Report on EnergyReport on Energy--Saving Survey by medium Saving Survey by medium voltage inverter for cement factoryvoltage inverter for cement factory
-- A case of cement factory in north Vietnam A case of cement factory in north Vietnam --
February, 2011February, 2011y,y,
Hitachi, Ltd.Hitachi, Ltd.Hitachi, Ltd.Hitachi, Ltd.
Table ContentsTable Contents
1. Background and Objective2 Summary of Survey2. Summary of Survey3. Evaluation & Results4 E i f Hit hi I t4. Experience of Hitachi Inverter
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1. Background and Objective
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Introduction of HitachiIntroduction of Hitachi
Founded 1910 (Incorporated in 1920)
Net Sales (Consolidated) US$ 96,436 million
Operating Income US$ 2,174 million Number of Employees 359 746 (E d f M h 2010)Number of Employees 359,746 (End of March 2010)
Consolidated Subsidiaries 900 (Including Hitachi, Ltd.)
The Hitachi Group’s 7 Industry SegmentsInformation & Telecommunication
Systems Electronic Systems & Equipment
The Hitachi Group s 7 Industry Segments
Power & Industrial SystemsFinancial Services
Logistics, Services & Others日立の事業
US$ 96.4billion
4%27%21%
17% 10%
Digital Media & Consumer ProductsHigh Functional Materials
日立の事業9%12%
27%21%
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Digital Media & Consumer Productsg
BackgroundBackground
Industrial motors consume approx. 70% of industrial electricity *1)
Use of VSD *2) can reduce 30% *3) of energy for driving motor
Energy Consuming Equipment
gy g
Energy Consuming Equipment
Energy saving & CO2 reduction by
PlantRotating Machineries
yadapting inverter on fixed occasion speed motor driving such as blower & fan
Plant with choke operation.
*1) data from a Report by FUJI KEIZAI CO LTD (March 2009)
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1) data from a Report by FUJI KEIZAI CO.,LTD. (March, 2009)*2) Variable Speed Drive*3) depending on the condition
Concept of Energy Saving
E i d CO d ti
Energy saving characteristic of fan(input power vs. flow rate)
Expected advantages:
Concept of Energy Saving
- Energy saving and CO2 reduction ( p p )
90%
100%
110%
Damper controlDamper control
Fixed speedLarge energy can be saved by speed control of fans, blowers and pumps.
60%
70%
80%
ower
[%]
P i
input powerinput power
BoilerDampercontrol
Exhaust air chimney
Fixed speed
30%
40%
50%
Inpu
t po Power saving
(%)
Inverter control
Energyloss
Commercial power
Variable speed control0%
10%
20%
% % % % % % % %
input power
Variable speed control
Exhaust air 30% 40% 50% 60% 70% 80% 90% 100%
flow rate [%]Boiler
INVERTER
chimney Fully open
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Motor InverterFan, Blower or Pump
IDF speedcontrol signal
Invertercontrol signal
IDF: Induced Draft Fan IM: Induction Motor
Survey OutlineSurvey Outline
Date : October 28, 2010 Site : Cement Plant in North Vietnam
(Production; 1,000,000t/year) Target : 3 Fan Motors Target : 3 Fan Motors
Hanoi
North Vietnam
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North Vietnam
Summary of the SurveySummary of the Survey
Survey Process
Current Status Energy-Saving Plan and Its Effect
Result of the Survey
Energy saving isOct. 28, 2010 :Site surveyInverters are not applied to motors.
