Energy saving project 2012 - polybandas.cl · Vattenfall Aalborg Drive station with motor 55kW,...

Energy saving project 2012

26|01|2012

ConsumptionInverterConventional drives

Placement of installationView of conveyorView of conveyor

DONG Aabenraa

22 KW motor - conventional drives

Existing motor dataLeft side drive stationRight side drive station

ConveyorConveyorView of conveyor

Dong Aabenraa

Dual Drive –

2 x 130 KW motor - conventional drives

Existing motor dataDrive pulleyRight side drive station

Conventional drivesView of conveyorView of conveyor

Aalborg Portland

Dual Drive –

2 x 132 KW motor - conventional drives

Noise levelV-belt driveGear-box

Conventional drivesDrive pulleyConveyor

Vattenfall Aalborg


Motor 55 KW - cos phi 0,85

Measured effect = 63,2 kW

4 x V-belts

2 x V-belt pulleys ø 175 mm

Ratio - 1 : 1

Efficiency : 0,95

Acctuel effect = 52,25 kW

Gear ratio - 1 : 16,80

Efficiency : 0,86


Vattenfall Aalborg


Induction Motor V-belt drive Gear Unit

Total efficiency: 0,71 ----- 71%

55 KW motor calculation

Vattenfall Aalborg

P*1000

Efficiency - IE2: 94,07 % U*I*1,732*cos

Size: 55 Kw U*I*1,732

Voltage: 400 Volt Measured effect: 67,20 kVA 1000

Power consumption: 97 Amp P

Efficiency - cos: 0,87 Measured effect: 67,20 kVA (IE2/100)*cos

Frekvens: 50 Hz P

Speed: 1.470 RPM Measured effect: 63,22 kW cos

Efficiency - IE2: % P*9550

Torque motor 357,3 Nm n

(IE2/100)*1,732*U*I*cos*9550

Torque motor 357,3 Nm Hz*(60/(3000/n))

Motor 55 kW

Calculation off - Efficiency IE2 - Measured effect - Torque

CalculationsMotor

Formel: *100

Formel:

Formel:

Formel:

Formel:

Formel: /1000

Motor 42 kW - cos phi 0,87


4 x V-belts

2 x V-belt pulleys ø 175 mm

Ratio - 1 : 1

Efficiency : 0,95


Gear ratio - 1 : 16,80

Efficiency : 0,86


Vattenfall Aalborg

55 KW motor with conventional drives

Load 950 tons/hour – 80 %

Motor V-belt drive Gear

Total efficiency: 0,71 ----- 71 %


Measured effect= 52,32 kW


Efficiency : 0,97


Vattenfall Aalborg

45 KW Motorized pulley – Sugested by Rulmeca

MP - Electrical MP - Mechanical


45 KW Motorized pulley calculation

Vattenfall Aalborg

P*1000

Efficiency - IE2: 92,90 % U*I*1,732*cos

Size: 45 Kw U*I*1,732

Voltage: 400 Volt Measured effect: 56,32 kVA 1000

Power consumption: 81,3 Amp P

Efficiency - cos: 0,86 Measured effect: 56,32 kVA (IE2/100)*cos

Frekvens: 50 Hz P

Speed: 1.470 RPM Measured effect: 52,33 kW cos

Efficiency - IE2: % P*9550

Torque motor 292,3 Nm n

MP Speed: 2,5 m/s (IE2/100)*1,732*U*I*cos*9550

MP diameter: 630 mm Torque motor 292,3 Nm Hz*(60/(3000/n))

Lagging: 10 mm Pmech*9550

Rubber / Ceramic R Torque MP 5.276 Nm ntr

Pmech*3,1429*D*9550

Torque MP 5.276 Nm 60*m/s

Formel:

Formel:

Formel:

Formel:

Formel:

Formel:

Formel: /1000

Motorized Pully 45 kW

Calculation off - Efficiency IE2 - Measured effect - Torque

Motorized Pully Calculations

Formel: *100


Efficiency : 0,97


Vattenfall Aalborg

45 KW Motorized pulley with inverter

MP - Electrical Inverter MP - Mechanical





Speed : 46 Hz


Motor 35,5 kW - cos phi 0,86

Efficiency : 0,97


Vattenfall Aalborg

45 KW Motorized pulley with inverter

Load 950 tons/hour – 80 %

MP - Electrical Inverter MP - Mechanical





Speed: 46 Hz

Measured effect = 38 kW

Calculation of Motorized pully

Vattenfall Aalborg

Conveyor Length (m) 44 35,5 kW

Tonnage Rate (metric tons/hour) 950

Belt Speed (m/s) 2,3 Force (N)

