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FEATURE Pneumatic conveying (negative pressure) in a system where ground stock product is carried, while volume of air moved changes, static pressure varies with the square of the speed, required power with the cube of speed. In summary, when volume of moved air is reduced by 20 percent, fan speed is also reduced at the same ratio, whereas power consumption is down by 50 percent. In pneumatic systems, removing vibration by mechanic balance, setting product and stock speed by a right system design and using minimum and wide angle elbow, optimising air volume to be absorbed by clacks, setting fan speed can be taken as first steps of a 10-20 percent saving in pneumatic system power. Conveying with blowers (positive pressure) is an expensive conveying method that consumes same or more power than pneumatic conveying. Amount of power to be used changes according to, correct design of conveying line, periodic maintenance and cleaning of blowers, reduction of number of blowers by connecting lines required in the same area, dimensions and speed of air locks to be used, and distances between blades. The most convenient method should be chosen among conveying systems. For example, with a 10 tonne per hour capacity; while a mechanic system consumes 0.8kW of power for 20m vertical conveying, this consumption, which is 4.7kW in pneumatic conveying, reaches 5.0kW in blower conveying. In aspiration system, by correct dimensioning, getting required airflow speed, preventing loss and leaks and by using manometer filters tracking filter cleanness and avoiding unnecessary energy expenses is possible. controllable through extraction scales, can be taken under control by extraction tracing and reporting through recording correct data. In new generation mills where the number or the size of windows is reduced in order to prevent contamination, the choice with the lighting control and the energy efficient armature has gained importance. To calculate milling capacity in the way not to run the plant at time zones with highest energy cost and if demand is available, to increase capacity, they must be carefully analysed since the latter will enable faster return of investment and if needed, be decided immediately without delay. It should not be forgotten that the way to compete in global markets and succeed is through establishing energy efficient, effective and lifetime systems, by considering operating costs rather than investment costs.
FEATURE
About the author: Mr Tuncay Lamci is General Manager of Integrated Machinery Systems (IMAS) More information: IMAS Integrated Machinery Systems 2 Organize Sanayi Bologesi Lalehan, Cad No:61, 42300, Turkey Tel:+903322390141 Website:www.milleral.com
percent for mechanical conveying. For this reason, we will study energy savings under three main titles: Methods of saving in motors Conveying systems Automatic control and energy management
conveyed with the remainder due friction, loading and discharge losses. Chain transfer systems require regular oiling, whereas belt transfer requires regular check, setting and replacement. The right choice of often used V-belts according to the pulley groove, synchronised replacement of multiple belts of the same brand, parallelism of the pulleys, tension of the belts are important parameters for the energy cost. Reduction of motor losses, definition of size of motor being used in relation to the duty, choice of lowest motor for full load, high efficient motor choice rather than a standard one at replacement would therefore reduce losses and enhance saving opportunity. A high efficiency motor of 90kW EFF1 type running 18 hours per day and 300 days per year at a plant, would yield 2500TL (1000 EUR) of energy saving in a year with actual energy costs. Reducing the speed of motors means reduction in energy expenses. For example, in pneumatic systems required air quantity for the transport of stock product varies with the ambient and seasonal conditions; setting motor speed by using variable speed drive would provide energy savings and would therefore return the investment cost.
Conveying systems
focus on energy costs right after raw material cost. It would be possible to get energy saving, through having maximum capacity usage in overall process by 5-10 percent, using high efficiency motors and total efficient maintenance by 2-5 percent, optimising air flow and avoiding leaks in conveying systems by 10-20 percent. While the process uses 50 percent electric energy for milling and grinding, 30 percent is used for pneumatic conveying, 11
22 | January - february 2012
would reduce additional loads in motors and gears resulting from the system through bearing condition and oil check in line with manufacturers advice. The choice with motor drive arrangement is of paramount importance. For example, as the friction losses will be lesser with direct drive methods, they will work efficiently compared to chain or belt coupled systems. For bucket elevators, about 80 percent of the input power is directly attributable to the weight of material being
We will study conveying systems as four types: Mechanical conveying, negative pressure pneumatic conveying, positive pressure pneumatic conveying and dust collectors and aspiration. Examples of mechanical conveying can be given as bucket elevators, screw and chain conveyors, in which some of the saving opportunities are use of products with proper bearings where the friction in these machines are at minimum, regular protective maintenance, product choice at right capacity.
Grain
Grain
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Direct interchange and replacement of existing pressed steel buckets. Safer Nonmetallic materials eliminate possible sparking from bent and torn steel buckets. Equal or greater carrying capacities of steel buckets. Thick walls provide superior impact strength and long life. Popular sizes in stock for immediate shipment.
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The color blue, when used in connection with elevator buckets, is a U.S. registered trademark owned by Tapco Inc. Super EuroBucket is a registered trademark of Tapco Inc. 2012 Tapco Inc. All rights reserved.
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