Energy saving is expecting by- Controlling the flow
t d t l b
Oct. 28, 2010 :Site survey•Surveyed target equipment and electrical rooms
•Collected equipment data rate adequately by damper
- Adapting inverter to th t ft
•Collected equipment data(Targets)- Raw Mill Fan- Preheater Fan the motor after
damper control- Preheater Fan- Cement Mill Air Fan
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Survey Process (Summary)Survey Process (Summary)
ProposalAnalysisField Survey
ケジ
Nov. 2010スケジュール Oct. 27 , 2010Date
• Calculate energy saving effects
• Site survey– Collected target
equipment dataequipment data– Checked operating
conditionsCh k d l t i l
Action
– Checked electrical rooms
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2. Evaluation & Results
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Target EquipmentTarget EquipmentClinkering Finish grindingRaw material grinding
CoalMillNew suspension
Raw Mill
Raw MillEP Fan
Coal Mill
Mill Fan
New suspensionPre-heater
Coal
Fan
BlendingSil
RawStorageRaw
Cement mill air fan
Coal Mill Separator
Cement AirSeparator
Silo gSilomaterial
Raw Mill Preheaterfan
ClinkerCooler
ClinkerPre-grinder
SurplusGas IDF
Gypsum
Rotarykiln
fan
Motor List
ClinkerSilo
CementSilo
Clinker Cooler Fan
GypsumCement
Mill No. Application Q Rated capacity
1 Raw Mill Fan 1 800kW
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AirProduct Water
2 Preheater Fan 1 800kW
3 Cement Mill Air Fan 1 400kW
Raw Mill FanRaw Mill Fan
Raw Mill Fan
Rated specification- Power : 800kW- Voltage : 6000Vg- Current : 94.9A- pf : 0.86- Speed : 1450rpm
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Raw Mill Fan
C ( )Operation data
Raw Mill Fan
Current data (10days)
rren
t (A
) Average:75A
Operation = 7,500hr/y (assumption)
Cur
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days
Raw Mill FanPower consumption
Raw Mill Fan
Characteristics of input power of fan*
90%
100%
110%
Assumed DOL controlelectricity
(Current power consumption)Input power (kW)
= √3VIcosφ
70%
80%
r [%
]
87.5%= √3VIcosφ = 670 (kW)
(@100%Load of DOL drive)
40%
50%
60%
put P
ower(@100%Load of DOL drive)
Input power (kW)= Rated shaft power / Motor efficiency= 766 (kW)
20%
30%Inp
Inverter controlInput power (%)
= 670(kW) / 766 (kW)
0%
10%
30% 40% 50% 60% 70% 80% 90% 100%
Flow rate[%]
Inverter controlelectricity
Flow rate (%) = 83.8(%)
670(kW) / 766 (kW)= 87.5(%)
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Flow rate[%]83.8%
Using the general characteristic of fan, because actual data could not be found,
Raw Mill FanEnergy saving estimation
Raw Mill Fan
1) Current power consumption- Input power (kW) = √3VIcosφ = 670 (kW)
2) Inverter driven- Speed rate (%) = 83.8 (%)- Shaft power (kW) = Rated Shaft Power (kW) * Average Speed rate (%)^3- Shaft power (kW) = Rated Shaft Power (kW) Average Speed rate (%) 3
= 720 (kW) * 0.8383 = 424 (kW)- Input power (kW) = Shaft power (kW) / Motor efficiency(%) / Inverter efficiency (%)
= 470 (kW)
3) Energy Saving- Input power △P (kW) = 670(kW) – 470 (kW) = 200 (KW)- Annual power saving (kWh/y) = 200 (kW) * 7 500 (h/y) = 1 500 000 (kWh/y)Annual power saving (kWh/y) = 200 (kW) 7,500 (h/y) = 1,500,000 (kWh/y)- Merit of energy saving (VND/y) = 1,500,000 (kWh/y) * 1,095 (VND/kWh)
= 1,642,500,000 (VND/y)
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Preheater FanPreheater Fan
Preheater Fan
Rated specification- Power : 800kW- Voltage : 6000V- Current : 95.7A- pf : 0.85- Speed : 1450rpm
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Preheater Fan
C t d t (10d )
Preheater FanOperation data
Current data (10days)
Average:83A
rren
t (A
)
Operation = 8,000hr/y (assumption)
Cur
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weeks
Preheater FanPower consumption Characteristics of input power of fan*
Preheater Fan
(Current power consumption)Input power (kW)
= √3VIcosφ 90%
