Environ Make Energy Efficient Aerators
100 HP Energy Efficient Aerators Installation at M/s. Aurobindo Pharma Ltd. - Vizag Plant
ENVIRON make ‘Energy Efficient Aerator’ is highly efficient mechanical surface aerator especially designed for the use in the following systems.
|
|
|
|
Years of intensive Research & Development have accomplished the development of the ‘Energy Efficient Aerator’. The result is a sturdy unit which combines high oxygenation efficiency (Oxygen Transfer Capacity ranging from 1.6 To 2.8 Kg per HP/Hour depending upon the size & atmospheric condition) with thorough mixing and propulsion of the influence to disperse the oxygen throughout the whole mass of the effluent zone and vigorous agitation to achieve the minimum ripple velocity to keep the solids in suspension. The entire design is amazingly so simple that it is very easy to install, to run AND to maintain. It can be mounted on R.C.C. platform or on fabricated steel platform or on pontoons.
New Generation of Energy Efficient Aerators with Specially designed Impellers. Offered for SIDE WATER DEPTH upto 6.0 mtrs. Aeration Tanks.
Special Features
- Fabricated & Machined Base frame for 5HP to 15HP rating & for 20HP & above Heavy ISMB Beam Base is used. So vibrations are lessened & again the base is machined on the top surface, so the life of the Gearbox is increased.
- Cantilevered load reaction is passed through additional bearings and housing to beam base bottom to RCC platform. So gearbox is not at all affected by overhung load. So life of the gearbox is increased.
- Additional Bearing Support is provided to the Aerator Shaft, so the unbalanced cantilevered loads are NOT passed to the output shaft of the Gearbox, but those loads are taken by TWO EXTRA bearings & housing. So life of the Gear box is increased.
- Floor / base support area is 100 times more, so possibility of vibrations is reduced accordingly.
- Due to conical Impeller and Solid MS shaft, CG lies nearer to center, so less impact loading.
- Impeller is machined at centre for its concentric running.
- Since shaft is fully machined, NO possibility of VOUBLING of shaft concentric running of impeller is ensured.
- Since Horizontal foot mounted motor is used, the conditions are not seviour as those of flange mounted motor.
- MAINTENANCE of the gearbox is minimal & handling is easier, as the Extra Bearings are provided to the Impeller Shaft.
- Spares of the worm gearbox are easily available at comparatively lower cost.
- Wetted Parts are FRP Lined.
- Oxygen Transfer Test as per International American Standard & Wrinklers Procedure of all the Proto type Aerators upto 100 HP are taken in our Inhouse Oxygen Transfer Testing Facility before placing in the market.
- Specially designed Impeller is offered for HIGHER WATER DEPTH upto 6.0 mtrs. Aeration Tanks. (Less area for Aeration Tank is required, so saving in space)
Main Design & Constructional Aspects
Electric Motor
Electric motor is standard horizontal foot mounted, Square cage induction type three phase, totally enclosed fan cooled with IP 55, enclosure suitable for outdoor installation, being standard motor, easy availability and minimum ‘DOWN TIME’ are the direct advantages. Flange mounted motor is used for Helical gear type Aerator.
Gear Reducer
The worm gears (or helical gears only if asked for) are used having suitable service factor. The reducer bearing and gears are ‘OIL BATH LUBRICATED’ housed in cast iron casing. Since Greaves (Radicon) / Elecon make gears are used, trouble free and long working life of the gears are ensured.
First in India to offer machined beam base
Base
Fabricated and Machined base frame for below 20 HP Aerators and fabricated ISMB BEAM base machined on top for 20 HP and above ratings upto 50 HP ratings of the aerators. We are the only manufacturer in India to provide this feature.RATORS.
Shaft
Amply designed MS FULLY MACHINED solid shaft to take care of heavy, cantilevered, unbalanced and torsional loads. Supported on two numbers heavy duty antifriction bearings housed in heavy duty cast iron bearing housing. Tubular shaft in Aerators with helical gears.
Impellers at centre & shafts are fully machined
Impeller
Impeller is fabricated from mild steel plates having minimum thickness of 6 mm and designed as single shrouded pump impeller to achieve maximum oxygen transfer and mixing efficiency. Being a semi open type impeller it has got a very valuable features of SELF CLEANING. No rag, threads, other solids can get caught on blades. Hence, practically zero maintenance is required for the impeller. We are the only manufacturers who are machining the fabricated impeller to achieve the concentricity. Impeller in S. S. & RUBBER LINED construction is also offered by us. ALL WETTED PARTS ARE EPOXY PAINTED (FRP LINED AS OPTION).
Coupling
‘LOVE JOY’ type flexible coupling is used between motor and Gearbox. Heavy duty rigid type coupling is used on output shaft of the gearbox.
New Generation of Energy Efficient Aerators with Specially Designed Impellers
For compact ETP plant, we have specially designed aerators with special designed Impellers which are used for the aeration tank with lesser area and more depth creating good mixing activity at the bottom level too. This design is given for fixed type and floating type aerators which are in demand nowadays, due to space restrictions. New specially designed impeller to create excellent VORTEX, for higher Depths of Aeration Tank, no needs to provide any support in RCC Bottom slab of aeration Tank.
Floating Slow Speed Aerator
Installation of Floating Aerator at Site
They are sturdy, vibration less & having higher influence zone as compared to high speed floating Aerators. They can cater higher depths as compared to high speed Aerators. We have got more than 900 installations of this type.
Special Features
Not affected by Hydraulic level variation in aeration tank, High mixing rate and oxygen transfer efficiency. Easy to install, easy to operate and no R.C.C. platform required, hence economical installation. Flexibility of position change of aerators in case of expansion and insertion of new aerator for increase load without any change in aeration tank. These aerators are also offered with Special Designed Impellers for depths upto 6 mtrs. of aeration tanks and hence one can go for very compact aeration system.
