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
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