100%
110%
95.7% Assumed DOL control= √3VIcosφ = 733 (kW)
70%
80%
r [%
]
Assumed DOL controlelectricity
40%
50%
60%
put P
ower(@100%Load of DOL drive)
Input power (kW)= Rated shaft power / Motor efficiency= 766 (kW)
Input power (%)20%
30%Inp
Inverter control
= 766 (kW)
= 733(kW) / 766 (kW)= 95.7(%) 0%
10%
30% 40% 50% 60% 70% 80% 90% 100%
Flow rate[%]
Inverter controlelectricity
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Flow rate[%]94.7%
Using the general characteristic of fan, because actual data could not be found,
Flow rate (%) = 94.7(%)
Preheater FanPreheater FanEnergy saving estimation
1) Current power consumption- Input power (kW) = √3VIcosφ = 733 (kW)
2) Inverter driven- Speed rate (%) = 94.7 (%)- Shaft power (kW) = Rated Shaft Power (kW) * Average Speed rate (%)^3 p ( ) ( ) g p (%)
= 720 (kW) * 0.9473 = 612 (kW)- Input power (kW) = Shaft power (kW) / Motor efficiency(%) / Inverter efficiency (%)
= 678 (kW)
3) Energy Saving- Input power △P (kW) = 733(kW) – 678 (kW) = 55 (KW)- Annual power saving (kWh/y) = 55 (kW) * 8,000 (h/y) = 440,000 (kWh/y)g ( y) ( ) ( y) ( y)- Merit of energy saving (VND/y) = 440,000 (kWh/y) * 1,095 (VND/kWh)
= 481,800,000 (VND/y)
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Cement Mill Air FanCement Mill Air Fan
Cement Mill Air Fan
Rated specification- Power : 400kW- Voltage : 6000Vg- Current : 48A- pf : 0.85- Speed : 980rpm
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Cement Mill Air Fan
C ( )Operation data
Cement Mill Air Fan
Current data (10days)
Average:40A
rren
t (A
)
Operation:68%hr = 6,000hr/y (assumption)
Cu
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days
Cement Mill Air FanPower consumption Characteristics of input power of fan*
Cement Mill Air Fan
(Current power consumption)Input power (kW)
= √3VIcosφ 90%
100%
110%
92.2%= √3VIcosφ = 353 (kW)
70%
80%
r [%
]
92.2%Assumed DOL control
electricity
(@100%Load of DOL drive)Input power (kW)
= Rated shaft power / Motor efficiency= 383 (kW) 40%
50%
60%
put P
ower
= 383 (kW)
Input power (%)353 (kW) / 383 (kW)
20%
30%Inp
Inverter control= 353 (kW) / 383 (kW)= 92.2(%)
0%
10%
30% 40% 50% 60% 70% 80% 90% 100%
Flow rate[%]
Inverter controlelectricity
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Flow rate[%]90.2%
Using the general characteristic of fan, because actual data could not be found,
Flow rate (%) = 90.2 (%)
Cement Mill Air FanCement Mill Air FanEnergy saving estimation
1) Current power consumption- Input power (kW) = √3VIcosφ = 353 (kW)
2) Inverter driven- Speed rate (%) = 90.2 (%)- Shaft power (kW) = Rated Shaft Power (kW) * Average Speed rate (%)^3
= 360 (kW) * 0.9023 = 264 (kW)- Input power (kW) = Shaft power (kW) / Motor efficiency(%) / Inverter efficiency (%)
= 293 (kW)
3) Energy Saving- Input power △P (kW) = 353(kW) – 293 (kW) = 60 (KW)- Annual power saving (kWh/y) = 60 (kW) * 6,000 (h/y) = 360,000 (kWh/y)
M it f i (VND/ ) 360 000 (kWh/ ) * 1 095 (VND/kWh)- Merit of energy saving (VND/y) = 360,000 (kWh/y) * 1,095 (VND/kWh) = 394,200,000 (VND/y)
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ResultsResults
Service Raw Mill Fan PreheaterFan
Cement Mill Air Fan Total
Motor capacity kW 800 800 400 2,000Motor capacity kW 800 800 400 2,000
Energy consumption kW 670 733 353 1,756
Energy saving kW ▼200 ( 30%) ▼55 ( 8%) ▼60 ( 17%) ▼315 ( 18%)Energy saving kW ▼200 (-30%) ▼55 (-8%) ▼60 (-17%) ▼315 (-18%)
Operation hours h/y 7,500 8,000 6,000 -
Energy saving MWh/y ▼1,500 ▼440 ▼360 ▼2,300
CO2 reduction *1) t-CO2/y ▼900 ▼264 ▼216 ▼1,380
Cost reduction *2) US$/y ▼82,500 ▼24,200 ▼19,800 ▼126,500
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*1) 0.6t-CO2/MWh (Assumption), *2) 1,095VND/kWh (0.055US$/kWh)
SuggestionsSuggestions
- Among surveyed three fan motors, “Raw Mill Fan” has the most energy saving potential at current operating gy g p p gcondition.
