Compressors Sidechannelblowers

Optimization of side channel blowers from an environmental standpoint

Dr.-Ing. habil. R. Dittmar, Dr.-Ing. T. Grohmann, Dipl.-Ing. M. Kempf

Introduction
The idea for a ring vortex compressor goes back to Prof. Eugen Oesterlen, who taught at the TechnischeHochschuleinHanover.In1937 hepro osedanaircompressorbased p on the already known side channel pump principle. The initial test compressors were destroyed during air raidsin1945.In1955hisideasabout ringvortexcompressorsgainednew attention.Sincethehighpressurecharacteristics that these devices were found to have made it possible to achieve substantial differential pressuresatlowrpmspeeds,thecompressors were intended for use in vacuumcleanersthatweretobepowered by 2-pole asynchronous motors. Until then, high-speed radial blowers driven by a.c./d.c. motors had been thestandard.Thesemotors,however, required carbon brushes, which wore outquickly. Following years of development work, the first ring compressor went

into standard production in 1964. With an impeller diameter of 256 mm,itachievedapressuredifference of 5 kPa at a volumetric flow rate of s 90m3/h.However,itssoundpres ure levelof79dB(A)wasstillhigh,andits efficiency of less than 40% was still low. Despite these modest figures compared with other pressure-generatingdevices,theringorsidechannel compressors, with their unique hydraulic characteristics, took over in important markets, such as the printing, pneumatic conveying, sewage aeration,andpackagingindustries.

Design and operation

When represented in a Cordier diagram, which compares various pressure-generatingdevicesindimensionless form /1/, side channel blowers assume a position between radial machines and piston machines; see Figure 1. Thus, side channel blowers arethetypeofpump/compressorthat offers the highest single-stage pres-

surelevels.Theycanachievevalues up to 30. Figure 2 shows a cross-section through a side channel blower. The gas is drawn in through the suctionportsandsilencers.Afterthegas entersthesidechannel,theexchange ofmomentumwiththebladesofthe rotating impeller compresses the gas andtransportsittothepressureport. Itthenpassesthroughtheabsorption silencer and leaves the machine. Today,sidechannelblowersarebuilt in single-andmultiple-stagedesignsfor multi-stagepressureratiosupto3and forvolumetricsuctionflowratesupto 3000 m3/h. Demands of plant operatorsforenvironmentalimprovements andpressurefromnewlawsandregulationsareleadingtoongoinginnovations in blower technology.The main focusison: efficiency, controllabilityandpower/weight ratio, noiseand modifications to implement environmentallyfriendlytechnologies.

Axialmachines Diagonalmachines Radialmachines

Sidechannelmaschines

Speednumber

Rotarylobemachines

Recip.pistonmachines

Diameternumber
Fig. 1: Cordier diagram /1/ Fig. 2: Design and operation of a side channel blower

94 Pumps,CompressorsandprocessComponents2011

Compressors Sidechannelblowers

Severalexamplesaredescribedbelow.

Efficiency
Asregardspolytropicefficiency

(1)

where (2)

Figure 3 shows, among other things, the relative efficiency improvements due to individual optimization measuresoverthepast20years. Asaresult,a50%increaseinefficiency was achieved. In other words, todayonly2/3oftheshaftoutputof 1990 is needed to achieve the same hydraulic performance. The efficiencies of modern side channel blowers are approaching those of positive displacement machines and radial blowers. By focusing design work on the performance characteristics of side channelblowers,engineershavebeen

Ingeneral,hydraulicefficiencyisconstrainedbylossesduetofluidfriction, volumetric efficiency is constrained by flow through gaps, and mechanicalefficiencyisconstrainedbyfriction effects between the impeller and the casingandcontactfrictioninbearings and seals. While fluid friction is of little consequence, especially at high flowratesandlowpressures,efficiencyathighpressuresisdependent ongaplosses.Thissuggeststhatthere areopportunitiesforoptimizationfor individualperformancecurveranges. Volumetric efficiency Reducing the gap losses between theimpeller,coverandcasing, Geometric optimizations at the interrupter, depending on the tip speedu,thepressureratiop2/p1,and thenumberofblades, Taking into account the optimal blocking ratio for the design range (blade cell volume/total volume of bladering); Hydraulic efficiency Reductionofpressurelossesthrough theuseofmorefavorableportpositionanddesign, Modified side channel cross-sections,variableinthecircumferential direction, Reductionoflossesduetoimpactat thebaseoftheblade, Designoflow-separationflowchannelsinthebladecells; Thepotentialforimprovingmechislimited and will not be discussed furtherhere.

