Kgwanyape Energy Solutions

By: Karel Smrcka

Energy efficiency is one of the most precious commodities of our industrial society. Greater energy efficiency is the goal for all solutions in the energy sector and in the field of industrial production. This ranges from power generation, transmission and distribution to the intelligent measurement and control of energy flows in industrial automation.

Energy efficiency, which is a well-esta- blished concept in the mechanical and plant engineering sectors, was a central theme at Hanover 2009, the international trade show .

Streamlined processes and modern machi- nery can pave the way to significant reductions in energy consumption. The special display, entitled Energy Efficiency in Industrial Processes, focused on the key issues.

Drive Systems

Werner Blass, MD of the electric power transmission section of the German Electrical and Electronics Federation, confirmed that the Energy Efficiency in Industrial Processes display gave manufacturers of electric drives an excellent opportunity to demonstrate their capabilities.

In standard applications, such as pumping, ventilation, handling, conveying, air conditioning and refrigeration, there is considerable scope for reducing energy consumption. The replacement of obsolete drive systems would save 27,5-billion kilowatt hours of electricity a year. This is equivalent to 11% of total annual indus- trial power consumption, valued at 2,2- billion. Such an investment would pay for itself in two to three years.

Pump Tuning

Pumps account for more than 30% of total electricity consumption in trade and industry. For this reason, pump systems figured prominently at the Energy Efficiency display. Energy costs make up around 45% of the total costs incurred during a pump’s life cycle. Servicing and maintenance are also expensive items.

An important realisation is that pumps often do not have to operate at full power all the time. On the basis of more than 70 fact-finding missions to industrial enterprises, the German Energy Agency estimates that optimised pump systems can generate annual savings of between 2 500 and 50 000  or even 100 000, in some cases. The average potential saving is around 30%. In one extreme case, it would be possible to slash energy costs by more than 90%.

Matching Pump Performance with Demand

KSB, a leading manufacturer of pumps, valves and related systems, was one of the companies represented at Hanover 2009.

KSB’s Automation Competence Centre showcased its speed control system for centri- fugal pumps. This demand-dependent system can achieve energy savings of up to 60%. It is designed for application in building installations, industry, water extraction and treatment, and transport.

Reduced Energy Consumption, Noise Emissions and Heat Losses

Bosch Rexroth demonstrated a smart variable- speed pump drive, which generates the precise flow volume required at any given time. In other words, the pump speed is reduced significantly during pauses in the processing cycle and when the hydraulic system is not operating at its full load. As soon as higher power output is required, the speed of dyna- mic and responsive motors is increased instantaneously. This lessens energy consumption by up to 45%, noise emissions by up to 15 dB as well as the transfer of heat to the hydraulic oil by up to 60%.

Energy efficient automation solutions give machine manufacturers an immediate competi- tive edge  particularly, as end-users are in a position to achieve substantial energy savings. The strategy of Bosch Rexroth is to combine mechanical components and smart electronic control systems in order to create ready-to- install mechatronic subassemblies. These modules have an immediate impact on energy efficiency and are relatively easy to design.