- “Preheater Fan” and “Cement Mill Air Fan” are operating as almost full load now. If they are operating as optimal flow rate there will be a possibility to save energyflow rate, there will be a possibility to save energy.
- We surveyed only three fans at this time. We think there y yare other potential equipment.
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3. Experience of Hitachi Inverter
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Introduction of Omika Works
■ Manufacturing Medium Voltage Inverters in Omika Works
Introduction of Omika Works
Omika Works is located in the north of Tokyo. The area is 201,000m2, 600m by north to west, 460m by east to west. There are approx. 2,000 people working at this works providing total solutions such as Information systems and Control
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this works, providing total solutions such as Information systems and Control systems for Power plant, Transportation, General industries.
MV-VFD Product Line-UpMV-VFD Product Line-Up
O V l■ Wide Range of Medium Voltage Drives
Output Voltage[V]
11,000 830 4,890 Water-cooled
7 200
10,000 750 4,450
10M 30M 60M
Air-cooled Multi-Level VFDHIVECTOL-HVI
5-Level VFDHIVECTOL-VSI-H5
(*)
6,6007,200
500 10M10M 30M 60MHIVECTOL HVI
(*): Set parallel
4,1603,300 500 5,000
630 4,000
2,400 360 3,630
10MVA1,000kVA 100MVA
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ApplicationsApplications
Rubber and Plastic Cement HVAC-Ban bury mixers-Extruders-Pelletizers-Agitators
- Kilns- Fans
- Chiller
Agitators
Power Generation- ID Fans and FD Fans for boiler combustion facilities
for energy saving
W t d W t W t
for energy saving- Coal mills- Pumps for nuclear power plants
Water and Waste Water- Pumps for energy savings
Oil and Gas- Compressor drives with motors and VFDs- Pumps
Marine
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Marine- Ship propulsion
Supply Record VFDSupply Record VFD
Air-cooled Multi-Level VFD : HIVECTOL-HVI (1999~2009)
End user Application Q’ty % RatingsRubber Ban bury mixer 122 36 750~4,000kVA
Water & aste ater Water p mp 68 20 250 4 000kVAWater & wastewater Water pump 68 20 250~4,000kVA
Metal Blower, Fan, Pump, Grinder 41 12 350~6,000kVA
Thermal power Fan 29 8.5 2,000~8,250KVA
Refinery &Petrochemical
Extruder, Agitator, Expander, etc. Compressor, Pump
32 9.5 350~4,000kVA
Cement Kiln, Fan 13 4 700~4,000kVA
AC t d i f St l R lli Mill
Others Compressor, Chiller, Agitator, etc. 36 10 250~15,000kVA
341 100 596MVA
( ) AC motor drive for Steel Rolling Mills IGBT drive GTO drive Cyclo-converter Total
Total number 428 38 59 525
(1986~2009)
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Total number 428 38 59 525Total capacity 1,404MW 191MW 202MW 1,797MW
Contact List
If you have interests in our survey, please feel free to contact to the f ll i dd
Contact List
following addresses.
Hitachi, Ltd.Ken Hirata: [email protected]@
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