Elektromotoren von Bauer gewährleisten eine wirtschaftliche und umweltfreundliche Abwasserbehandlung
Die Aufbereitung von Wasser und Abwasser leistet einen maßgeblichen Beitrag zum Erhalt unserer Wasserressourcen und zum Umweltschutz
(PresseBox) - The treatment of water and waste water makes a significant contribution to the preservation of our water resources and to environmental protection. However, the treatment methods are energy-intensive and thus themselves at environmental factor, not to mention the costs in the face of further rising energy prices.
Many wastewater treatment plants are pursuing targeted strategies for improving energy efficiency. Bauer Gear Motor optimizes the energy consumption of the Bayreuth sewage treatment plant and reduces its environmental impact and energy costs.
Although this example is a municipal sewage treatment plant, the processes and technology are not significantly different from those in commercial and industrial water treatment, so the benefits in terms of efficiency, reliability, and cost of ownership are thus apparent.
The municipal sewage treatment plant in Bayreuth is looking to optimize the electric motors for the plant in order to increase its energy efficiency and reduce energy consumption costs.
The original system, built in 1999, consisted of several 50 Hz direct-on-line (DOL) induction motors of 1.5 kW. These engines had been running trouble-free since installation by Bauer Gear Motor (Type BF50-35A / D09LA4-TF-D). However, as their energy efficiency could not reach the level of the state of the art, they decided to decommission the existing system and specify a high-tech alternative.
As a supplier of the original engines, Bauer Gear Motor, a company of Altra Industrial Motion Corporation, was invited to propose a solution that would ensure cutting-edge energy efficiency and reliability. Bauer''s reputation as a leading provider of innovative, energy efficient geared motor solutions has made the company the ideal partner for the project.
Harald Bezold, the responsible wastewater master of the municipal sewage treatment plant, said: "We were satisfied with the original Bauer solution developed during the construction of the water treatment plant. However, after 19 years of operation, we felt that a smart investment would help us to improve operations. We knew that in the course of modernization, it would also be necessary to consider the environmental impact of our processes. Our goal is to provide the best water management services at the lowest cost and with the least possible impact on the surrounding environment. "
Markus Kutny, Business Development Manager at Bauer, added: "We have carried out a site revision and an inspection of existing equipment. We have equipped one of the existing system components with a frequency converter to measure the behavior of this configuration. Based on this data, we were able to analyze this application accurately and perform a calculation for the customer to demonstrate the benefits of permanent magnet synchronous motor (PMSM) technology. The theoretically calculated values, savings and behaviors were identified and presented to the customer. In addition to achieving environmental and performance goals, we have developed a system that meets the latest industry 4.0 standards. We have equipped the site with an unprecedented degree of engine control. "
The customer''s original wish was to replace the original engines with asynchronous motors of efficiency class IE3 - this is typically considered a panacea for an "energy-efficient solution" in the water industry. However, Bauer''s assessment of the plant indicated that the water treatment plant would benefit even more by specifying PMSM operated on the same frequency, namely 50 Hz.
The benefits of PMSM are not just the energy savings; They also have the advantage that the customer can control all gearmotors directly from the office via the "PROFINET bus system". Another great advantage was that the service technicians use the intelligent frequency converter and bus system to monitor the performance of the motors and see them on screen immediately when an application is not running optimally.
The IE3 PMSM technology consumes less energy and, with the same torque load, can handle smaller power classes than the corresponding IE3 asynchronous motors. When the system is operating in partial load operation, the asynchronous motor has a drastically reduced efficiency compared to the PMSM under the same conditions. Concretely, Bauer measured the required power for this application and found it to be lower than the installed engine power, allowing Bauer to reduce the engine size from the original 1.5 kW to 1.1 kW with the power unchanged.
In addition, according to measurements of the applications with the new motors, the replacement of asynchronous motors with PMSM alternatives operating at 50 Hz could save over 93,000 kW / h per year. With an assumed energy price of 0.20 ? per kW / h, 93,000 kW / h are worth more than 18,600 ? in savings in just one year.
