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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Research Reveals Best Wear Solutions for Ventilation Equipment

Long lasting equipment is a must have for many industries due to the cost savings that can be derived from a longer lifespan on equipment and components. At their recently upgraded testing facility, TLT-Turbo GmbH are using a new research methodology based on dust particulate samples from steel manufacturing and processing facilities to determine the best solutions for minimizing wear on ventilation equipment based on the unique abrasive factors of this specific operating environment.

TLT Turbo GmbH is one of the world’s leading suppliers of heavy-duty centrifugal fans designed to operate efficiently in the most challenging applications. In the steel industry, these fans are exposed to high dust loads which causes them to prematurely fail due to faster wear. To determine the best solutions for slowing wear and tear, TLT-Turbo researchers procured original samples of the dust present at customer facilities and used these to investigate the reasons for wear and to determine remedies for reducing it.

Factors Affecting Wear on Fans

According to Sabine Groh, Product Manager for industry fans at TLT-Turbo in Bad Hersfeld, Germany, the main contributing factor to wear is the velocity of the abrasive particle. The erosion rate measurement below illustrates the exponential increase in the erosion rate based on velocity.

(Above) Figure 1: Erosion rate in relation to velocity of particles

Groh states that additional factors include hardness, shape, number of particles and the angle between the particle jet and the surface of the fan component. The image below provides an indication of the typical shape of the abrasive particles used for research at TLT-Turbo’s newly upgraded particle jet test stand in Zweibrücken.

(Above) Figure 2: Magnified image of typical dust used in particle jet experiments

Finally, Groh argues that the particle size in comparison to the size and distribution of grain of the coating also plays a role. Figure 3 below shows a micrograph of a hardfacing layer suitable for abrasive dust with small particle sizes using a prototypical particle of 20µm. Figure 4 below shows a micrograph of a common Chrome Carbide hardfacing with a prototypical particle of 20µm as well. “In Figure 3 we can observe that the particle is less able to wash out the matrix because of the more homogenous distribution of the smaller grains. Figure 4 however shows that the large grain size and large distribution allows for easier erosion of the matrix,” Groh explains.

(Above) Figure 3: 250x magnified photomicrograph of
special Hardfacing optimized for small abrasive
(Above) Figure 4: 250x magnified photomicrograph of typical Chrom Carbide Hardfacing

This proves that if the abrasive particles are small enough to impinge between the relatively hard grains of a hardfacing, then the matrix will be washed away and the grains will easily fall out afterwards. If the grains of the hardfacing are small enough with less space between them, matrix erosion will be prevented and the hardfacing will have a higher durability.

Emerging Research Trends

Over the last 10 years, TLT-Turbo performed thousands of particle jet tests to determine the erosion rate of different coatings and materials. To achieve a comparison between these coatings, a standardized test sand with a specific grain size distribution was utilized as abrasive material (as illustrated in Figure 2 above).

“TLT-Turbo has developed an extensive database on the erosion rates of different coatings and materials that have been exposed to the test sand at different angles and velocities. This database allows us to select promising solutions for customer’s abrasive problems,” says Groh. 

TLT-Turbo has recently upgraded its test equipment and now has the capability to test using original dust supplied by the customer. Groh explains that this allows for the specific customer application, with all major influencing factors to be reproduced. In addition to the velocity and angle of the abrasive dust, a realistic indication of particle size, shape and hardness can now contribute to more accurate test results. “This means that we can provide a more definitive prediction of how a change in wear protection will affect the service lifespan of the equipment to each customer.”

Wear Test Case

The TLT-Turbo test lab asked a European customer to provide samples of dust from their facility for testing to determine how they could benefit from a coating solution suited to their specific application and environmental challenges.

(Above) Figure 5: A sample of the dust provided for testing

From this specific dust particle sample, the grain size distribution was determined by performing a sieve analysis. Particle jet experiments were then performed on two preselected coatings. These experiments are in accordance with the norm DIN 50332 and were executed for three angles: 20°, 45° and 90°.

Figure 6 below illustrates the test results. The TLT W-104 coating was determined to be the best alternative for all impact angles, however the superiority of W-104 is best illustrated when used for the 90° impact angle.

