in rotating equipment. Even the most reliable cars in the world will encounter problems on a short commute if the wrong transmission fluid is used during a flush. The same is true with your Positive Displacement (PD) blower or vacuum booster that operates around the clock. In our experience, approximately 80% of all bearing and gear failures are the result of improper lubrication.

Black & Veatch: Ensuring Aeration Blowers Meet the Needs of Wastewater Treatment Plants

Julie Gass, P.E., is a Lead Mechanical Process Engineer at Black & Veatch and an industry veteran with extensive experience in mechanical equipment in wastewater treatment plants. She also served on the American Society of Mechanical Engineers (ASME) Committee responsible for ASME PTC 13, Wire-to-Air Performance Test Code for Blower Systems, which is the performance test code published in October 2019 for all blower technologies. Blower & Vacuum Best Practices Magazine interviewed Gass to gain her views on aeration blowers, PTC 13, and the firm’s rigorous specification process to ensure treatment plants get the blower best suited for their application.

Riding the Waves to Resolve Common Issues with Dilute-phase Pneumatic Conveying

A long-held practice in the plastics industry is the use of high-speed, dilute-phase pneumatic conveying to deliver plastic resins to plant processes even if those same materials are the kind that can create problems ranging from excessive dust to damaged resins and more. All the while, slower-speed conveyance is normally unthinkable given production goals and the potential for plugged conveyor lines. 

Leveraging Rental Blowers for Pneumatic Conveying Applications

Pneumatic conveying applications are critical to many facilities – when you can’t move material you can’t make or sell your product. Because of a historical lack of availability of specialized rental blowers and air compressors for pneumatic conveying, plants often either accepted the production outage or rented a more readily available two-stage, oil-free rotary screw air compressor designed for 90 to 150 psig plant air service that is very inefficient at the reduced pressures needed for pneumatic conveying.

How to Calculate Aeration Blower Energy Costs

Aeration blower upgrades may be part of a total plant upgrade and minimizing energy consumption is a critical consideration. Blower replacements are also a common Energy Conservation Measure (ECM) in cost-reduction programs.

A Review of ASME PTC 13 Wire-to-Air Performance Test Code for Blower Systems

Finally, a test code has been created that will provide accurate performance comparisons for both positive displacement and dynamic (centrifugal) blowers. ASME PTC 13 provides procedures for determining the required total operating electrical power of a packaged blower system, termed the “wire-to-air” performance. Here’s a review of PTC 13 and considerations related to this important standard.

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