How to reduce energy consumption of pumping systems in mining by up to 30%

transcript

How to reduce energy consumption of

your pumping systems by up 30% used

in mining operations Jack Creamer

Segment Manager – Pumping Equipment

Schneider Electric

2 Schneider Electric

Topics

●Energy Challenge

●Energy and Pumping

●What is the World Doing?

●Passive and Active Energy Efficiency

●Where are the Savings

Energy Dilemma

vs Energy demand by 2050

Electrical energy demand by

CO2 emissions to avoid dramatic

climate changes

The facts The need

Source: IEA 2008 Source: IPCC 2007, figure (vs. 1990 level)

Energy management is the key

to address the dilemma

Energy Demand

Legislation and Influencing Bodies

Support Energy Efficiency

●Legislation texts

● Economic Stabilization Act

● Energy Independence and

Security Act

● European Union Energy Directive

● Kyoto Protocol

●Other government initiatives

● State Policy and Incentives

● White certificates

●DOE

● Pump Energy Efficiency

Standards under development

●Non-governmental initiatives

● Clinton Climate initiative

● Energy Efficiency accreditation

● Utility Programs

● Alliance to Save Energy

Pumps represent about

25% of industrial motor

energy use.

Source: DOE Office of Industrial Technology

Energy Use in Pumping Systems

1000 H

Rewind Savings

Downsize Savings

Fan Savings

Other Savings

Air Compressor Savings

Motor Upgrades

Pump Savings

Source: U.S. Industrial Motor Systems

Market Opportunities Assessment,

U.S. Department of Energy

GWhr / Year

Pumping –

Energy Savings Potential

Pumping –

Energy Savings Potential

Source: DOE Office of Industrial Technology

Pumping systems have

the most to gain from

energy savings efforts.

Metals Mining Example

Source – Sulzer Pumps

Motor use in mining

●Typical Distribution of Motor Population by HP and Application

What is the World Doing?

Schneider Electric 12 - Power NA Leadership Forum – January 2010

Lifecycle solutions for Energy Efficiency

Energy Audit

& Measure

Active Energy Efficiency Passive Energy Efficiency

Optimise through

automation &

regulation

Monitor,

maintain,

improve

Fix the basics

Low consumption devices,

insulation material, power

factor correction

Pump control, lighting control,

variable speed drives…

Meters installation, monitoring

services, EE analysis software

Passive Energy Savings –

By Design Motor Starting Example

●Energy efficient design provides more features while using less

energy than a standard starter and overload

SPMS versus IEC based solution -> 50.97% savings

SPMS versus NEMA based solution -> 92.71% savings

Contactor + MCP

Starter + Circuit Breaker

Self Protected Motor Starter

Active Energy Savings – VFD Example

●Variable Speed Drives

● On centrifugal loads such as pumps, VFD’s save energy because of the Affinity Laws

● Provide precise speed control of an AC motor

● Can generate full torque and low motor speed

● Protect a motor and wiring from overload currents

● Have inherent power factor correction increasing efficiency

● Limits inrush current to provide soft-start and soft-stop

Active Energy Savings – By Design

VFD Example

●Affinity Laws of Centrifugal Loads:

● FLOW is proportional to motor speed

● PRESSURE is proportional to the motor speed squared

● POWER is proportional to the motor speed cubed.

A motor running at 90% of full speed requires 70% of the electricity

of a motor running at full speed.

●Situation – Dewatering Application

● A 50hp centrifugal Pump

● Supply air 10 hours/day for 250 days

● Cost at full speed would be:

50 hp x 0.746 kW/hp x 2500hours x $0.08 /kWhr = $7,460

●Assuming the Pump does not have to run at full speed all the time

● 25% of time at 100% speed = 625 hours

●Cost running with an AC Drive:

● 50 x (1.0)3 x 0.746 x 625 x $0.08 = $ 1,865

● 50 x (0.8)3 x 0.746 x1250 x $0.08 = $ 1,910

● 50 x (0.6)3 x 0.746 x 625 x $0.08 = $ 428

Annual savings ($7,460.00 - $4,203.00) = $3,257

Potential Utility Rebate at $50 per HP = $2,500

Schneider Electric 18 - Power NA Leadership Forum – January 2010

Monitoring & Maintenance

Maximize the savings

Lack of monitoring,

maintenance programs,

regulation and control

systems

●Efficient devices and installation (saves 10 to 15%)

●Optimized usage via automation (save 5 to 15%)

● Without regulation and control systems (up to 12 % lost)

●Without Monitoring and Maintenance (2 to 8% lost)

Energy Savings – Through Monitoring

System Level

●Power Monitoring Equipment

● Provides monitoring of facility’s power system

● Capture an record numerous parameters such as:

●Voltage

●Current

●Harmonics

●Power factor

●Transient Voltage

●Energy Consumption

●Peak Consumption

●Monitoring this data allows a facility manager to monitor,

understand, and correct any power issues in order to

maximize the energy usage of the facility

Energy Savings – Through Monitoring

Pump Specifics

●Motor Management System

● Allows control and power monitoring of individual devices

● Allows a user to monitor things such as a motor where it

would be traditionally too expensive for an dedicated power

monitoring device

● Predictive logic can alert a user to potential problems such as an

increase in motor current over a period of time

● Built in communication macros drive integration into System Level

systems allowing a facility to monitor all power aspects from

distribution to device

Conclusions

●Pumps are a primary consumer of energy in mining applications

●Solutions are available that will greatly reduce these costs

●Legislation is driving/incenting energy management

Source - www.pumpschool.com

Act NOW!

Thank you!