(Above) Figure 6: Erosion rate of customer dust for preselected coatings

In extremely abrasive applications, the choice of wear protection determines the service life of the fan. The upgraded test lab and particle jet test stand has afforded TLT-Turbo engineers a deeper understanding of the mechanisms behind wear and the effects of specialized solutions. This has led to new approaches in product advancement and development that are grounded in providing solutions that meet market requirements.

“The ability to use the original dust from the customer’s facility and duplicate the conditions such as velocity and the impingement angle on the coating, allows us to determine how all these factors including the shape, size and hardness of the abrasive particles affect erosion rates. TLT-Turbo has taken another great step forward in being able to reliably calculate the effect that changing in coatings to prevent wear will have on extending the service life of ventilation equipment. Establishing the best solution for wear related challenges now becomes a collaboration between TLT-Turbo and the customer.” Groh concludes.

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Exciting Development from the MVR Department!

Announcing our first MVR low flow range order!

We are excited to announce that an order has been secured for the supply of TLT-Turbo MVR fans from a globally renowned manufacturer for installation at an instant coffee production facility in Colombia.

Securing of this order comes after extensive engagement with this client over the past 4 years. The commitment and perseverance of the sales representatives involved, and the MVR team is highly commendable. Having a relationship with this client already in place means that this order may be the first step in a long-term strategic partnership.

The MVR fan that will be supplied is from the new Low Flow MVR Series. Having been in development for the past 18 months, this new addition to the MVR range is characterized by having a significantly smaller and more compact size while still delivering higher efficiencies. The development of this range is an exceptional achievement of our R&D department and product management team. Their delivery of this new range has allowed us to enter the small mass flows market which makes us more competitive.

The scope of work for the delivery, includes the supply of a 120kW drive power, approx. 4,500 kg/h mass flow, >83% efficiency high-speed MVR fan. The final installation site is an instant coffee production facility located in Medellin, Colombia.

The securing of this contract has already caught the attention of other global coffee producers and bodes well for the continued growth of our MVR department.

For more information on the TLT-Turbo MVR Range, click here.

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Pursuing Air Flow Perfection: 90 Years of Wind Tunnel Innovation

TLT-Turbo have a long-standing tradition of supplying wind tunnels especially for the motor vehicle and aerospace industry. TLT-Turbo were among the first to focus on aero-acoustic wind tunnel fans. As a supplier for some of the world’s most prominent car manufacturers, TLT-Turbo aims to become renowned as a global leader in wind tunnel fans and systems through continual innovation and a deeply ingrained passion for performance.

The development of wind tunnel production at TLT-Turbo started with their ancestral company, Dinglerwerke, who built their first wind tunnel back in 1936. Decades later, the company now known as TLT-Turbo, would be responsible for some of the world’s most notable wind tunnel installations. “From the start we set out to establish a tradition of being pioneers and innovators in this field of ventilation as we recognized the significance of these systems for vehicle testing,” says Volker Szemskat, Vice President of TLT-Turbo.

TLT-Turbo’s first wind tunnel installation for the motor vehicle industry was built in 1940 for FKFS (Research Institute of Automotive Engineering and Vehicle Engines) in Stuttgart. It was a low speed wind tunnel designed for wind speeds of up to 72 m/s. This wind tunnel was later taken over by Daimler.

Testing vehicles in wind tunnels started with projects such as Peugeot’s passing a car through the Eiffel Wind Tunnel at the rue Boileau, in Paris in 1914. The goal was to gain information on how to modify the shape of models to decrease aerodynamic drag. Since then these types of tests have advanced significantly and today, they are becoming more and more relevant as a means of testing for reducing pollutant and noise emissions. “Even the smallest gain in the aerodynamic drag leads to a decrease in consumption of fuel,” Szemskat explains.

In total, over the past 90 years, TLT-Turbo have supplied around 70 wind tunnels and test stands, of which about 30 were delivered for the automotive industry. This includes more than 70 customized fans ranging from 100 kW to 88.000 kW with diameters from 1 to 15 meters. Among these are some of the most notable facilities in the world – such as the ONERA (French Aerospace Center) Transonic Wind Tunnel S1 in Modane, France, being installed in 1949, with a 2-stage counter-rotating fan measuring 15 m in diameter with a drive power of 88.000 kW. This colossal fan remains to this day the largest wind tunnel fan in the world being in continuous operation since 1952.

Another example of the longevity of TLT-Turbo’s fans is the wind tunnel installed for Volkswagen in 1965. Its 9-meter diameter fan has been in operation in operation for over 50 years.