Year

1997 Improved gapsealing

2006 Reductionof laminarsep.in bladecell Modifiedpathof sidechannelflow Dyn.gapsealing

2010 Optimal portdesign/ position Interrupter optimization

Fig. 3: Environmentally relevant improvements in side channel blowers in the past 20 years

Pumps,CompressorsandprocessComponents2011 95

Compressors Sidechannelblowers

the performance map of a singlestage high-performance blower with local flow velocities in the transsonic range.Itcanbeseenthatthecontrol rangeextendsacrosssuctionvolumetricflowsofupto1100m3/handsuction-side differential pressures of up to60kPa.Thehigherefficiencyofover 50%inthecenterofthemapisnoteworthy.Hightipspeedsupermitsize reductionswhilemaintaininghydraulic performance; this manifests itself inahigherpower/weightratio: (3) As can be seen in Figure 3, the power-weight ratio of side channel blowershasincreasedduringthepast 20 years by a factor of nearly 10. In other words, only 10% of the former designenvelopeisrequiredtoachieve the same hydraulic performance.The weight and the amount of material used in these devices have decreased significantly. This too represents a contribution to environmentally consciousinnovation.

Fig. 4: Performance curves for an operating point OP with a) non-modified blower geometry and b) geometry modified for optimal efficiency at the given OP

able to achieve favorable efficiencies atspecifictargetoperatingpoints;see Figure4. At this operating point the requiredshaftoutputcanbeminimized by dimensioning the blower to have carefullymatchedparameters,suchas side channel cross-sectional area AK, impeller diameter D, and blade area AS.IntheexampleshowninFigure4, the required power was reduced by 50%atthegivenoperatingpoint. Thestatutorydemandsontheefficiency of electric drive motors are also increasing continuously. For example, Directive DIN EN 60034-30 must be implemented by mid-2011. Itrequiresanincreaseintheefficiency ofIECstandardmotorsof2to4%dependingontheshaftoutput/2/.

ter technology also makes it possible todynamicallysetanydesiredoperatingpointsintheperformancecurve. For example, it is possible to continuous yadaptpressures,tempel ratures, and volumetric flows to the current process parameters /3, 4/ by addingelectronicmodules.Inthisway, losses caused by conventio al throttn ling devices, bypasses, or switching operations can be avoided, operating costs can be cut, and environmental impactcanbereduced.Figure5shows

Noise
Increasingly strict noise emission standards are forcing manufacturers andoperatorsofindustrialfacilitiesto reducethenoisegeneratedbymachinery. In /5/ the permissible noise levelswerereducedby5dB(A).Thenew action value (daily exposure value) is now80dB(A).

Power/weight ratio, controllability

Frequency converter technology for electricalmotors,whichhasbeenimprovingsteadilysincetheearly1990s, isallowingtherangeofapplicationsin which side channel blowers are used to be expanded considerably.The degree of variation can be reduced, since a single controlled blower can be used to achieve rpm ratios of up to 10. Furthermore, frequency conver96 Pumps,CompressorsandprocessComponents2011

Fig. 5: Suction-side performance map of a single-stage high-performance side channel blower

Compressors Sidechannelblowers

turbulent flow

magnetic noises

motorfannoise

Pressurereleaseprocesses, Bladeentry

Pressureside

Suctionside

periodicturbulent separations

Fig. 6: Noise sources of side channel blowers

In order to meet the new requirements,primarymachinedesignmeasuresmakethemostsensesincethey avoidthepossibilityofaffectingother facility components. Figure 6 shows the dominant noise sources in side channelblowers. It is characteristic of these units that the turbulent intermixing zones intheportsandinthesidechannel along with the motor fan produce broad-spectrumnoiseuponwhichthe tonalnoisecomponents,whichthemselvesarehighlyobjectionableinsubjective terms, is superimposed. They areproducedwhenthebladespassby the interrupter between the suction and pressure ports. As the blade ap-

proaches theinterrupteronthe pressure side, pressure variations, which radiateoutwardintheformofnoise, areproduced.Ontheinterruptersuction side, the processes that occur when the pressure is relieved as the bladecellsopenareresponsibleforthe noise that is emitted. Under certain operating conditions periodic turbulenceseparationsoccurringalongthe facesofthebladesareafurthersource oftonalnoise.Thenoisecalculationis basedontheLighthillequation,which is fundamental in aeroacous ics; (4) t foundin/9/.

