Installing 2 MW drive and motor to reduce energy costs

Customer needs

Modernizing the grate cooler fan system, an essential part of a cement plant’s industrial operations is the subject of this case study. The project’s goal was to replace outdated components with cutting-edge, energy-efficient technology in order to increase energy efficiency and lower operating expenses. The client used an older fan system with a direct on-line (DOL) starter and an IE1 (EFF2) motor, which we suggested updating the system to a more contemporary and effective configuration after realizing the need for increased energy efficiency and cost savings. The alternative system consisted of new INNOMOTICS IE4 motors coupled with SIEMENS variable speed drives (VSD), with the damper modified to enable full flow, as opposed to the reference system, which consisted of an outdated IE1 Motor with a DOL starter. The attempt to market energy-savings goods was spearheaded by Alpha Drives Ltd. and the project commenced in January 2019. Our objectives were to:

1. Demonstrate the viability of utilizing VSD and modern motor technology to save energy
2. SIEMENS SinaSave is an energy-saving tool that may be used to calculate and verify possible savings
3. To guarantee the best possible efficiency and airflow, put the new system into place and monitor its performances

Solution

1. Initial assessment and calculation:

• We 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 0. We then built the control panels using the G120X fan VSD and configured INNOMOTICS 1LE15/6 serve duty IE4 motors
• The motor and switchgear were valued at zero to emphasize the savings and efficiency improvements

2. Why Choose us?

• Since SIEMENS has a wide product range we were not stuck for choice. We used these products to guarantee maximum efficiency without sacrificing airflow, the system was commissioned utilizing VSD energy-saving wizards.
• The different motors supplied by Alpha Drives Ltd up to 250kW resulted in a 1.3 megawatt total power boost.

3. Performance monitoring:

• We kept an eye on the functioning of the system to make sure it achieved the anticipated efficiency and saving goals.
• The project’s last phase was finished by January 2023

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

Customer benefits

There were notable energy savings and efficiency gains when an IE1 motor with a result DOL starter was replaced with an IE4 motor with a VSD. Among the main results were:

Energy efficient

• The savings were significant even with conservative estimates (50 percent of the anticipated savings).
• The actual energy use was substaintially lower, in line with the estimates given by SinaSave

Saving on costs

• Over the course of the 5 year duration, the reduction in energy use resulted in significant cost savings
• Because of increased motor efficiency and better control, the customer saw a decrease in operating costs

System efficiency

• The operational integrity of the grate cooler fan was guaranteed by the new technology, which preserved the necessary airflow without compromising
• The performance was dependable and effective thanks to the sophisticated VSD and motor technology

Upgrading the grate cooler fan system effectivity illustrated the advantages of switching to more energy-efficient motor  and VSD technology. The project helped the customer accomplish its net-zero transformation targets in addition to achieving considerable energy and cost savings. We achieved this by utilizing cutting edge technology and sophisticated tools like SinaSave to provide a solution that both met and surpassed the customers expectations.