“The combination of our experience, with the field-proven performance and long operational life spans of these fans has made us a trusted supplier across the globe,” says Szemskat.

(Above) Diffuser section of a TLT-Turbo Aero-acoustic Wind Tunnel Fan

This status has been well maintained over the years with clients including Volkswagen, Ferrari, Ford and Audi coming back to TLT-Turbo for repeat orders.

TLT-Turbo’s 145 years of experience in ventilation design and supply has contributed to the innovations and new methods they have been able to apply to their wind tunnel designs. In 2010, TLT-Turbo supplied a fan for an aero-acoustic wind tunnel for the DLR (German Aerospace Center) which features a special blade and guide vane design for particularly low noise generation as well as composite material for the fan blades. Since then, this innovation has been applied to most of their automotive wind tunnel fans.

“Most often the development of innovations in the application of wind tunnels is guided by the needs of a particular client or the project itself. We need to think on our feet to come up with new approaches to solving challenges that arise as a project unfolds. This then informs future designs and installations and ensures that our offering is constantly evolving.”

Some of TLT-Turbo’s latest field-driven innovations include the application of their ‘Cut-off’ and ‘Lean/Sweep’ design that they have applied to their low speed aero-acoustic fan design to reduce blade tone and broadband noise. “We have also been working with the use of composite materials which has allowed us to apply 3D-geometry on the guide vanes which increases efficiency and overall performance,” Szemskat says.

The use of composite materials is also being applied in their current projects for the CAERi and CATARC automotive research institutes in China. These projects are currently in installation and commissioning phase.

For the past 12 twelve years, TLT-Turbo have changed their focus to the centerpiece of wind tunnels; the fan. “In the past, TLT-Turbo supplied turn-key wind tunnel solutions. From 2007, this offering changed to focus solely on the fan itself as the key component of a wind tunnel system. Our clients still benefit from our extensive experience and expertise in complete wind tunnel systems. This allows us to provide a tailored solution because we understand how the separate components interact with each other,” Szemskat reports.

(Above) TLT-Turbo now focuses solely on the fan itself as the key component of a wind tunnel system

“This gives us greater scope for customization. Every fan and its project planning is adapted to its specific installation. Stand-alone drive systems with local operation, control and monitoring systems and their connection to the parent digital control system also form part of our portfolio. Our experience with the supply and installation of turn-key wind tunnels means that we are able to recognize the significance of specific wind tunnel features to the design of the fan.”

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TLT-Turbo Fan Range Redesigned to Meet Specific Mining Industry Needs

Global ventilation fans and systems manufacturer, TLT-Turbo GmbH, has announced the redesign of its Auxiliary and Booster fan range. Developed in close collaboration with clients, the new designs address both efficiency and cost effectiveness, in a versatile product range that meets the specific ventilation requirements of the mining industry.

Development of the new fan range concept began in early 2015. Following a lengthy global market study to gain an understanding of the market requirements, the range was defined in mid-2017, with fabrication of the first units taking place shortly thereafter. “The development of the Auxiliary and Booster fan range would not have been possible without the input of clients. This ensured that we focused on key market driven requirements including energy efficiency, noise reduction, cost effectiveness and turnaround time,” says Michael Minges, Technical Director at TLT-Turbo Africa, who headed up the fans’ designs.

“To sell these products we needed to ensure close customer relationships and visibility. We are striving to change the industry’s mindset on the use of such fans to ensure proper fan selection for the ventilation required. In optimizing mine ventilation, efficient, high quality Auxiliary and Booster fans can add as much value as surface fan installations.”

(Above) The new TLT-Turbo Auxiliary and Booster fan range addresses both efficiency and cost effectiveness

TLT-Turbo started commissioning of the first iterations of the fan range towards the end of 2017 within the Sub-Saharan market through its Africa office. From there, they based the development of the various fan sizes of the new range on market interest. The fan designs and their performance validation was completed at the end of July 2019. They aim to complete product roll out, with all supporting documents and certification, by the end of September 2019.

Minges explains that meeting identified market demands was the main focus of the improved designs. “As energy efficiency is one of the main drivers of industrial equipment usage, and minimum efficiency requirements on certain equipment are often legislated, TLT-Turbo identified the need and opportunity in the market for more efficient mining fans compared to what is currently in use.”