Construction Features
Electric Motor, Gear Reducer, Base, Shaft, Impeller & Couplings are same for both the types of aerators. (Fixed & Floating Type Surface Aerators)
Floats
FRP lined as standard, or Stainless Steel SS 304, SS 316 construction can be provided if required, with necessary hooks for mooring, Nylon or Galvanized Steel rope with specially designed AIR VENT SYSTEM.
Inhouse Hydraulic Testing Facilities
Floating slow speed Aerator in our hydraulic testing facility
We are the only manufacturers who have got Hydraulic testing facilities for Aerators upto 150HP ratings. The ‘Energy Efficient Aerators’ are shop assembled and Hydraulically tested before despatch. The only ‘Energy Efficient Aerator’ in the market having one piece impeller machined to achieve concentricity after complete welding. The ‘Energy Efficient Aerator’ is supplied with wetted parts Epoxy painted (FRP lined as option). We are the only manufacturers who can supply the aerators with wetted parts, i.e. Impeller and Shaft in ‘RUBBER LINED CONSTRUCTION’ also. This is possible because of our special constructional features of the aerators. Other coats can be given on requests for right applications of ‘Energy Efficient Aerator’. For further assistance, kindly contact our process engineers to assist in selection.
Oxygen Transfer Test Carriedout For
Under the pursuit of quality assurance, ENVIRON has conducted and given in-house Oxygen Transfer Tests as per American Standard and Wrinkler’s Procedure to :
- M/S. AUROBINDO PHARMA LTD. – VIZAG for 100HP – on 20th Sept. 2002 & achieved 2.24 kg of O2/HP/HR.
- M/S. RELIANCE – HAZIRA for 50HP on 9th September 2004 and achieved 1.6 kg of O2/HP/HR.
- M/S CHEMINOR DRUGS LTD. – HYDERABAD for 30HP on 20th July 2000 and achieved 2.82 kg of O2/HP/HR.
- M/S. KODINAR SUGAR FACTORY – KODINAR FOR THEIR ORDER OF 4 NOS. 30HP AERATORS.
- M/S TAMILNADU PETRO PRODUCTS – CHENNAI for 25HP AERATOR on 16th Feb 1999 and achieved 2.20 kg of O2/HP/HR.
- M/S. SOUTH INDIA VISCOSE (SIV INDS.) – COIMBATORE for THEIR ORDER OF 10 NOS. 20HP AERATOR on 18th Aug 1994 and achieved 1.72 kg of O2/HP/HR.
- M/S. TAMILNADU PETRO PRODUCTS – CHENNAI for THEIR ORDER OF 20 NOS. 10HP AERATORS on 15th Nov 1997 and achieved 1.70 kg of O2/HP/HR Oxygen Transfer.
- M/S. TAMILNADU PETRO PRODUCTS – CHENNAI for 10HP – Aerator – with 3% salinity Water used in Testing Tank – and achieved 1.03 kg of O2/HP/HR.
- M/S. GUJARAT INSECTICIDES LTD. – ANKLESHWAR for Order of 5 Nos. 5HP Aerators on 2nd Aug 1999 – and achieved 1.82 kg of O2/HP/HR.
- M/S PATTANCHERU ENVIRO TECH LTD. – PATTANCHERU CETP– for 30HP AERATOR on 27th December 2004 and achieved 1.91 kg of O2/HP/HR.
- DEONAR SLAUGHTER HOUSE – DEONAR for 10HP – Aerator – on1st July, 2003.
- DEONAR SLAUGHTER HOUSE – DEONAR for 30HP – Aerator – on 28th Aug. 2003
- M/S DOMBIVILI BETTER ENVIRONMENT – DOMBIVILI (CETP),MIDC – for 40HP AERATOR on 7th Feb 2005 and achieved 1.98 kg of O2/HP/HR.
- M/s. Vapi CETP, VAPI – For 40HP Aerator on 20.05.2009.
- M/S TORRENT PHARMACEUTICALS LTD.,INDRAD (AHMEDABAD) for 30HP AERATOR on 13th Dec 2006 and achieved 1.96 kg of O2/HP/HR.
- M/S HINDUSTAN NEWSPRINT LTD., KOTTAYAM DIST. – for 25HP AERATOR on 9th Dec 2004 and achieved 2.40 kg of O2/HP/HR.
- M/s. Arvind Accel Ltd.- Ahmedabad – for 15 HP AERATOR on 26 August 2011 and achieved 1.84 kg of O2/HP/HR.
Product Range
The product range available is 2 HP, 3 HP, 5 HP, 7.5 HP, 10 HP, 12.5 HP, 15 HP, 20 HP, 25 HP, 30 HP, 40 HP, 50 HP, 60 HP, 75 HP, 100 HP, 125 HP, 150 HP.
Advantages of Slow Speed Aerators Against High Speed Floating Aerator
ENVIRON does not recommend High Speed version of Aerators, since 1) Their influence zone is less compared to Slow speed ones 2) They cater SHALLOW DEPTHS as compared to Slow speed ones 3) They need Rigorous preventive maintenance because of a) Shaft and Bush pattern, remaining in effluent b) Possibility of clinging, adhering of bunch of threads, bunch of hair, plastic bags, cotton rags etc. between the blade tips & housing pipe. So from the process point of view and maintenance point of view, ENVIRON highly recommend SLOW SPEED FLOATING AERATORS.
INSTALLATIONS AT CETP / ETP WITH ENERGY CONSERVATION BY “ENVIRON” ENERGY EFFICIENT AERATORS
|
||
|
||
|
||
|
||
|
