Regen Blower Technology from Becker Pumps

regen blower

Regen blowers move air using non-positive displacement. Becker regen blowers are available in two different models that include eight variations, all of which are dry, oil-less pumps. Each model features one or two stage operation and are available for pressure or vacuum service.

Our regenerative blowers feature integrated accessories, so there is no need to select and install separate valves or filters, making them less expensive and reducing the space required for installation. They are also reconfigurable, so if need be, the relief valves and filter positions can be modified or reversed.

Our regenerative blowers are compact, quiet, and come standard with TEFC Motors. They are environmentally friendly and never require oil or grease. This means they deliver clean, oil-free discharge air.

 

Improving Efficiency for the Regen Blower Machinery

Introduction

The side channel, regen blower design has been a core product in the industry for over fifty years. Continuous, pulsation-free volumetric flow is a distinctive feature of the regen blower, this is particularly the case when equated to reciprocating machinery. When compared to axial and radial machines, the side channel blower generates a substantial pressure ratio.

In the side channel regen blower, a rotor disc accelerates all intake air that it then passes around the outer area of the side channel. Then the air is transported around the outside of the side channel and into a chamber of the rotor disc. While it is revolving around the rotor disc, this process is consistently repeated and pressure is built up. After half a rotation, a portion of this compressed air leaves the device. The rotor disc then sends the remaining air to the inlet of the device where it mixes with the fresh air.

The regen blower model series the production stage has already been reached, however, it is still a possibility to make optimizations that are important for enhancing efficiency. With some statutory requirements for optimization of the regen blower drive, improving the flow area will increase the efficiency of the blower.

Regen Blower Drives

New efficiency classes were recently introduced by legislature that must now be implemented by users.

The legislature states that all motors with 0.75 kW or more need to have a rating of at least 77.4% (2-pole motor) efficiency. Motors with higher power ratings must have an efficiency of at least 95.4%. This efficiency class IE2 (high efficiency) is the starting point in significantly reducing the energy consumption of a motor. These efficiency values were further tightened after January 1, 2017. During these first two phases, the minimum efficiencies were required to increase. In the first phase, the minimum was pushed up to 95.8%, based on a 2-pole motor, and is required for any motors with shaft power ratings of 7.5 kW and higher. On January 1, 2017, smaller motors with power of 0.75 kW and above were required to meet the values of efficiency class IE3 (premium efficiency). There is, however, an alternative option which required users to equip motors with an electronic speed control.

The regen blower motors can be advanced by increasing the quality of materials they are made from and making geometric revisions such as motor size and package length. This often leads to high production costs, but these costs are recouped quickly by significantly lower operating costs. Nevertheless, these initial costs can make it difficult to maintain success in the market.

Motor efficiency is already relatively high when compared to side channel blower efficiency. This makes it vital for the hydraulic and volumetric efficiency of the compressor to reach a substantial power consumption reduction. Any increases to the motor cost should be remedied by a further optimized side-channel blower. The regen blower drive makes up a large percentage of the total cost of the regen blower, and it is a struggle to maintain a low cost while also increasing overall efficiency. The regen blower is capable of being utilized at a variety of operating points. It is important to reach the highest efficiency of all possible applications. This is because the device load will change with each operating point in addition to the efficiency changing.

efficiencies of regen blower motors

Regen Blower Device Concepts

3.1 Stages

Common in many regen blower designs is the double-sided rotor discs. They can be used for two-flow or two-stage configurations. In these two-stage operations, the pressure ratio is increased causing volume flow to decrease. The construction of the rotor disc must ensure that both halves of the rotor disc are completely sealed off from each other. However, in the double-flow operation, the volume flow is upped by dropping the pressure ratio. By utilizing both operating configurations the device is capable of being better adjusted to each customer’s operating point while utilizing many of the same parts. This helps increasing overall efficiency.

3.2 Flow Route

Specifications of the primary dimensions are a crucial aspect of reaching regen blower optimal design. The basic variables of the geometry are configured through a combination of rotor disc outside and inside diameter, length and design of the interrupter, number of blades, blade angle, etc. Once all these values have been established, inlet and outlet flow channels are designed so the pressure build-up can take place in a controlled manner. 3D CAD software ensures optimization of these channels. Using a computational fluid dynamics (CFD) simulation, the effectiveness is tested. In this simulation, the regen blower represents a complex, transient computational model.