The new designs include several innovative additions to enhance performance in order to provide exceptional underground ventilation. The fan range was developed using the latest in engineering flow technology which allowed TLT-Turbo to improve the aerodynamics, and thus efficiency of the fans. A unique stator design and aerodynamic fairings, all manufactured from wear resistant composite materials, result in improved efficiencies and reduced noise levels. The modularity of the fan casings allow for quick and easy assembly with interchangeable ancillary fan parts.  The motor mounting in coherence with a machined impeller track ensures low and controllable blade tip clearances for improved performance and efficiencies. Pad mount motors are used for all fan sizes and help reduce vibration levels in the axial direction of the motor significantly which leads to longer motor bearing life and lower maintenance requirements.

(Above) The first orders for the new range were received at the end of 2017

Minges says that all possible measures are taken to ensure the highest quality and best possible performance of every fan supplied by TLT-Turbo. “All fans are ISO 5801 tested, unless the client agrees to type testing on higher volume orders. We ensure the client quoted performance is met before the fans leave the factory. Test certificates on both raw data and calculated performance can be provided on request. Fan efficiency is determined with the performance test and this quality check ensures we deliver on what we promised the client. Clients are regularly invited to witness the performance tests to sign off on acceptance. The fans also come with pressure ports that can be hooked up to a calibrated handheld measuring device to measure performance in-situ.”

In addition to performance and efficiency, ease of maintenance was also a major consideration in developing the new Auxiliary and Booster range. The modularity of the product design and the interchangeable standardized parts allows for quick turnaround time on parts supply. “For example, we only have two blade types for the full product range and generally only one motor barrel per fan size accommodating various motor sizes and types. Standardization on the product is the key to successfully managing maintenance and repair as it allows ample supply of spares for companies certified to do the repair work. The design track record has indicated a longer mean time between failure (MTBF) than previous products,” Minges explains.

(Above) The new TLT-Turbo Auxiliary and Booster fan range is available to clients worldwide

The fan range is being rolled out in phases. The preliminary testing at sites located in Sub-Saharan Africa has been launched successfully. The next phase is globalization as the new range will be rolled out in the USA, Canada, Europe, Russia and Australia. Following this, product supply and support will be extended to TLT-Turbo offices in South America and India. In the interim though, Minges says that these fans can be supplied to clients worldwide from TLT-Turbo Africa.

TLT-Turbo Africa has received a number of orders for these fans since the end of 2017. These orders include South African clients seeking a solution for deepening a gold mine, and for Kamoa Copper in the DRC as an exclusive supplier. “The feedback that we have received thus far has been that the fans are meeting our and client expectations. I am proud to say that one EPC consultant used the phrase ‘super fan’ to describe the new range and indicated that he has not heard a fan of this size so quiet before,” says Minges commenting on the reception of the new range.

“The Auxiliary and Booster fan range was developed to enhance TLT-Turbo’s mining ventilation product portfolio. The product is based on historic innovative designs by the TLT-Turbo Africa R&D team. Continual product development and keeping up to date with the latest technologies is ingrained within the engineering teams of TLT-Turbo. Ensuring that innovations are market and client driven with the end result being a benefit to the industry, puts us in the forefront of advancement in ventilation solutions,” Minges concludes.

– ENDS –

MEDIA CONTACT                                                       TLT-TURBO GLOBAL CONTACT

Oxigen Communications                                            Global Marketing Office

Nicola Weir                                                                 Anna Renner

nicola@oxigencomms.com                                        a.renner@tlt-turbo.com

About TLT-Turbo

TLT-Turbo GmbH builds radial and axial flow fans for virtually any application. First-rate engineering, tradition and progress in air handling technology and a worldwide support network have been the cornerstones of their excellent global renown as a fan and systems manufacturer for more than 140 years. TLT-Turbo GmbH fans and the associated system components are deployed successfully all over the globe. To date over 10,000 fans have already been installed. Their subsidiaries, branches and agencies span the globe including TLT-Turbo offices in Germany, China, Austria, Russia, South Korea, USA, Chile, Hungary, Australia, India and South Africa.

Visit www.tlt-turbo.com for more information.

