This
case study explores the transformation project undertaken to upgrade the grate cooler fan system, which is a critical component in industrial processes in a cement plant. The project aimed to enhance energy
efficiency and reduce operational costs by replacing components with advanced, energy-efficient technology. The
customer operated an older fan system equipped with IE1 (EFF2) motor and a direct on-line (DOL) starter. Recognizing the need for improved energy
efficiency and cost savings, Alpha Drives Ltd. proposed upgrading the system to a more modern and
efficient configuration. The reference system was an old IE1 motor with a DOL
starter, while the alternative system comprised new Siemens
IE4 motors paired with Siemens Variable Speed Drives (VSD), with the
damper adjusted to allow full
flow. The
project began in January 2019, driven by Alpha Drives Ltd. initiative to promote energy-saving products.
Our goals were to:
Prove the concept of using advanced motor and VSD
technology for energy savings.
Calculate and validate potential savings using Siemens SinaSave, a tool for estimating
energy savings.
Implement the new system and measure its performance to
ensure optimal efficiency and airflow.
1. Initial Assessment and Calculation:
Alpha Drives Ltd. gathered details of the existing motor and fan system.
Using SinaSave, we calculated the potential savings based on a specific contract rate over five years, with the system running 7,512 hours per year at 70% flow rate.o Alpha Drives Ltd. built control panels using the G120X fan VSD and configured Siemens SIMOTICS 1LE Severe Duty IE4 Motors.
The motor and switchgear were valued at zero to emphasize the energy savings and efficiency improvements.
2. Why Alpha Drives Ltd.?
Alpha Drives Ltd used the Siemens product range as they find it to be the most reliable product in the market.o The system was commissioned using VSD energy-saving wizards to ensure optimal efficiency without compromising airflow.
Alpha Drives Ltd. supplied various motors up to 250 kW, culminating in a total power upgrade of 1.3 megawatts.
3. Performance Monitoring:
Throughout the process, we monitored the system's performance to ensure it met the projected savings and efficiency targets.
By January 2023, the final phase of the project was completed.
4. Net Zero - Carbon Saving:
Mannok has committed to the ambitious goal to reduce carbon emissions by 33% this project helped to achieve this.
This project is important in the drive towards Net Zero and future sustainability
The
upgrade from an IE1 motor with a DOL starter to an IE4 motor with a VSD yielded
significant energy savings and efficiency improvements. The key outcomes
included:
Energy Savings
Even with conservative
estimates (50% of the projected savings), the savings were substantial.
Actual energy
consumption was reduced significantly, aligning with the calculations
provided by SinaSave
Cost Savings
The reduction in energy
consumption translated into considerable cost savings over the five-year
contract period.
The customer
experienced lower operational costs due to improved motor efficiency and
optimized control
System Performance
The new system
maintained the required airflow without any compromise, ensuring the
operational integrity of the grate cooler fan.
The advanced VSD and
motor technology provided reliable and efficient performance.
The grate cooler fan system upgrade successfully
demonstrated the benefits of transitioning to more efficient motor and VSD
technology. The project not only achieved significant energy and cost savings
but also contributed to the customer's net-zero transformation goals. By
leveraging advanced tools like SinaSave and implementing cutting-edge
technology, we were able to deliver a solution that met and exceeded the
customer's expectations.
