Power Savings.air Lift. B Elevator. Aumund

download Power Savings.air Lift. B Elevator. Aumund

of 34

Transcript of Power Savings.air Lift. B Elevator. Aumund

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    1/34

     

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    2/34

     

    Energy Savings

    Belt Bucket Elevators

    versus

    Pneumatic Transport

      Introduction Comparison Assessment Special Features

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    3/34

     

    Introduction

    With their ability to handle large capacities and lifts of 130 m and more,

    Belt Bucket Elevators offer significant advantages compared to airlifts :

    only 2 ! 33 " of the energy #hich is re$uired for airlifts

    reduced dedusting volume

    reduced e%haust fan po#er #ith preheater feeding

    reduced noise level as no air blo#ers are re$uired

    Energy Savings - Belt Bucket Elevators vs. Airlifts

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    4/34

     

    Energy Savings - Comparison cart !ased onconveying capacity of "## t$

    k% re&uired

    Belt Bucket Elevator 

    Airlift

      Introduction

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    5/34

     

    ROI assessment – theoretical comparative study

    Energy Savings - Belt Bucket Elevators vs. Airlifts

    Example 1 – kiln capacity nom. 2, ! max. 2,2 t!d clinkerExample 1 – kiln capacity nom. 2, ! max. 2,2 t!d clinker

    Introduction

    &oday, #e #ill focus on e%ample 2featuring a kiln capacity of nom' 3,000 t(d

    Example 2 – kiln capacity nom. ", ! max. "," t!d clinkerExample 2 – kiln capacity nom. ", ! max. "," t!d clinker

    &his study consists of:

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    6/34

     

    )eeding of preblending silo

    ** + 0 m ! 300 t(h ra# meal

    )eeding of preheater to#er 

    ** + 100 m ! 22 t(h ra# meal

    E%ample 2 ! kiln capacity 3000 t(dE%ample 2 ! kiln capacity 3000 t(d

      Comparison

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    7/34

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    8/34 

    Comparison

    B' Po(er savings on dedusting

    20'000 m(h vs' 11'000 m(h '000 m(h saving

      20 kW vs' 11 kW ( k) savin*

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    9/34 

    Comparison

    C' Po(er savings on E)aust fan

    2$.

    0

    0

    10'000

    20'000

    30'000

      r  e  $  u   i  r  e   d  a   i  r

      m   1   (   h

     -irlift Elevator 

    Example 2 ' kiln capacity " t!d

    /reheater feeding

     .aving on air volume 2,000 m(h %+ k) poer savin*

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    10/34

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    11/34 

    Comparison

    Summary of Po(er Savings

    conveyin* "(1 k)

    dedustin* ( k)

    exhaust fan %+ k)

    add. e-uipment '2# k)

    otal #"2 k)

    "(1

    (%+

    '2#

    #"2

    60

    0

    10

    20

    30

    50

    .otal savin*s Example 2 ' kiln

    capacity " t!d

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    12/34 

    Assessment

    /ased on/ased on

    &2 h ! per year of operation&2 h ! per year of operation

    +early savings

    and 0 .1 ! k) hand 0 .1 ! k) h

    3dependin* on country of3dependin* on country of

    installation4installation4

    ",11,# k)h

    0 "11,#

    Example 2Example 2

    5iln 6apacity " t!d5iln 6apacity " t!d

    otal 7oer avin* #"2 k)otal 7oer avin* #"2 k)

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    13/34 

    Assessment

    Investment Costs

    E)ample " , kiln capacity ### t$d

    ilo feedin*ilo feedin* 7reheater feedin*7reheater feedin*

    )ei*ht 0 )ei*ht 0

     -umund supplies and services 13 t 10,000 1 t 230,000

    7ocal manufacturing part 35 t ,000 58 t 5,000

     -dditional e$uipment 3,000 ,000

    )ield assembly 58 t 0,000 2 t 0,000

    *ivil #ork 13,000 1,000

    Electrical installation 23,000 2,000

    &otal "$2, %2,

    &otal investment costs 0 $$#,0 $$#,

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    14/34 

    Assessment

    /I Assessment

    E)ample " , kiln capacity ### t$d

    otal investment costsotal investment costs

     8early savin*s 8early savin*s

    0 $$#,0 $$#,

    0 "11,#0 "11,#

    ROIROI " years

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    15/34 

    Assessment

    Increased kiln capacity

    !y e)ploiting te po(er saving for e)aust fan

    9ependin* on the kiln system, the fresh air can :e used to9ependin* on the kiln system, the fresh air can :e used to

    increase the kiln capacity :y "; to %;.increase the kiln capacity :y "; to %;.

