CASE STUDY

EFFICIENCY PLANT MVR

Galbani, establishment of Corteolona PV
Replacement of traditional impeller with Perfettibile® Turboimpeller

The plant in question evaporates water at 27% from milk whey. The installed Turbofan was of traditional type with an impeller of 1980 mm of effective diameter, with 9 curved backward blades. The objective of revamping was the achieving of 10% reduction of the absorbed power during the whole production year which is normally around the 30 consecutive hours of operation.
Process data under baseline conditions:
-Qm 42000 kg/h
- ΔT 3,3°C
-Vapour temperature 64°C
Beginning from process data and with the help of the advanced tools that Perfettibile® provides, it has been designed a new Turboimpeller that could satisfy process data with a lower energy consumption. The replacement of the impeller only enabled us to contain intervention costs maximising the performance of the new Turboimpeller. In the months following intervention, the Turbofan's energy consumption has been monitored continuously. The average value measured far exceeded the target. During the early stages of the process, when the plant is still clean, the saving reaches peaks of 20%, but at the end of the production year the average value recorded is 14%.

EFFICIENCY BYPASS CL3 PLANT

Buzzi Unicem, establishment of Robilante
Replacement of traditional impeller with Perfettibile®
Turboimpeller

The fan installed in cement plant with a traditional blade forward impeller of 2230 mm of effective diameter was subject to strong abrasion of the blades and rear disc of the impeller and presented major problems of clinker dust accumulation at the entrance of the same. This condition limited the functioning of the fan at reduced speeds due to strong vibrations. The objective was the solution of the problems described above and the reduction of energy consumption. Therefore, we have designed an impeller that could completely solve accumulation and abrasion problems. this has been possible thanks to the experience that Perfettibile® has acquired over the years. Moreover, energy savings of 8% have been achieved.
Operating data:
–Qv 84803 m3/h
–Pst 1158 Pa
–Tin 258°C
After analysing the original operating conditions at CFD and verifying the wear points by comparing them with field measurements, CFD tests have been carried out on the new geometry so that the passage of the fluid inside the blade channels is well distributed and free of recirculation and turbulence that could encourage the accumulation of clinker powder.

EFFICIENCY SMOKE PLANT

Ecowatt, establishment of Castiraga Vidardo
Replacement of traditional impeller

The fan installed in the smoke pant was of traditional type with an impeller of 1400 mm of effective diameter with flat backward blades. The objective of revamping was to increase the pressure supplied by the fan without increasing the absorbed power.
Operating data:
– Qv 83660 m3/h
– Pst 4760 Pa
– Tin 138°C
Beginning from process data and with the help of the advanced tools that Perfettibile® provides, it has been designed a new Turboimpeller that could satisfy process data with a lower energy consumption and increasing the static pressure as required by the costumer. After installing the new Turboimpeller inside the existing screw, the operating data have been measured again detecting the increase in pressure required and a decrease of 23.5% in energy consumption.