Another proposal was to use a motor for inverter operation to reduce the line frequency without affecting mixing performance. The result was that the frequency of 50 to 60 Hz was needed to start the mixing process. After the waste water was in motion and the sludge was suspended in the water, the speed could be reduced to 34 Hz. Further optimization takes place in the ongoing clarification process. This reduction in speed with the same mixing result and the same quality of preparation currently enables savings of more than 260,000 kW / h in energy consumption and ? 52,000 in annual energy costs.
The low power consumption of the PMSM compared to conventional asynchronous motors is due to the design. While asynchronous motors require electrical current in the rotor to achieve induction, which rotates the rotor and generates torque, in the PMSM a permanent magnet sets the rotor in a rotary motion. Compared to asynchronous motors of the same rated power, performance improvements of up to 40% have been demonstrated for PMSM technology in some water treatment applications. Therefore, many PMSM pay for themselves within a few months.
When designing the Bauer engineers had to make sure that the new engines fit into the existing installation space. This was to ensure that the original fixtures and gearbox dimensions did not have to be changed - in the interests of the lowest possible project costs. Since they should be installed outdoors, the new engines must be equipped for adverse weather conditions and the general dangers of such environments. Bauer therefore chose motors with IP65 protection and matching IP66 rated inverters to protect against dust ingress and strong jets of water from all directions.
In order to make the combination of motor and frequency-variable drive as effective as possible, individual decentralized frequency inverters (EtaK2.0 gearmotors) were preferred over a series connection of all inverters. In this way, if a drive failed, the remaining geared motors would remain unaffected and continue to run, which would minimize plant downtime and maintenance costs.
In addition, the new solution from Bauer simplified the system and reduced the required system components. The mounted frequency inverters of the EtaK2.0 made shielded cables in the system superfluous and supplied the motors decentralized, so that it was possible to dispense with converters in control cabinets. As a result, the maintenance costs were reduced, resulting in additional cost savings.
The EtaK2.0 also offers new communication and control options. More specifically, the mounted frequency inverters transmit a constant data stream to the programmable logic controller (PLC) via the widely used Industrial Ethernet standard PROFINET. This allows the state of each individual unit to be remotely monitored without the need for physical on-site inspection.
In this way, the sewage treatment plant benefited from an automated network and created the conditions for Industry 4.0 and the Industrial Internet of Things (IIoT). The significantly more extensive control options also make it easier and earlier to identify signs of machine defects, reducing maintenance and costs as much as possible.
Harald Bezold continues, "When we approached Bauer''s engineers, we told them that we wanted to make the site future-proof by making sure the drive solution was state-of-the-art by default. By setting up an automated network, we are now able to precisely monitor engine performance data to ensure that they are always working efficiently. "
By working closely with Bayreuth Sewage Treatment Specialist on site, Bauer is ready to understand the requirements of the application and, thanks to its industry know-how, deliver a solution that sets standards in terms of environmental technology and industrial communication. Not only did the technology provide measurable improvements in energy efficiency and productivity, so it handled without the need for re-engineering and minimal downtime.
With this project, the costs of generating, transmitting and distributing energy from the power plant to the end-user facility, and thus significantly reducing operating and maintenance costs.
Themen in diesem Fachartikel:
Unternehmensinformation / Kurzprofil:
Datum: 11.05.2018 - 12:51 Uhr
Sprache: Deutsch
News-ID 1609802
Anzahl Zeichen: 0
Kontakt-Informationen:
Ansprechpartner:
Stadt:
Esslingen
Telefon:
Kategorie:
Vermischtes
Anmerkungen:
Dieser Fachartikel wurde bisher 49 mal aufgerufen.
Der Fachartikel mit dem Titel:
"Elektromotoren von Bauer gewährleisten eine wirtschaftliche und umweltfreundliche Abwasserbehandlung
"
steht unter der journalistisch-redaktionellen Verantwortung von
Bauer Gear Motor GmbH (Nachricht senden)
Beachten Sie bitte die weiteren Informationen zum Haftungsauschluß (gemäß TMG - TeleMedianGesetz) und dem Datenschutz (gemäß der DSGVO).