    &he follo#ing additional benefits are possible as #ell:

    9ncreased hot gas volume for the e%haust fan to supply to ra# mill

    and ( or coal mill system

    9ncreased drying efficiency of ra# mill and ( or coal mill system

    educed electricity consumption of ra# mill and ( or coal mill

    system

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    16/34 

    Comparison

    Summary of Po(er Savings

    conveyin* "(1 k)

    dedustin* ( k)

    exhaust fan k)

    add. e-uipment '2# k)

    otal "&+ k)

    "(1

    (

    '2#

    #"2

    60

    0

    10

    20

    30

    50

    .otal savin*s Example 2 ' kiln capacity

    " t!d

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    17/34 

    Assessment

    /ased on "; capacity increase/ased on "; capacity increase

    " t!d x ." x " d!y" t!d x ." x " d!y

    +early savings

    and additional profit of 0 &. ! tand additional profit of 0 &. ! t3dependin* on country of installation43dependin* on country of installation4

    0 2&,&2

    0 1$(,

    Example 2 5iln capacity " t!dExample 2 5iln capacity " t!d

    7oer avin* of "&+ k) and increased kiln capacity7oer avin* of "&+ k) and increased kiln capacity

    /ased on &2 h ! year operation/ased on &2 h ! year operation

    and 0 .1 ! k)h 3dependin* onand 0 .1 ! k)h 3dependin* on

    country of installation4country of installation4

    2,&&,2 k)h

    2&, t ! y

    In totalIn total 0 #%(,&2

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    18/34 

    Assessment

    /I Assessment

    E)ample " , kiln capacity ### t$d

    Investment costsInvestment costs

     8early savin*s 8early savin*s

    0 $$#,0 $$#,

    0 #%(,&20 #%(,&2

    ROIROI 2 years

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    19/34 

    Assessment

    ummary of advanta*es and disadvanta*esummary of advanta*es and disadvanta*es

    Energy consumption

    ;edusting volume

    *apital investment

    /elt :ucket elevator /elt :ucket elevator   AirliftAirlift

    < <

      <3loer volume4

    '

    '3hi*her volume4

    ' '

    <

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    20/34 

    0aintenance1 !elt !ucket elevator vs. airlift

      Assessment

     -irlift < lubrication =oil filling control> of

    blo#ers

    < filter cleaning at air blo#er inlet

    Bucket elevator  < lubrication of drive bearings

    < control of belt shore hardness

    once a year 

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    21/34

     

    Special Features

    /rimarily installed in the cement industry

    and designed to suit the

    demand for :

    ?  high availability

    ?  long service life of the chain or belt

    ?  temperature resistance

    ?  reduced #ear and maintenance

    A0=0>9 hi*h capacity :ucket elevatorsA0=0>9 hi*h capacity :ucket elevators 

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    22/34

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    23/34

     

    Special Features

    *istinguising Features of te A2023* Belt

    Bucket Elevator

    longitudinal steel ropes #ith close

    spacing + high tensile strength

    less belt thickness

    smaller drum diameter 

    teel re'inforced :eltteel re'inforced :elt

    additional cross #ires + high strength for bucket fi%ing

    tear6off resistance

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    24/34

     

    Special Features

    9istin*uishin* ?eatures of the A0=0>9 /elt /ucket9istin*uishin* ?eatures of the A0=0>9 /elt /ucket

    ElevatorElevator

    /elt splicin* – 6lampin* connection/elt splicin* – 6lampin* connection

    *lamped steel ropes

    .teel ropes cast in a resin

    compound

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    25/34

     

    Special Features

    9istin*uishin* ?eatures of the A0=0>9 /elt /ucket9istin*uishin* ?eatures of the A0=0>9 /elt /ucket

    ElevatorElevator

    /enefits of the steel re'inforced :elt/enefits of the steel re'inforced :elt

    @ /elt ends prepared in the orkshop

    @ ?ixed rate of elon*ation 3max. .2% ;4

    @ >o need for :elt shortenin* on site

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    26/34

     

    Special Features

    9istin*uishin* ?eatures of the A0=0>9 /elt /ucket9istin*uishin* ?eatures of the A0=0>9 /elt /ucket

    ElevatorElevator

    &ensioning unit for uniform and stable belt

    run, no off6track, tolerance only 1 mm

    9rive drum and tensionin* unit9rive drum and tensionin* unit

    )lat drive drum surface for even load

    distribution bet#een belt drum

    Belt centering achieved #ith minimum slope at

    drum edges

    emovable segmented friction lining for easy

    maintenance

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    27/34

     

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    28/34

     

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    29/34

     

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    30/34

     

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    31/34

     

    Special Features

    A0=0>9 /elt /ucket Elevators 9evelopment overA0=0>9 /elt /ucket Elevators 9evelopment over

    the past 2 yearsthe past 2 years

    $

    +2

    2

    ("

    $1

    22

    12

    1."

    2$

    1#

    1.%

    "+

    2

    #

    +

    $

    1

    12

    1#

    1+

    1($'1($% 1($+'1(( 1((1'1((% 1((+'2

    CC m Capacity t/h Installed power kW

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    32/34

     

    Special Features

    >um:er of A0=0>9 /elt /ucket Elevators installed>um:er of A0=0>9 /elt /ucket Elevators installed

    over the past 2 yearsover the past 2 years

    total number installed in 2001: 12(

    S i l F t

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    33/34

     

    Special Features

    &he trend for large belt bucket elevators for feeding of ra# meal silos and&he trend for large belt bucket elevators for feeding of ra# meal silos and

    preheaters is steadily increasingpreheaters is steadily increasing

    since kiln capacities no#adays often reach 10,000 t(daysince kiln capacities no#adays often reach 10,000 t(day

    and lifting heights of 130 m and more are re$uired for multi6stageand lifting heights of 130 m and more are re$uired for multi6stage

    preheater and pre6calcining systempreheater and pre6calcining system

    A2023* (ill !e tere to meet te callengeA2023* (ill !e tere to meet te callenge

  • 8/18/2019 Power Savings.air Lift. B Elevator. Aumund

    34/34