Theleftsidecharacterizestheacous ic t field;therightsidewithitsthreeadditive terms characterizes the acousticsources.Thefirsttermenclosedin the braces describes broad-spectrum turbulentflownoises;theseconddescribes fluid interactive forces at fixed boundary surfaces, and the third represents mass flows that vary over time.The turbulent flow areas in the sidechannel,thechangesofdirection, the silencers, and the motor fan may beassignedtothefirstterm.Fluidinteractive forces are generated at the pressure-side interrupter and by turbulent separations that occur on the facesoftheblades;seesecondtermin (4). The nonstationary, periodic pressure relaxation processes that occur onthesuctionsideoftheinterrupter canberepresentedbythethirdterm . After the source terms have been expressed relative to location and time, their acoustic effects may be calculated/6,7,8/.Forasingle-stageblower fittedwithhosesonbothsides,theAweightedoverallsoundpressurelevel is

(5)

(4)

Petrochemical, Gas Processing, Refineries

You are in charge of the process. We supply the matching compressor.

Oilfree Mehrer-compressors have a long history in robust gas process technology and petrochemical industry. They are well known for their purity, range and reliability.

Customized Compression

www.mehrer.de

Josef Mehrer GmbH & Co KG P.O. Box 10 07 53, 72307 Balingen, Germany Phone +49 (0)7433 2605-0, Fax +49 (0)7433 2605-41 E-Mail info@mehrer.de, Web www.mehrer.de

Pumps,CompressorsandprocessComponents2011 97

PG3E

Compressors Sidechannelblowers

where K1 stands for a design seriesspecific constant and Lp stands for the motor fan sound level at rotationalspeedn.Forasidechannelblower under high loads, in other words for high differential pressures p across the blower, the following applies to the narrow-band blade tonal sound levelatfrequency (6) (7) Here, the level increases substantiallywithtipspeedu;itdecreasesasthe numberofbladeszincreases.Thelast additive term characterizes the rapidityoftheentryofthebladeintothe pressure-side interrupter in other words, what angle max is available untilalloftheedgesofthebladesmax are completely enclosed by the interrupter. Accordingly, in a side channel blower a large angle max results in smallbladetonalsoundlevels. A narrow-band spectrum typical of a side channel blower is shown in Figure7.

acoustics it is a common practice to define acoustic efficiency as the ratio ofacoustictohydraulicoutput. (8) Figure 3, which shows acoustic efficiency for the past 20 years, illustrates the progress that has been made in combatingnoise.Thereductionofthe acoustic output to 1/3 of the initial valuecorresponds,withthesamehydraulic performance, to a noise level reduction of about 5 dB. Currently, a research consortium consisting of manu acturersanduniversitiesisworf kinghardtoreducefurtherthenoise producedbycompressors,pumpsand similarmachinesandalso,inparticular,totakethepsychoacousticaspects intoaccount.

Inwatertreatmentandsewagetreatment facilities using ozone or oxygen,thespecificationsthatapplyto sealintegrity, theoxygenresistanceofall materialsused,and noiseemissions arestrict. Likewise, in order to transfer gas in fuelcells highoperatingreliabilityandalong lifecycles, lowdrivepower, lownoiselevels,and highcontrolaccuracy arerequired. Technical specifications for the bloweranditsaccessoriesmustalso be ob erved when blowers are used s in sewage aeration systems and in flue gas analysis and filtration systems.Thelargenumberofmodificationsmadeonmachinesusedforenvironmental applications presents a major challenge for manufacturers intermsofdesignvariationmanagement, quality assurance, and cost control.

Specific blowers for environmental technology

In recent years, specific side channel blowershavebeendevelopedtomeet thehighdemandsoftheenvironmentalindustry.

