TLT-Turbo GmbH to Attend Power Plant Technology Congress

TLT-Turbo GmbH nimmt am Kraftwerkstechnischen Kolloquium teil

TLT-Turbo gab heute seine Teilnahme am Kraftwerkstechnischen Kolloquium der Technischen Universität Dresden bekannt. Die Veranstaltung findet vom 18. bis 19. Oktober im Internationalen Congress Centrum in Dresden, Deutschland, statt.

Mit rund 900 Teilnehmern pro Jahr und über 150 ausstellenden Unternehmen ist diese Veranstaltung, die bereits zum 54. Mal stattfindet, eine der stärksten wissenschaftlich-technischen Konferenzen.

Patrick Baumgärtner, Produktmanager für Service & Power Fans bei TLT-Turbo kommentiert:

„Wir nehmen bereits seit mehreren Jahren an dieser wichtigen Veranstaltung teil. In diesem Jahr werden wir die TLT-Turbo-Kraftwerksbelüftungssysteme und die damit verbundenen Dienstleistungen vorstellen. Das Angebot von TLT-Turbo deckt ein breites Spektrum an Herausforderungen und Anliegen der Betreiber ab, darunter Effizienz, Nachhaltigkeit, Betriebszeit und Zuverlässigkeit. Erfahren Sie mehr über die Optimierung und Nachrüstung Ihrer aktuellen Belüftungssysteme, neue Trends beim der Effizienzsteigerung und die neuesten Innovationen von TLT-Turbo. Einige der Lösungen amortisieren sich bereits nach einem Jahr und lohnen sich daher auch trotz kurzer Restlaufzeiten für Sie. Auch die Verfügbarkeit von Ersatzteilen und die unvorhergesehene Notwendigkeit, Kohlekraftwerke als eine starke Säule der deutschen Wirtschaft zu betreiben, ist heutzutage eine Herausforderung für uns alle. Deshalb möchten wir Sie einladen, mit uns ins Gespräch zu kommen.“

Der Messeauftritt von TLT-Turbo befindet sich am Stand 1 und wird von Produktmanager für Service & Power Fans Patrick Baumgärtner, Gruppenleiter für Aerodynamik & Akustik Florian Neff,Regional Sales Manager Ersin Cetin und Head of Service & Power Fans Johann Freer betreut.

Für weitere Informationen über TLT-Turbos Kraftwerksventilatoren klicken Sie bitte hier.

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Korrosion an Kraftwerksventilatoren

Die Energietechnik befindet sich weltweit im Wandel. Der rasche Ausbau der erneuerbaren Energien, volatiler Stromerzeugungsanlagen, erfordern eine deutlich höhere Flexibilität der konventionellen Anlagen. Dies hat zu einer Reihe neuer Herausforderungen für die dort eingesetzten Ventilatoren geführt, dazu zählen z. B.:

  • Eine erhöhte Anzahl von Start- und Stoppvorgängen
  • Weniger Volllaststunden,
  • Vermehrt Teillastbetrieb,
  • Geringere Abgastemperaturen durch Restwärmenutzung sowie
  • Kleinerer Abstand zum Säuretaupunkt

Diese Faktoren führen zu einer erhöhten Belastung der Systeme, was ein erhöhtes Korrosionsrisiko während des Betriebs mit sich bringt. Dies begünstigt Taupunktkorrosion, die zum Totalausfall von Ventilatoren und Systemkomponenten führen kann.

TLT-Turbo bietet Ihnen eine maßgeschneiderte Lösung für Ihre Anlage durch die Implementierung effektiver Korrosionsschutzmaßnahmen zur Aufrechterhaltung der Betriebszeit Ihrer Ventilatoren.

Effizienter Schutz gegen Korrosion

Der TLT-Turbo Korrosionsschutz für Ventilatoren umfasst zwei wichtige Maßnahmen: Verhindern von Korrosion, wo es möglich ist und Schutz von Bauteilen, bei denen Korrosion nicht verhindert werden kann.

Verhindern von korrosiven Bedingungen:
  • Vermeidung oder Reduzierung von Leckage von Sperrluft
  • Erwärmen von Ventilatorkomponenten
  • Optimierung der Isolierung
Einsatz von korrosionsbeständigen Materialien:
  • Wetterfester Stahl
  • Polymere und polymere Beschichtungen
  • Edelstahl
  • Beschichtungen oder Grundwerkstoffe auf Ni-Basis

Um die geeigneten Maßnahmen zur Vermeidung und Bekämpfung von Korrosion an Ventilatoren in Ihrer Anlage auszuwählen, führt TLT-Turbo eine individuelle Korrosionsrisikobewertung durch. Diese Bewertung basiert auf Ihren Betriebs- und Umweltbedingungen.

