Guided by the national "Dual Carbon" strategy and theNotice on Implementing Energy-Saving and Carbon-Reduction Actions, tapping into the energy-saving potential of flue gas desulfurization (FGD) systems has become a strategic priority for corporate low-carbon transformation. A power plant under Guangdong Energy Group implemented a technical iteration for the oxidation blower systems of Units 1-4, introducing Greatall High-Voltage Direct-Drive Maglev Blowers. Upon completion of the retrofitting in April 2026, field tests verified a system energy-saving rate of 37.62%, establishing a benchmark for energy efficiency reconstruction in desulfurization systems.
Pain Point Analysis: Efficiency Bottlenecks and O&M Challenges of Traditional Mechanical Structures
The plant originally utilized single-stage high-speed centrifugal blowers with traditional gearboxes. During long-term operation, the limitations of these mechanical structures became increasingly prominent:
● Obsolete Efficiency Regulation: Flow was regulated solely via inlet guide vanes. Throttling losses under variable operating conditions caused the equipment to deviate from its high-efficiency zone, resulting in excessive energy consumption.
● Transmission Loss and Severe Vibration: Frictional power loss from the speed-increasing gearbox and mechanical bearings accounted for a significant portion of total power consumption. Furthermore, limited by gear meshing precision, the equipment exhibited intense vibration with ambient noise levels reaching 90-100 dB(A), compromising operational safety and stability.
● Redundant O&M Assets: The oil-circulation lubrication system required frequent refills and posed risks of oil leakage and contamination, maintaining a high Total Cost of Ownership (TCO).
Technical Reconstruction: Greatall High-Voltage Direct-Drive Maglev Solution
Addressing these challenges, Greatall implemented an "in-situ replacement" strategy based onActive Magnetic Bearing (AMB) technology, achieving a systemic overhaul through technical innovation:
● High-Voltage Direct Drive & Full-Spectrum VFD Regulation: Featuring a 6kV high-voltage direct power supply design and integrated high-voltage vector control algorithms, the system achieves precise decoupling of flow and pressure via Variable Frequency Drive (VFD) technology. This ensures the equipment consistently operates within its peak efficiency range across all load profiles.
● Frictionless Transmission & Near-Zero Vibration: By utilizing electromagnetic force to keep the rotor in a state of total levitation, mechanical contact friction is eliminated. This results in zero mechanical loss and "near-zero vibration" performance, suppressing structural noise at the source.
● Precision Fluid Dynamics & Constant Output: To meet the 115 kPa high-pressure rise requirement, Greatall optimized the precision fluid models. This ensures a constant oxidation airflow of 165 m³/min even when faced with backpressure fluctuations caused by absorber liquid level changes, thereby securing desulfurization efficiency.
● Intelligent Control & Predictive Maintenance: The new system is equipped with a digital intelligent monitoring platform, providing real-time visualization of operating parameters, alarms, and maintenance alerts, marking a transition from traditional control to autonomous intelligent regulation.
Performance Verification: 37.62% System Energy Saving Rate
Field measurements post-commissioning demonstrate superior performance data:
● Efficiency Leap: Under identical oxidation conditions, the measured comprehensive energy-saving rate reached37.62%.
● Vibration-Free Operation: Maglev bearings achieved completely non-contact, vibration-free operation.
● Acoustic Environmental Improvement: Operational noise was reduced to below 80 dB(A), significantly enhancing the site environment.
● Oil-Free O&M: Due to the non-contact nature of AMB, the system achieves zero oil contamination. Maintenance is simplified to periodic air filter replacements, drastically reducing O&M expenditures.
Pre-retrofit baseline:
Post-retrofit monitoring point 1:
Post-retrofit monitoring point 2:
Industry Insights and Outlook
According to the2024 White Paper on Energy Efficiency Improvement of Industrial Motors in China, the adoption of magnetic levitation for high-power rotating machinery has become a definitive trend in the process industry. The successful implementation of Greatall’s solution at Guangdong Energy Group validates the high adaptability of maglev equipment in complex desulfurization environments and provides a proven technical roadmap for energy conservation in aerodynamic systems across the steel, chemical, and paper industries.