8,4 Standard Loading Belt Pull 14.734

Ambient temperature (°C) Min -20 Extra pull for Hopper (if any)

Ambient temperature (°C) Max 40 Extra pull for Slider Bed (if any)

Extra pull for Diverter or Tripper (if any)

Number of Belt Cleaners 1 TOTAL Required Belt Pull (Te): 14.734

Number of Return Belt Scrapers 1

Length of Skirt Zone (m)

1. Mechanical Backstop

Number of Non-driven Pulleys 1

Elevation Above Sea Level

Belt Width Go to Design Parameters

Belt Carcass Type

Idler Roll diameter Power: 37 kW

Belt Speed: 2,5 m/s

Troughing Idler Spacing Face Width: 1250 mm

Type of Lagging Power: 22 kW/ea

Type of Take-up Belt Speed: 2,5 m/s

Type of Belt Face Width: 1250 mm

Power savings - 1 shift and 3 shift per day:

(Motorized Pulley compared to exposed conveyor belt drives)

RECOMMENDED OPTIONS:

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Models Available:

500, 630, 800

SPECIAL NOTES (if any):

Models Available:

630, 800

Material Lift Height (m)

Initial Velocity of Material (m/s)

Standard Loading Conditions:

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

REQUIRED POWER:

BELT PULL SUMMARY:

Depth of Mat'l in skirt zone (mm)

Material, fric coeff

Condition of Idlers & Pulleys

Angle of Wrap**

Bulk Density (Kg/m3)

CEMA Type

Coal, bitum. mined, 0.075

1200 mm

C

1.0 meters

108 mm

Fabric

1.0 Km

180 degrees

Full Lagging

Manual

3 ply, 330 piw

Coal, lignite, 720

well maintained

Calculation of mechanical efficiency

Vattenfall Aalborg

Data from - Motorized Pulley Engineering Calculations

Calculated power to drive conveyor belt: 33,9 kW

Drive pulley bearing friction: 0,5 kW

Power at motor: 34,4 kW

Gear loss in motorized pulley: 1,1 kW 0,970

Calculated power 35,5 kW

Derate for high elevation 0,0 kW

Derate for high temperature 0,0 kW

Required Power for motorized pulley: 35,5 kW

Power Calculation Summary

Calculation of energy and CO2 savings

Vattenfall Aalborg

Drive station with motor 55kW, conventional drives and pulley,

replaced with Rulmeca motorized pulley 45kw.- 2,5 m/sec.

At the same time an inverter will be installed, and the speed will be reduced

to 46 Hz to be able to reduce the speed of the conveyor to 2,3 m/sec.

Below is a schedule showing the energy savings (kWh), and reduce CO2

emissions.

In the savings the following are not included:

1. Longer life time for rubber belt and less mechanical maintenance on

. pulley, roller and roller frame, when the MP starts and stops more gently

. because of the ramps in the inverter

2. Cost of maintenance on old pull station with conventional drives.

3. Savings on purchases of inverter - 45 / 55 kW. – ca. 1.300 euro.

4. Savings on purchases of motorized pulley - 45 / 55 kW – ca. 3.300 euro.


Document in Danish

Vattenfall Aalborg


Vattenfall Aalborg

Days/Hours in period 264,0 6336

Date: Consumption before energy saving

08-10-2010 kWh kWh kWh kWh

29-06-2011 63.360 50.160 13.200 11.748kr. 18.250 16.243kr.

6.925€ 9.574€

CO2 - kg CO2 - kg

6.925 789kr. 9.574 1.091kr.

105€ 146€

Motor size: 55,0 kW

Motor load: 87 %

Mesaured Consumption off motor,

before energy saving: 48,00 kW

Consumption after energy saving: 38,00 kW

Operating hours per day: 5 Timer

Price - 1 kWh: 0,89kr. 0,12€

Conversion factor - 1 kWh 0,5246 kg / CO2

Price - 1000 kg CO2: 114,00kr. 15,20€

Period Year

Consumption after energy saving

Consumption

after energy saving

The energy calculation is made with a load of 950 t / h.

hours

Energy saving project 2012 - polybandas.cl · Vattenfall Aalborg Drive station with motor 55kW,...

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