Summary
Side channel blower technology has advanced noticeably in recent years. Efficiency levels, which now approach those of volumetric pressure-generatingmachines,highpower/ weight ratios, the ability to control devices over a broad range of rotational speeds, and low noise levels haveimprovedtheimageofthistype ofblower.20yearsagoitwasconsidered by many to be a dying breed. Thehighsingle-stagepressurelevels, which cannot be achieved by other compressors,pumpsandsimilarmachines, permit high pressure ratios atlowspeeds.Thisoffersdesignadvantages for high-load components andforshaftbearingsystems.Application-specific modifications of the blower now permit it to be used in sensitive areas like medical and environmental technology as well as inmarketsofthefuturelikeresidualenergyutilizationandrenewable energies.

Fig. 7: Narrow-band spectrum of a side channel blower

Fortheinitialmachineoneseesanintense tonal increase in the sound level at 4.5 kHz. By optimizing the interrupter and blades, it was possible to reduce this level by 13 dB, a level thatissubjectivelyexperiencedbyhumanbeingsasroughlyhalfasloud. Forspecificnoisecomparisonsinaero98 Pumps,CompressorsandprocessComponents2011

Herearesomeexamples: For conveying biogas, only compressorshaving lowleakrates, non-corrosivesurfacesexposedto gas,and insomecasesATEXconformity aresuitable.

Compressors Sidechannelblowers

Symbols and abbreviations: A a c D fST K1,K2 Lp M m2 m/s m/s m N/m3 Hz dB dB Nm kg/s kg/(sm )
3

References
Area Speedofsound Fluctuationvelocity Impellerdiameter Fluctuationforcerelativetovolume Bladefrequency Constants Soundpressurelevelat1mdistance Torque Massflow Massflowrelativetovolume Polytropicexponent rpm Power Soundpressure Pressure Acousticsourceterm Gasconstant Lengthofwettedbladeoutsideedges Temperature Time Tipspeed Volume Volumetricflow Numberofblades Diameternumber Efficiency /6/ Dittmar, R.: Side Channel Noise, Overview and Summary, GDD-Report 96.05.07,unpublished /7/ Grohmann, T.: Lokalisierung und Klassifizierung tonaler Schallquellen inSeitenkanalgeblsen,Diss.Univ. Erlangen-Nuremberg,2009 /8/Dittmar,R.:GeruschvonSeitenkanalverdichtern, GDD-Report96.01.02,2002, unpublished /9/ Lighthill, M.J.: On sound generated aerodynamically, Part I: General theory;PartII:TurbulenceasaSource ofSound;Proc.Roy.Soc.London(A)211 and222(1952,p.564587);(1954,p. 131) /1/Grabow,G.:Daserweiterte CORDIER-Diagramm fr Fluidenergie- maschinen und Verbrennungsmotoren, Deutscher Verlag fr Grundstoffindustrie,Leipzig/Stuttgart,1993 /2/ DIN EN 60034-30, Beuth-Verlag, 2009 /3/Schreiber,C.:Investigation Control, GDD-Report 92.08.09, 2009, unpublished /4/GDD,DruckerzeugerfrstrmendeMedien,DE-Gebrauchsmuster [Germanutilitymodel]200220578.9 /5/ECNoiseDirective2003/10/ECof Feb.15,2003

n n,n P p p q R smax T t u V z max

min W N/m2 N/m

2 2 1

kg/(ms4) m /(s K)
2

m K s m/s m3 m3/h kg/m degrees 1/s

3

Density Speednumber Flownumber Interrupterenclosureangleonthe pressureside Pressurenumber Angularfrequency

Subscripts ak DS G hyd K mech pol R S vol W 1 2 Acoustic Pressureside Blower Hydraulic Sidechannel Mechanical Polytropic Restingvariable Blade Volumetric Shaft Entry Exit

Dr.-Ing. habil. Rudi Dittmar, Manager Development Engineering Gardner Denver Deutschland GmbH, Bad Neustadt Dr.-Ing. Thomas Grohmann, Development Engineer Gardner Denver Deutschland GmbH, Bad Neustadt Dipl.-Ing. (TU) Mario Kempf, Development Engineer Gardner Denver Deutschland GmbH, Bad Neustadt

Pumps,CompressorsandprocessComponents2011 99