This testing ensures the optimizations produce desired results before the first models are created, making many other tests unnecessary.
Next, resulting parts are tested using casting production methods. These casting tests will indicate what designs cannot be used or will have higher costs. There are compromises which must be made when costs and flow optimization are taken into consideration.

Another aspect which is important to the optimal design of the regen blower is the distance of the gaps between moving and static parts. Depending on what casting process is used, different manufacturing tolerances can be reached. It is commonly found that die casting is more accurate than sand casting. The manufacturing tolerances for the subsequent device are also important. The larger the tolerances and gaps between parts, the greater the cause of loss. This plays a very important role on the overall efficiency of the regen blower. Due to this, the goal is to keep tolerances as small as possible while still maintaining reasonable production costs and reliable production processes.

Speed Adjustments to Change the Point of Operation

Side channel regen blower with integrated converter

For contact-free turbomachinery, a regen blower is best suited for operation with several speeds. This allows the user to increase the power density by increasing speed, usually up to 100-120 Hz. This also makes it possible for the customer to adapt the speed and the volumetric flow to their personal needs.

It is because of these characteristics that the device is applicable in a wide range of operating conditions at a reasonable efficiency without losses from blow-off valves or throttles. Frequency converters can also be built into the drive for more user-friendly oprerations.

Design of the Regen Blower

Design now plays a very important role in the regen blower. Efficiency-optimized designs must not have a negative impact on the flow route. The overall design has limitations with respect to the outer shape of the device. In general, it must be a good compromise between appearance and optimal function.

Summary

When the previously mentioned aspects are put together, it leads to a new, optimized regen blower. This blower consumes less power at a comparable operating point. Improving upon the individual components of a regen blower makes it possible to achieve major optimization, even for devices that have existed for some time.

There are many positive effects to this process. These include the decrease of the weight and size as well as improving the ease of integration. This conserves resources and positively effects the energy performance of the regen blower. The optimization of the flow route is also a positive effect on the noise the device produces. Normally a large amount of flow noise is created, this issignificantly reduced in the newly designed regen blower.

The Becker Regen Blower for Vacuum

Single stage blowers for vacuum feature:

  • 100% oil-less operation
  • Quiet
  • Compact
  • High performance
  • Integrated inlet filter
  • Integrated vacuum relief valve
  • Contact-less
  • Minimal maintenance
  • Convertible to two stage operation

Two stage blowers for vacuum feature:

  • 100% oil-less operation
  • Quiet
  • Compact
  • High performance
  • Integrated inlet filter
  • Integrated vacuum relief valve
  • Contact-less
  • Minimal maintenance
  • Convertible to single stage operation

Variair Regen Blowers for Vacuum

  • 100% oil-less operation
  • Patented intelligent variable speed controller
  • Quiet
  • Compact
  • High performance
  • Integrated inlet filter
  • Contact-less
  • Minimal maintenance
  • Maintains constant vacuum level

 

The Becker Regen Blower for Pressure

Single stage blowers for pressure feature:

  • 100% oil-less operation
  • Quiet
  • Compact
  • High performance
  • Integrated inlet filter
  • Integrated pressure relief valve
  • Contact-less
  • Minimal maintenance
  • Convertible to two stage operation

Two stage blowers for pressure feature:

  • 100% oil-less operation
  • Quiet
  • Compact
  • High performance
  • Integrated inlet filter
  • Integrated pressure relief valve
  • Contact-less
  • Minimal maintenance
  • Convertible to single stage operation

Variair Regen Blowers for Pressure feature:

  • 100% oil-less operation
  • Patented intelligent variable speed controller
  • Quiet
  • Compact
  • High performance
  • Integrated inlet filter
  • Contact-less
  • Minimal maintenance
  • Maintains constant pressure

To learn more or to discuss what type of regenerative blower is right for you, contact Becker Pumps.

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