Energy saving project 2012 26 01 2012
22 KW motor- conventional drives View of conveyor View of conveyor Placement of installation Conventional drives Inverter Consumption DONG Aabenraa
Dual Drive 2 x 130 KW motor -conventional drives View of conveyor Conveyor Conveyor Right side drive station Left side drive station Existing motor data Dong Aabenraa
Dual Drive 2 x 132 KW motor -conventional drives View of conveyor View of conveyor Conventional drives Right side drive station Drive pulley Existing motor data Aalborg Portland
55 KW motor- conventional drives Conveyor Drive pulley Conventional drives Gear-box V-belt drive Noise level
55 KW motor - conventional drives Induction Motor V-belt drive Gear Unit Motor55 KW -cosphi0,85 Measured effect = 63,2 kw 4xV-belts 2xV-beltpulleys ø175 mm Ratio- 1:1 Efficiency : 0,95 Acctuel effect = 52,25 kw Gearratio-1: 16,80 Efficiency : 0,86 Acctuel effect = 44,90 kw Total efficiency: 0,71 ----- 71%
55 KW motor calculation Motor Motor 55 kw Calculation off - Efficiency IE2 - Measured effect - Torque Calculations P*1000 *100 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 /1000 Torque motor 357,3 Nm Hz*(60/(3000/n))
55 KW motor with conventional drives Load 950 tons/hour 80 % Motor V-belt drive Gear Motor42 kw -cosphi0,87 Measured effect = 48,3 kw 4xV-belts 2xV-beltpulleysø175 mm Ratio- 1:1 Efficiency : 0,95 Acctuel effect = 39,90 kw Gearratio-1: 16,80 Efficiency : 0,86 Acctuel effect = 34,31 kw Total efficiency: 0,71 ----- 71 %
45 KW Motorized pulley Sugested by Rulmeca MP -Electrical MP -Mechanical Motor45 kw -cosphi0,86 Measured effect= 52,32 kw Motor45 kw -cosphi0,86 Efficiency : 0,97 Acctuel effect = 43,70 kw Total efficiency: 0,84 ----- 84 %
45 KW Motorized pulley calculation Motorized Pully 45 kw Calculation off - Efficiency IE2 - Measured effect - Torque Motorized Pully Calculations P*1000 *100 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 /1000 MP diameter: 630 mm Torque motor 292,3 Nm Hz*(60/(3000/n)) Lagging: 10 mm P mech *9550 Rubber / Ceramic R Torque MP 5.276 Nm n tr P mech *3,1429*D*9550 Torque MP 5.276 Nm 60*m/s
45 KW Motorized pulley with inverter MP -Electrical Inverter MP -Mechanical Motor45kW -cosphi0,86 Measured effect= 52,32 kw Motor 45 kw -cos phi0,86 Speed : 46 Hz Measured effect = 48,10 kw Motor45kW -cosphi0,86 Efficiency: 0,97 Acctuel effect = 43,70 kw Total efficiency: 0,91 ----- 91 %
45 KW Motorized pulley with inverter Load 950 tons/hour 80 % MP - Electrical Inverter MP - Mechanical Motor35,5kW -cosphi0,86 Measured effect= 41,28 kw Motor 35,5 kw -cos phi0,86 Speed: 46 Hz Measured effect = 38 kw Motor35,5kW -cosphi0,86 Efficiency: 0,97 Acctuel effect = 34,44 kw Total efficiency: 0,91 ----- 91 %
Calculation of Motorized pully Standard Loading Conditions: Conveyor Length (m) 44 REQUIRED POWER: 35,5 kw Tonnage Rate (metric tons/hour) 950 Belt Speed (m/s) 2,3 BELT PULL SUMMARY: Force (N) Material Lift Height (m) 8,4 Standard Loading Belt Pull 14.734 Ambient temperature ( C) Min -20 Extra pull for Hopper (if any) Ambient temperature ( C) Max Initial Velocity of Material (m/s) 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) RECOMMENDED OPTIONS: Depth of Mat'l in skirt zone (mm) 1. Mechanical Backstop Number of Non-driven Pulleys 1 Elevation Above Sea Level Material, fric coeff Belt Width Belt Carcass Type SPECIAL NOTES (if any): Go to Design Parameters RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY: Idler Roll diameter 108 mm Power: 37 kw Models Available: CEMA Type Troughing Idler Spacing 1.0 meters Face Width: 1250 mm Angle of Wrap** Belt Speed: 2,5 m/s 630, 800 RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: Type of Lagging Full Lagging Power: 22 kw/ea Models Available: Type of Take-up Manual Belt Speed: 2,5 m/s 500, 630, 800 Type of Belt 3 ply, 330 piw Face Width: 1250 mm Bulk Density (Kg/m 3 ) Condition of Idlers & Pulleys 1.0 Km Coal, bitum. mined, 0.075 1200 mm Fabric C 180 degrees Coal, lignite, 720 Power savings - 1 shift and 3 shift per day: well maintained (Motorized Pulley compared to exposed conveyor belt drives)
Calculation of mechanical efficiency Data from - Motorized Pulley Engineering Calculations Power Calculation Summary 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
Calculation of energy and CO 2 savings 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 CO 2 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. Savingsonpurchasesof motorized pulley -45 / 55 kw ca. 3.300 euro.
Calculation of energy and CO 2 savings Document in Danish
Calculation of energy and CO 2 savings The energy calculation is made with a load of 950 t / h. Days/Hours in period 264,0 6336 Consumption Date: Consumption before energy saving after energy saving Consumption after energy saving Period Year 08-10-2010 kwh kwh kwh kwh 29-06-2011 63.360 50.160 13.200 kr. 11.748 18.250 kr. 16.243 6.925 9.574 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 hours Timer Price - 1 kwh: kr. 0,89 0,12 Conversion factor - 1 kwh 0,5246 kg / CO 2 Price - 1000 kg CO 2 : kr. 114,00 15,20 CO 2 - kg CO 2 - kg 6.925 kr. 789 9.574 kr. 1.091 105 146