TLT-Turbo unterstützt Sie darüber hinaus mit einer Analyse Ihrer spezifischen Betriebsbedingungen, z. B. durch eine Taupunktmessung auf der Grundlage einer gemeinsamen Anlagenbegehung.

Setzen Sie sich mit TLT-Turbo in Verbindung, um Ihren Korrosionsschutzbedarf zu besprechen und das richtige Servicepaket für Ihre laufenden Anforderungen zu finden.

Optimaler Schutz gegen Korrosion bei Bestandsanlagen

TLT-Turbo führt Korrosionsrisikobewertungen durch und implementiert geeignete Präventivmaßnahmen bei der Konstruktion und Herstellung neuer Ventilatoren. Diese Maßnahmen können auch bei der Nachrüstung bestehender Anlagen oder im Rahmen der vorbeugenden Wartung während eines geplanten Stillstands durchgeführt werden.

Weitere Informationen zur Durchführung einer maßgeschneiderten Risikobewertung in Ihrer Anlage erhalten Sie von Ihrem Service-Mitarbeiter oder der Serviceabteilung von TLT-Turbo.

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TLT-Turbo Optimizes Air Flow at European Power Plant Based on CFD

In TLT-Turbo’s 145-year long history of developing centrifugal and axial fans, every fan has always been carefully evaluated through extensive testing before being deemed fit for application. These tests were greatly enhanced when computational testing became available. More recently, Computational Fluid Dynamics (CFD) simulation has greatly enhanced not only TLT-Turbo’s ability to conduct thorough product testing but has also created opportunities for developing new and improved fan types.

According to Sabine Groh, Product Manager for industry fans at TLT-Turbo in Bad Hersfeld, Germany, every TLT-Turbo fan type once was carefully evaluated and aerodynamically measured in aerodynamic test stands before being released for application in the customer’s operating environment. “The arrival of stronger computer performance has allowed us to utilize CFD simulation which has had a massive effect on our ability to develop new products and to improve existing fan types.”

Groh explains that CFD has numerous advantages, all of which have become integral to TLT-Turbo’s product development. One of the greatest advantages is that CFD has enhanced the understanding of flow phenomena more efficiently than empirical testing. By using CFD it is possible to zoom in and out of any area within the simulated geometry to determine most advantageous or disadvantageous parts or geometries. With examination options such as vectorplot, a detailed analysis of the direction within the flow is possible. Similarly, using streamlineplot or velocityplot provides a detailed view of irregularities or aerodynamic phenomena.

“This analysis helps us understand the parts or geometries that cause flow separations and turbulence which allows us to address these in our product design. We can use the CFD simulations for the development or improvement of different fan types, blade geometries or spiral casing for centrifugal fans,” says Groh.

Additionally, TLT-Turbo uses CFD to understand problems in the flow of a given customer application that might result in a loss of pressure, efficiency or untypical wear of parts exposed to the flow. This equips TLT-Turbo with the knowledge needed to carry out retrofitting and product enhancements to ensure improved future performance (see flow optimization use case below).

Flow Optimization Case Study

At a European power plant, a centrifugal fan was controlled by an inlet vane control. During operation, the blades of the vane were rattling after a while and needed repair. After replacement, the same blades were showing the same failure after some operation time. Figure 1 below shows the blade of the inlet vane control dismounted of the socket.

Figure 1: blade shaft of inlet vane control with too much clearance in the socket

It was assumed that the flow was not homogeneous before it reached the inlet vane control blade, and the use of air guiding plates was considered to correct the flow. Through the use of CFD, this pattern could be more deeply investigated resulting in a superior solution.   

Groh unpacks the process and explains how a better solution was found using CFD: “Each CFD requires four process steps. The first step is the creation of the 3D model of the geometry to be analyzed. The second step is discretization. This involves creating a three dimensional computational mesh in the model for the volume in which the medium flows. The third step is defining the boundary conditions for the simulation and as the fourth step, the simulation of the flow can be performed.”

In this specific instance, the ductwork ahead of the malfunctioning inlet vane control, the blades of the closure unit itself and the suction box behind the closure unit were all rendered in 3D models. Figure 2 below shows the geometry that was analyzed in detail in the computer model. The ductwork upstream and downstream was included to ensure the stability of the calculation in the simulation.

Figure 2: Scope of detailed simulation in the plant

After meshing of the 3D model, a simulation was performed to determine the direction of the stream in the ducting ahead the inlet vane control in more detail. Figure 3 below shows the result of the simulation.