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TLT-Turbo On-site Test Lab Advances Product Quality

Global ventilation fans and systems manufacturer, TLT-Turbo GmbH, has spent the past five years investing in and equipping its on-site test lab. The test lab now provides streamlined processes for research, advancing product quality and expanded capabilities for material testing. With a focus on particle impact wear testing, the test lab is driving innovation forward at TLT-Turbo as the results help improve product reliability, quality and performance in their final operating environment.

Patrick Baumgärtner a Research and Development Engineer – and expert in wear and corrosion protection – at TLT-Turbo, has played an instrumental role in building up the test lab – located at the TLT-Turbo Development Centre in Zweibruecken, Germany – to its current capabilities. Together with Sabine Groh, Industrial Fans Product Manager at TLT-Turbo, they have been spearheading the current research.

Currently, the core field of research at the test lab is the testing of new wear-resistant materials and coatings for fan components. Baumgärtner says that the testing takes place in the lab’s solid particle impact wear test bench. There, various types of dust or abrasive particles are blasted onto the test material, varying the angle and speed of the blasting to observe the resulting wear. “We also carry out caking tests in which we select, for example, anti-adhesive layers for our fans, in order to find suitable solutions for customer applications. A further main focus is the analysis of process residues that can have an abrasive or corrosive effect. Here the composition, size distributions, pH value and conductivity in the eluate are determined,” Baumgärtner explains.

(Above) Part of the materials testing laboratory in Zweibrücken

TLT-Turbo’s approach is to continuously test materials, coatings and components in order to produce fan components that are designed for performance excellence in any operating environment – no matter how abrasive. This testing is applied to current and new products in development but also to samples that are brought in from client sites in order to establish the wear patterns caused by their specific environment. In this way, TLT-Turbo is able to provide each client with a customized solution that will last longer and require less maintenance. 

The test lab now offers facilities for metallography, a stereomicroscope, a pycnometer for determining the density of materials and coatings, and an automated solid particle impact wear test bench. “The capabilities of the test lab open a lot of doors for advanced research that will make a positive contribution to the engineering community at large as well,” says Baumgärtner. “Under my supervision, studies and thesis research takes place in the laboratory in cooperation with local colleges and universities. For me, this is the basis for successfully researching and developing new solutions in our field.”

According to Groh, the test lab has almost endless possibilities for the improvement of product delivery to clients. “Our customers are often operating TLT-Turbo fans in abrasive and/or corrosive environments. To develop suitable solutions that match the wear resistance against particle impact we use our automated solid particle impact test bench. Compressed air accelerates a defined mass flow of abrasive particles to velocities up to 300 m/s and propels them onto a piece of sample material. This leads to material loss and wear that we can examine.  It is even possible to use original dust from a customer’s plant to evaluate the most suitable solution for them. By varying the impact angle we can observe system characteristic wear curves. With this knowledge we can provide customized solutions for many processes.”

(Above) Exchangeable impeller blade exposed to massive wear

These customized solutions can be best illustrated in the selection of coatings. This, says Groh, has an immensely positive impact for TLT-Turbo clients. “If we were to propose a new coating for a customer, the wear rate of the coating would be determined first. That is the main scientific-based decision criteria for wear resistant coatings. If the coating has a superior wear rate compared to other coatings or at least a wear rate that is on par with other coatings and another beneficial quality such as anti-stick effect, corrosive resistance or a cost advantage it will be implemented into TLT´s coating portfolio.”

Groh says that they have also conducted tests that have led to the development of completely new proprietary coatings. “During the manufacturing process, coatings were tested to see the influence of welding heat on coating qualities – such as the development of cracks – to ascertain how to avoid damage caused by heat or weld splashes. We conducted research and testing on combining welded coatings and thin layer coating into a Hybrid Coating which can dramatically increase the operational lifespan of TLT-Turbo fans at their clients’ plants.”

This is one of numerous examples of how TLT-Turbo’s testing capability can positively impact ventilation systems across all applications. “Due to the broad database of wear tests on various materials and coatings, we are able to offer tailor-made wear protection solutions for various processes of our customers,” Baumgärtner acknowledges.

(Above) Blasting nozzle and sample holder of test bench

Groh agrees, adding that the wide variety of chemical compositions and coating conditions such as acceleration of coating powder and heat development make it extremely difficult to objectively find the best coating by carrying out testing at a customer plant. “The process of reaching just initial findings in these conditions is very time consuming. In addition to this, there is a broad variety of conditions to contend with at different customer plants that hinder an accurate comparison of different coatings at different plants. If you test different coatings on one machine you might get a rough estimation what coating is superior, however different wear rates of coating cause imbalances in the impeller and vibrations at the fan.”

