Energy Saving Solutions

    KON-TEK provides service regarding with “Energy Saving” subject which is becoming more important in recent years with its expertise and application experience in industrial automation market.After taking necessary information from the process, we can calculate theoretically the energy saving amount with presentation and in final step to be able to define more clear on the progress, test application is done and saving amount is measured. All these things are in KONTEK’s scope.

Why Energy Saving ?

• Increasing production costs
• Requirement because of competition
• Increasing need of energy in industry day by day.
• Environmental sensitivity and requirements dur to the Kyoto Protocol 

Electric motors consume %65 of total energy in the world. Every 1 EURO spent in 1 electric motor purchase progress equivalent  to the 100 EURO consumption energy during life cycle of the motor.

If one compressor motor is given as an example, cosidering the compressor life cycle is 15 years and annual working time total is 40000 hours. If the total life of the compressor is taken into account, first investment and total maintanence cost during life cycle is %22. The rest of the total which %78 is the electric consuption of the compressor for the life cycle.

Graph 1 

What do we mean by saying energy saving with frequency converters? By speed control, %20 to %70 energy saving can be achieved. Fans and pumps are the loads from which we can achieve the most energy saving.

It means that the energy saving projects based on fan and pumps causes lots of energy saving.

Graph 2
When the motor speed is controlled by the inverter, energy consumption decreases.In case of constant torque loads as it can be seen in Graph 3, power consumption decreases linear as long as the motor speed decreases.

Graph 3
In case of fan and pumps which are square torque loads, energy consumption decreases cubically as long as the motor speed decreases.Compressors, Crane, conveyor and extruders are this type of loads.

In graph 4, we can see the information regarding with square torque applications. If we look the case from the process variables in Graph 4 ; flow changes linearly with the motor speed. Presssure changes with the squared of the motor speed. Power changes with the cubical of the motor speed.

Graph 4
As a result, if flow control can be done with frequency converter instead of conventional methods, more energy saving can be achieved.

The Benefits of AC Drives

1. It eliminates the mechanical stress on the system during sudden start operation.
2. It prevents water-hammer when the pumps are operating in coast-stop mode. 
3. Switching to the automation system is easier when ac drive is used. 
4. Electromechanical equipment and cables sections are minimised  due to the lower starting current.
5. Less compensation need.

Who needs more energy saving?

The facilities in which the power consumption is high : There are many funs,pumps and compressors in this kind of facilities to save energy.

New and relatively new plants : Driving system AC drive, motor and reducer system) efficiency should be taken into account from advance for the new invesments projecting side should be done accordingly.

The importance of energy saving is known by everyone. The more important thing is the realization energy saving progress which can be done by solution companies.

 
How should the solution company such as KON-TEK ?

As the first step, to explain how to save the energy to the customer side and determine the points  where there will be good energy saving together with the customer.
Taking the necessary technical information from the determined points in the system calculate approximate energy saving.All studies are reported based on realist values.
 

Pilot Project (KORTEKS Energy saving Project)

There are 382 motors applied ac drive for energy saving Project and changed from conventional starting methods.Uygulamada, geleneksel kontrol yöntemleri ve start metotları AC hız kontrol cihazları ile değiştirildi (toplam 382 motor).

• Air Handling Units,
• Cooling fans, 
• Pump stations

?At the end of the Project, power consumption has been decreased %36 and annual saving was 827.000 USD.