Figure 3: direction of the stream in the ductwork ahead of the inlet vane control

The simulation showed that a separation of the stream led to turbulence in the flow ahead of the closure unit. With the validated conclusions of the simulation, TLT-Turbo was able to investigate different proposed solutions to remedy the problem. Figure 4 below shows the streamline plots of these different solutions.

Figure 4: Comparison of different countermeasures against the turbulence

The conclusion was that a combination of two countermeasures in the ducting would be the most advantageous solution. So ahead of the closure unit, TLT-Turbo installed a suction nozzle that helped guide the incoming flow into the duct (see blue colored suction nozzle in Figure 5 below).

Behind the closure unit, TLT-Turbo also welded a split plate (blue colored plate in Figure 5) into the suction box to help guide the stream further into the inlet vane control ahead of the centrifugal fan.

Figure 5: implemented solution to solve the problem with the inlet vane control

In Conclusion

The use of CFD has become an essential tool to TLT-Turbo for the development of new and more efficient fan types and blades. Instead of building numerous test models for each proposed blade or impeller type with subsequent aerodynamic model testing, different geometries can be compared in the CFD simulation directly. However, the value of CFD doesn´t end there. Increasingly, TLT-Turbo is also using CFD for aerodynamic optimization of flow in customer operating environments.  That includes solving aerodynamic problems such as the example above, and for reducing wear, pressure loss or in general creating a more homogenous flow of the gas or air in the plant to maximize efficiency. Finally, the success of performance improvements as a result of replacing a fan in an existing casing, can be verified.

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TLT-Turbo GmbH Announces Contract for Wuhan Sinter Project

TLT-Turbo GmbH, global ventilation fans and systems manufacturer, today announced its success in winning a contract for the supply of Sinter fans, including complete drive system, to Baosteel for the Wuhan Sinter Project. The announcement comes amid the COVID-19 global health crisis and further indicates improving business conditions in Wuhan.

TLT-Turbo has secured a contract together with consortium partner, TMEIC (Toshiba Mitsubishi-Electric Industrial Systems Corporation) for the supply of two complete fan systems to Baosteel. Headquartered in Shanghai, China, Baosteel is globally recognised as one of the most competitive iron and steel companies with the highest level of modernization in China.

TLT-Turbo’s delivery on the project will include the supply of two sinter waste gas fans as well as the accompanying drive motors, frequency converters, transformers, switch gears and control panels. TLT-Turbo will also fulfil the role of consortium leader for the project and will take the lead on commissioning and final installation of the fan systems.

“This newly secured contract adds to the growing list of projects that TLT-Turbo has been a part of in China recently – each of which reflects our excellent teamwork and long-term success,” says Ma Le, TLT-Turbo Sales Representative based in the region.

Ma Le adds that this is the fourth contract that TLT-Turbo has won since establishing a working relationship with Baosteel in 2013. Since 2013, TLT-Turbo has delivered a total of eight sinter fans to Baosteel – one of which is the largest operational sinter fan in the world.

“The success of this relationship is built completely on teamwork. The fact that Bao Steel always returns to TLT-Turbo to order our fans also speaks highly of our commitment of quality. The resilience shown by the TLT-Turbo global team is evident in their continued success in securing contracts in this region,” adds Ralph Mansius, TLT-Turbo GmbH Sales Liaison.

A Growing Presence in China

In total, TLT-Turbo has won contracts for 18 Sinter Fans since entering the Sinter market in China in 2012. Aside from their continued success with Baosteel, TLT-Turbo also signed an additional two contracts in China’s sinter market this year.

Another notable success coming out of the region is the continued business in the CDQ (Coke Dry Quenching) market. In 2020, TLT-Turbo has won contracts for a total of 10 CDQ Fans. Says Mansius: “This proves that we are a market leader in our field – and that we are committed to working together as a global team to keep up momentum throughout the COVID-19 crisis.”

Enduring Through the COVID-19 Crisis

Ma Le acknowledges that with the COVID-19 crisis still evolving in all parts of the world, it is to be expected that some orders might be coming in slower than usual. “Businesses across the world will all be bracing for its long-term effects. However, we strongly believe that through the combined efforts of the regional TLT-Turbo teams across the world, we will be able to endure through this crisis and for long after it has passed. We are sincerely thankful to every member of the TLT-Turbo global team for the part they have played in our continued success and resilience. We have all risen to the challenge of temporarily changing how we do things – but this is just another example of Ventilation Redefined.”

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