How to make industrial drives
smart?
Massive Energy Savings by Applying
Control Theory
Hans Hellendoorn
February 12, 2008
1
SIEMENS
Observations
• Share of electricity in energy consumption increases –
the future is all electric
• Energy consumption grows with 59-75% until 2030 –
mainly because of the non-OECD countries
February 12, 2008
2
The Motor Challenge Program –
US and EU
• Over 80 million electric motors
• EU: electric motor driven systems account for up to
30% of all electricity used
• US: nearly 70% of all electricity used in industry is
consumed by motor systems
• Savings up to 10 billion kilowatt-hours per year are
possible
February 12, 2008
3
Europe in 2007
• Daily 7 Million Euro wasted in electrical drives
(probably 8.3 Million)
• Per year 18-19 Million tons CO2 can be saved
• This is equivalent to 19 fossil power plants
• Also equivalent to 3.5 Million cars
• How?
• 3 Million tons by more economic motors
• 15 Million tons by frequency converters !!!
February 12, 2008
4
Drives
Generator
Power
Industrial
drive
Electricity
network
February 12, 2008
5
Current practice
• Drives rotate continuously at one optimal level
• Redundant energy is destroyed by shifts and valves
• Over 80% of all large drives is operated in this way
February 12, 2008
6
Variable Frequency Drive
Variable Frequency
Power
Sine Wave Power
Industrial
drive
Variable
Frequency
Controller
Operator
IGBT
February 12, 2008
7
RTG
February 12, 2008
8
ECO RTG power pack (on-site)
February 12, 2008
SIEMENS
9
ECO RTG Power Pack system
February 12, 2008
SIEMENS
10
RTG operation
• Fuel consumption RTG depends on:
• size and operation of diesel engine
• loads, speeds, ramp times hoist, gantry, trolley
• auxiliaries
• utilization
• Typical fuel consumption of RTG about 16 - 25 liters /
operating hour
• Full load: diesel engine 100 - 120 liters / op.hour
February 12, 2008
11
ECO - RTG layout
i
G
~
G
~
200 – 650 V, 50 – 150 Hz
~
=
~
=
DUO inverters
=
~
=
M
~
Hoist
February 12, 2008
~
=
=
~
~
M M
~
~
=
~ ~
M M
~ ~
Gantry
Resistor
=
=
M
~
~
M
~
=
~
Auxiliaries
Trolley
12
Operational data 20-28 February ’07
RTG nr.
Consumption Hours
Moves
Liters / hour
Liters / move
56
1252
171
959
7,32
1,31
57
1342
136
1067
9,87
1,26
58
1551
178
1249
8,71
1,24
59
1984
181
1636
10,96
1,21
60
1620
188
1500
8,62
1,08
61
1915
183
1217
10,46
1,57
62
1347
171
1207
7,88
1,12
63
1290
165
876
7,82
1,47
64
1683
177
923
9,51
1,82
65
1887
178
1327
10,60
1,42
Average
1587
173
1196
9,18
1,35
February 12, 2008
13
[source: APM Terminal, Algeciras]
Benchmark
Defined operating cycle: 1 hour 45 min.
predefined operation
Result fuel consumption measurement
• Conventional: 28,1 liters = > 16,1 liters / hour
• ECO-RTG:
14,2 liters = > 8,1 liters / hour
Fuel savings:
February 12, 2008
48%
14
[source: APM Terminal, Algeciras]
ECO - RTG finance
Pay back, I.R.R. and N.P.V.
Example from Algeciras, Spain:
• Diesel liter price = 0.62 USD
• Fuel consumption = 12,000 litres /
month
• Additional investment USD 120.000,Pay back period = 2.7 years
I.R.R. = 37%
N.P.V. = USD 294,700,Annual savings = USD 893,000,February 12, 2008
(!)
15
ECO - RTG references (69 units)
Noell
Algeciras, Algeciras Container
Terminal, Maersk Espana S.A.
Spain
1
2004
refurbishment 1994
crane
40 ton, 4
DUO, 2.4 kWh
Ucaps
ZPMC
Algeciras, Algeciras Container
Terminal, Maersk Espana S.A.
Spain
17
2006
in operation Nov
2006
50 ton, 5 DUO
ZPMC
Tangiers, APMT
Morocco
15
2006
in operation May
2007
50 ton, 5 DUO
ZPMC
Algeciras, Algeciras Container
Terminal, Maersk Espana S.A.
Spain
3
2007
in operation Jan
2007
50 ton, 5 DUO
ZPMC
Xiamen, Xiamen Songyu Phase
I Container Terminal
China
8
2007
in operation March
2007
50 ton, 5 DUO
ZPMC
Gujarat Pipavav Port Ltd
(GPPL)
India
10
2007
in operation
November 2007
50 ton, 5 DUO
ZPMC
Algeciras, Algeciras Container
Terminal, Maersk Espana S.A.
Spain
4
2008
in operation January
2008
50 ton, 5 DUO
ZPMC
Tangiers, APMT
Morocco
11
2008
order July 2007
50 ton, 5 DUO
February 12, 2008
16
Other examples
• German paper company, replacement of pulp drive,
savings 40%, payback time 1.5 years
• Belgian Sojamilk producer, payback time 14 months,
yearly savings € 131,000
February 12, 2008
17
Hybrid Drive Technology
• Hybrid drives are increasingly prominent in automotive
industry
• Combination of primary power source with secondary
power source for usage of regenerated energy
• Advantages: cost-effective, fuel savings, reduced
emissions
• Concept applied in container terminals and crane
technology
February 12, 2008
SIEMENS
18
Hybrid Bus
February 12, 2008
SIEMENS
19
Ultracapacitors
February 12, 2008
SIEMENS
20
Comparison with battery
Double layer capacitor
February 12, 2008
21
Balance
February 12, 2008
22
From Theo Hofman
Balance
From Theo Hofman
February 12, 2008
23
Car example, charging, discharging
February 12, 2008
24
Hybrid-ECO-RTG
G
~
i
G
~
=
~
=
M
~
~
=
=
~
~
M M
~
~
Resistor
SIEMENS
~
=
=
~
=
=
=
~ ~
M M
~ ~
Gantry
Hoist
February 12, 2008
200 – 650 V, 50 – 150 Hz
M
~
~
M
~
=
~
Auxiliaries
Trolley
25
Supervisory level
Ultracap level
Motor size
Container specs
Schedule (if available)
Control level
Container lifting
Container moving
…
February 12, 2008
26
Additional savings
Hybrid technology promises 40% extra energy savings
Application areas
• Cranes
• Hoists
• Centrifuges
• Compressors
• Ventilators
• Elevators
February 12, 2008
•
•
•
•
•
Transport belts
Trains
Buses
Test banks
Pumps
27
Thank you
February 12, 2008
SIEMENS
28