She elaborates by explaining that finding a precise comparative measurement on different coatings is impossible without being able to analyse how the wear rate changes at different angles. “At the test lab we can control the conditions to find precisely what we are looking for in a shorter timeframe. Additionally we are able to replicate the fan’s operating environment. We can run tests using dust collected from the client site while simulating particle speeds that match the client’s environment to precisely simulate wear rates.”

In the laboratory environment, the TLT-Turbo team is also able to determine additional coating properties as they have the capability to run additional experiments, e.g. corrosive resistance, anti-stick effect, robustness, heat resistance, suitable application methods, and combination possibilities like hybrid coatings.

The test lab has afforded TLT-Turbo engineers a deeper understanding of the mechanisms behind wear and the effects of specialized solutions. This has led to new approaches in product advancement and development that are grounded in providing solutions that meet market requirements.

“The analysis of residues from plants has a great influence on product development as we are making more informed decisions when choosing materials for corrosive and abrasive environments,” says Baumgärtner.

This has also had an impact on TLT-Turbo’s aftermarket service offering. The test lab, has allowed for new customer services can be generated, such as the performance of specific tests for customers. “The development of new solutions for specific customer problems is now much faster and more accurate. Also the suitability of low cost approaches or solutions that allow for wear induced damages to be repaired on-site integrate effortlessly into TLT-Turbo’s existing solutions,” Groh concludes.

The test lab enables TLT to continuously improve their solution portfolio for different customer problems with a focus on wear. The combination of understanding the client’s exact requirements and challenges and having a tool that allows engineers to find the best solutions from a scientific basis are a key factor for success in the market and play an important role for TLT-Turbo’s on-going product development and quality client delivery.

– ENDS –

MEDIA CONTACT                                                       TLT-TURBO GLOBAL CONTACT

Oxigen Communications                                            Global Marketing Office

Nicola Weir                                                                 Anna Renner

nicola@oxigencomms.com                                        a.renner@tlt-turbo.com

About TLT-Turbo

TLT-Turbo GmbH builds radial and axial flow fans for virtually any application. First-rate engineering, tradition and progress in air handling technology and a worldwide support network have been the cornerstones of their excellent global renown as a fan and systems manufacturer for more than 140 years. TLT-Turbo GmbH fans and the associated system components are deployed successfully all over the globe. To date over 10,000 fans have already been installed. Their subsidiaries, branches and agencies span the globe including TLT-Turbo offices in Germany, China, Austria, Russia, South Korea, USA, Chile, Hungary, Australia, India and South Africa.

Visit www.tlt-turbo.com for more information.

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TLT-Turbo Introduces the Next Generation of Mechanical Vapor Recompression

TLT-Turbo GmbH, a global ventilation fans and systems manufacturer, has launched a new range of mechanical vapor recompression fans, with ceramic hybrid bearings that provide an exceptionally long operational lifespan. Integrating the latest ventilation technologies, this fan offers numerous advantages regarding performance efficiency, minimal maintenance and high reliability.

The TLT-Turbo fan for mechanical vapor recompression (MVR) has been in development since 2012 since the first case studies were carried out. Following intensive discussions with clients, TLT-Turbo established that a need existed for low maintenance MVR fans. This was followed by four years of intensive research, product testing and consultations with clients. The first MVR fans were rolled out in 2016 while continual product improvement has remained a focus area for TLT-Turbo.

“MVR fans have been available on the market for some time but instead of just following the trend, TLT-Turbo took time to ensure that we came to the market with a completely new, state of the art MVR solution,” says Mario Schmidt, Head of TLT-Turbo’s Vapor Fans business segment. “And we continue to have on-going discussions and feedback exchanges with our clients worldwide in order to continuously adapt and improve our MVR offering to their requirements.”

According to Schmidt, the features of TLT-Turbo’s MVR fan, such as the lower maintenance requirements and the introduction of hybrid ceramic bearings, underscores their commitment to developing products in close alignment to their clients and their needs, and also speaks to TLT-Turbo’s key objective for continual innovation.

