GEA Mechanical Equipment / GEA Westfalia Separator Group GmbH

directdrive∞

GEA Mechanical Equipment2

Part 1:New Drive Generation – The Integrated Direct Drive

• Development history of separator drives• Comparison of different drive concepts• Features of the integrated direct drive• Comparison of synchronous- und asynchronous drive technology

Part 2:Energy Saving – Optimized Feed and Discharge System

• Energy consumption – Impulse losses• Geometry comparison of feed and discharge systems• Features of the optimized feed and discharge system• Comparison of fully hermetic and hydrohermetic sealing system

Content

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Development History of Separator drives

G

ear D

rive

Bel

t Driv

e

S

tand

ard

Dire

ct D

rive

Inte

grat

ed D

irect

Driv

e

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Drive Comparison

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Geardrive

Beltdrive

Standard directdrive

Integr. directdrive

Efficiency - - + ++ ++

Space requirement + - - ++

Max. drive power - + ++ -

Wear parts - - + + ++Reliability / Availability - + + ++

Ease of maintenance - + - +

Noise emission - + + ++

Comparison of different drive concepts

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Drive System Developement

gear drivegear drive

belt drivebelt drive

direct drive

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Drive System Efficiency

gear drivegear drive belt drivebelt drive direct drivedirect drive

ɳtotal ≈ 76%ɳtotal ≈ 76%

ɳtotal ≈ 90%ɳtotal ≈ 90%ɳtotal ≈ 93%ɳtotal ≈ 93%

ɳtotal = ɳmotor x ɳclutch x ɳgearɳtotal = ɳmotor x ɳclutch x ɳgear

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highest energy efficiency

continuous wewatchcondition monitoring possible

very high availability

reduced noise level

easy maintenance

access from all sides

less wear parts – less wear

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GEA Westfalia Separator directdrive∞

Standard Arguments:

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Easy System!!

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Spindle

Stator

Rotor

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Motor Comparison

Comparison: standard motor (left picture) / motor for integrated direct drive (right picture)

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Synchronous Drive

Comparison of Synchronous and AsynchronousMotor Technology

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Asynchronous Drive

• Efficiency approx. 1 to 2% higher as comparable asynchronous motor

• Motor efficiency in accordance with efficiency class IE2 possible

• Specialized rotor handling due to high magnetic forces of the rotors permanent magnets

• Serious health hazard for service personnel with medical equipment such as hearing devices, heart pacemakers, electronic implants, …

• Risk of damage to mechanical and electrical devices in the magnetic field of the rotor such as watches, sensors, measuring equipment, …)

• Simple assembly/disassembly and handling

• Motor control with additional sensors necessary (closed loop operation)

• Difficult VFD control in open loop operation

• Simple and well proven technology

• Very restricted choice of suppliers• Motor und VFD usually available only in

combination from the same supplier

• Wide range of different motor and VFD suppliers

• Risk of motor fouling due to collection of metallic particles by permanent magnetic forces of the rotor

• Robust technology – widely independent of environmental influences

• Loss of motor power possible because of demagnetization of the permanent magnets of the rotor

• No „ageing“ of the motor

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Energy Saving – Optimized Feed and Discharge System• Energy consumption – Impulse losses• Geometry comparison of feed and discharge systems• Features of the optimized feed and discharge system• Comparison of fully hermetic and hydrohermetic sealing system

Part 2

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Energy Consumption

Energy consumption ofa separator bowl:

Example:GSE 300 with 600 hl/h

Impulse losses: 60%Air friction: 35%Liquid friction: 5%

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Geometry Comparison – Feed and Discharge Systems

New Feed and discharge geometry Previous Feed and discharge geometry

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Optimized Feed and Discharge System

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• Approx. 10-15% reduced energy consumption by means of optimized centripetal pump

• In some cases 20-30% energy reduction possible

• Discharge pressure can be provided without external pump

• High efficiency of the pump and compact design• Gentle feed and discharge of the liquid• Optimization by means of computer aided flow

simulation (CFD)• Approx. same energy consumption as fully

hermetic feed and discharge system with mechanical seals

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Fully hermetic conzept – Feed through spindle

Comparison of Feed and Discharge Concepts

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Hydrohermetic concept

• Completely maintenance-free • Regular exchange of expensive and fragile seal units necessary

• Laborious assembly of delicate parts

• Extremely robust even at severe operating conditions or incidents (bowl imbalance, power failure, …)

• Susceptible to failure if operating conditions are not optimal

• Water cooling necessary – Consumption of cooling water

• No cooling necessary

• Approx. 5-6 bar feed pressure required to achieve a necessary feed flow velocity of 20 m/s(Assumption: 700 hl/h; Spindle bore hole Ø35)

• Low feed pressure (< 0,5 bar at 700 hl/h)

• Product contamination with wear particles coming from mechanical seals

• Feed product is subjected to strong magnetic fields from the motor while flowing through the spindle

• No influencing of the product

• Restricted possibility of full bowl ejections due to air entry into the feed system which causes heavy feed resistance

• No restrictions regarding bowl ejections (partial and full ejections possible at any time)

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Possible Energy Savings by new Centrifuge Design

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Depending on flowrate, feed pressure, required discharge pressure and desluding frequencyGEA Westfalia Separator is able to save 5 to 15 kWCompared to standard centrifuges.

Based on 7000 h/a and 0,08 €/kWh gives anual savingsof 2800€ to 8400€.

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Direct Drive as Modern Technology

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References

Perla Brewery, Poland - 1 x GSC 200i-06-772