(Above) The new TLT-Turbo fan for Mechanical Vapor Recompression

The implementation of hybrid ceramic bearings is a key differentiator of the TLT-Turbo MVR fan. “Our clients are amazed by the possibility of a hybrid bearing operating at high speed without circulating oil. Conventional roller bearings do not provide the required support for operating the fan in a broad operational speed range without running into harmful resonance frequencies (under critical operation). Thanks to continuous enhancement in recent years, especially through the use of ceramic materials, more effective roller bearings are available today. The use of hybrid bearings with steel rings combined with ceramic rollers has been established in many industrial applications and in the case of the TLT-Turbo MVR fan, hybrid ceramic bearings mean significantly lower maintenance requirements and better operational performance,” Schmidt explains.

The hybrid ceramic bearings used in TLT-Turbo MVR fans are life time greased and can be operated for up to 10 years without requiring maintenance. To enhance this benefit for clients, TLT-Turbo introduced an additional device to the fan’s design that allows for the bearing to be re-greased from the outside in order to further simplify maintenance and to increase the fans’ service life.

High motor speeds, a wide range of optimized impellers and the allowance for high temperature and pressure increases complement the lifetime greased hybrid ceramic bearings to ensure that clients benefit from the enhanced performance and efficiency that they have come to expect from TLT-Turbo products. These factors allow for operation of the fan below critical speed which ensures both reliability and safe operation.

(Above) A high efficiency will be achieved with an optimized impeller design

“Reliability and safety are key concerns for our clients and TLT-Turbo has addressed this in the MVR fan by using high quality components. Thanks to the use of the hybrid bearings, no oil supply or oil pump is necessary which means that no oil can contaminate the product. In addition to this, the fan also features temperature and vibration monitoring and remote monitoring of the bearing is possible as well. Our entire manufacturing process is carried out according to all major quality standards, including DIN ISO 9001,” says Schmidt.

The TLT-Turbo MVR fan is suited to numerous applications in the chemical, pharmaceutical, waste water treatment, and the organic natural product production industries as well as in the food and beverage process and manufacturing sectors. “Since 2018, we have received 35 orders for MVR fans across the globe with one installation completed. Thus far, the feedback from clients has been very positive. We have received reports that the bearing temperature is considerable lower than that of other comparable MVR fans and that our fan runs with less vibration than other MVR fans,” Schmidt affirms.

“Overall, TLT-Turbo’s objective was to offer our clients a mechanical vapor recompression solution that would outperform what was currently available on the market. We have delivered a fan that requires less maintenance while providing high efficiency and reliability. This is exactly what clients would expect from TLT-Turbo as a world class fan manufacturer and global service organization.”

– ENDS –

MEDIA CONTACT                                                       TLT-TURBO GLOBAL CONTACT

Oxigen Communications                                            Global Marketing Office

Nicola Weir                                                                 Anna Renner

nicola@oxigencomms.com                                        a.renner@tlt-turbo.com

About TLT-Turbo

TLT-Turbo GmbH builds radial and axial flow fans for virtually any application. First-rate engineering, tradition and progress in air handling technology and a worldwide support network have been the cornerstones of their excellent global renown as a fan and systems manufacturer for more than 140 years. TLT-Turbo GmbH fans and the associated system components are deployed successfully all over the globe. To date over 10,000 fans have already been installed. Their subsidiaries, branches and agencies span the globe including TLT-Turbo offices in Germany, China, Austria, Russia, South Korea, USA, Chile, Hungary, Australia, India and South Africa.

Visit www.tlt-turbo.com for more information.

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ACHEMA 2018 – Strong visitor Interest at the
TLT-Turbo Booth

At this year’s ACHEMA 2018, we once again presented our MVR Turbo Fan for mechanical vapor recompression. This year, we demonstrated the fan to the audience with a sanded and highly polished impeller, as an example of how it is applied for use in the pharmaceutical industry.

The TLT-Turbo Mechanical Vapor Recompression (MVR) fan attracted a large number of visitors to the booth. Our engineers presented the energy-efficient process in detail to interested visitors representing the process, chemical and pharmaceutical industries.

The innovative bearing concept – a hybrid ceramic bearing that is grease-lubricated at the factory and requires neither regular oil changes nor an oil supply – aroused great interest. With this concept, maintenance and thus operating costs can be reduced significantly.

The units are available in two different versions: the basic version includes the fan on a base frame with monitoring sensors whereas the complete package contains a motor and frequency converter. Depending on the application, different stainless steel housings and impeller types can be selected. In addition to the standard impellers made of duplex stainless steel, and models made of super duplex or titanium are also available.

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TLT-Turbo at Drinktec 2017

Drinktec 2017 held in Munich, with over 76,000 visitors, was a special highlight for TLT-Turbo GmbH. It was TLT’s first participation at Drinktec and at our booth we presented the TLT-Turbo fan for mechanical vapour recompression – MVR for short.

In a relaxed atmosphere with pretzels and TLT-Turbo wheat beer, trade visitors were able to see the outstanding technology of the MVR fans for themselves. The innovative storage concept in particular was met with great interest from numerous visitors. Both plant constructors and plant operators see the TLT-Turbo Hybrid Ceramic Bearing as a major advantage over conventional oil-lubricated bearing arrangements.

Come and see TLT-Turbo’s quality and innovation for yourself. Visit us at the ACHEMA 2018 in Frankfurt. You will find us in Hall 5.1 at Stand A90.

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New Service Workshop Now In Operation

Repairing up to 40 tons in four weeks! Our new service workshop enables cost-effective and fast overhauls of industrial fans.

Sustainability is becoming increasingly important for industrial ventilation systems. Significantly fewer new investments are being made in this area and old systems are used and maintained for as long as possible instead. In order to support its customers, TLT-Turbo GmbH, one of the world’s largest fan manufacturers, commissioned a new service workshop in Bad Hersfeld at the beginning of November 2017. In this workshop, all types of large industrial fans – both radial and axial –with weights of up to 40 ton will be overhauled and repaired in the future. In addition, the production area was expanded by 1500m² and the production and assembly areas were updated to meet new requirements.

“With regard to revisions, our customers increasingly make their decisions based on price and leadtime, which can be explained by growing cost pressure,” explains Matthias Adamy, Sales Director for After Sales Services at TLT-Turbo GmbH. “This increases the need for cost-effective and fast revisions. This is why we have decided to set up a service workshop that supports our customers with fast, flexible and uncomplicated service. Rapid processing in particular is an essential requirement here as the rapid replacement of defective or maintenance-needy rotors is crucial. Downtime can be shortened and system availability increased thanks to a short throughput time. For this reason, three types of revisions will be offered in the service workshop in future, which are characterized by a standardized procedure for diagnosis and repair. In addition to the standard and findings-oriented overhauls, there is now also a so-called rapid overhaul. This only takes four to six weeks, which means a time saving of about six months compared to conventional maintenance and repair. The reduction in processing time is also accompanied by a reduction in costs.”

Despite the short duration, TLT Turbo can guarantee the highest quality with the aid of component tests, functional tests for rotors, quality and surface crack tests. For this purpose, the specialist workshop has qualified personnel, all the necessary machinery and testing equipment for disassembly, cleaning, diagnosis, repair and assembly, as well as close links to the specialist departments, such as design and quality assurance. “In contrast to a repair on site, it is more advantageous to have a diagnostic report made in the service workshop, as the equipment, workshop and personnel support at the location where the fans are used are often not ideal,” Adamy explains. “An inspection directly at the customer should therefore always be an exception due in special circumstances”.

Process optimisation for smooth handling

In order to ensure that orders can be processed smoothly in the workshop even at full capacity, separate sections for dismantling and final assembly were set up and route and transport optimisation was implemented. “Due to the greatly reduced processing time, the new concept requires continuous improvement of internal processes and external communication. Through efficient cooperation and communication with subcontractors, for example, spare parts can be delivered and installed more quickly,” Adamy confirms. Especially for components with comparatively long delivery times, TLT-Turbo offers its customers consulting appointments with regard to spare parts stocking, so that revisions can be carried out as quickly as possible. The spatial extension also allows significantly more flexibility and space for handling workpieces of all kinds. For this purpose, several storage racks were installed in which up to 450 pallets can be accommodated. TLT-Turbo attaches particular importance to the transparency and traceability of the orders: This means that the status of the revision can be queried online at any time.

The new service workshop was presented to selected business partners at a Customer Day on 8 November 2017. “We want to signal to the industry that our focus is on service. To this end, we deploy highly qualified personnel who are familiar with diagnostic findings, repairs and the replacement of parts,” concludes Adamy.

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