Coating as a way to reduce energy consumption About the research - PowerPoint PPT Presentation

ECEEE summer study 2007 Erik Gudbjerg Coating as a way to reduce energy consumption  About the research shown in this paper  What is coating (introduction)  Why use coating / case from paper mill  Conclusions part 1 (pumps)  Part 2 – ventilators in tough environment (agriculture) Characteristics new - versus new coated surface  Characteristics used - versus new surface   Conclusions about coating for ventilators in agricultural sector  What about the industrial sector, radial ventilators ?  Next step eg@lokalenergi.dk

About the paper  Research project partly financed by ELFOR, see more on www.elforsk.dk  EEMODS  Partners of the project • Danish Technological Institute (measurements, analyses) • Hans Andersen (co- author) • Desmi (pumps), SKOV (ventilators) • Mastertech (Cheramic coatings) • Bygholm (Danish Agriculture Researsh) • Jakob Albertsen A/S (coating factory) • LokalEnergi (dissemination)  Purpose of the project • Collect information about the coating technology • Dissemination of knowledge about the coating technology in DK • What is it - how does it work - what kind of benefits are there ? eg@lokalenergi.dk

What is coating - introduction eg@lokalenergi.dk

eg@lokalenergi.dk

Why ? - Case paper mill ! Lifetime economics Coated Uncoated Pump cost 7000 7000 Maintenance - sealing 4875 4875 Maintenance - wheel 0 4875 Electricity 360000 420000 Coating cost (twice) 10000 0 Total cost 15 years period 381875 436750 55 kW water pump , electricity price 8 Euro cent pr. kWh Plus reduced “down time” eg@lokalenergi.dk

Improvement during lifetime with planned maintenance ! 0 Energy Loss Energy Loss Energy Loss Energy Loss Efficiency Drop % 5 Energy saved with 10 routine mechanical maintenance 15 0 5 10 15 20 Time (years) eg@lokalenergi.dk

Further Savings 0 Energy Loss Efficiency Drop % 5 Energy saved with 10 routine maintenance and coating 15 0 5 10 15 20 Time (years) eg@lokalenergi.dk

Conclusions Part 1 Hospital Hospital Roskilde Roskilde Product. Product. Heat Heat Skagen Skagen Swimming Swimming Holstebro Holstebro Supply Supply Heat Heat Hjørring Hjørring Supply Supply Heat Heat Holstebro Holstebro projekt projekt Ny1 Ny1 Projekt Projekt Ny2 Ny2 Paper mill Paper mill Dalum Dalum Water Water Ejby Ejby Flow [m 3 /h] Flow [m 3 /h] 15 15 200 200 200 200 700 700 300 300 34 34 34 34 120 120 450 450 � p [mWC] � p [mWC] 6 6 19 19 14 14 37 37 30 30 18 18 18 18 75 75 15 15 N [o/min] N [o/min] 2840 2840 1450 1450 1500 1500 1325 1325 1445 1445 2900 2900 2900 2900 2915 2915 1460 1460 Ns Ns 2850 2850 2250 2250 2950 2950 2350 2350 1950 1950 1950 1950 1950 1950 1250 1250 4060 4060 _before [%] _before [%] 34 34 77 77 58 58 81 81 72 72 50 50 50 50 48 48 50 50 _after [%] _after [%] 34 34 77 77 69 69 86 86 74 74 56 56 57 57 62 62 52 52 � _ [%] � _ [%] 0 0 0 0 19 19 6 6 3 3 12 12 14 14 29 29 4 4 Pump type Pump type C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl Hidrost Hidrost Sz. P 2 [kW] Sz. P 2 [kW] 0,75 0,75 7,5 7,5 11 11 110 110 37 37 3 3 3 3 55 55 30 30 Coat Coat 855 HT 855 HT 855 HT 855 HT S2 S2 855 HT 855 HT 855 HT 855 HT 855HT 855HT S2 S2 855 855 855 855 Status Status USED USED NEW NEW USED USED USED USED NEW NEW NEW NEW NEW NEW USED USED ”NEW” ”NEW” Environment Environment Vand Vand Vand Vand Chlor Chlor Vand Vand Vand Vand Vand Vand Vand Vand Vand Vand Slam Slam eg@lokalenergi.dk

Part 2 – Agricultural sector eg@lokalenergi.dk

New versus new coated single ventilator 200 700 180 630 160 560 • No difference in effieciency or performance Pressure [Pa], eta [%] 140 490 • Low pressure/high flow axial construction 120 420 Power [W] 100 350 • Need for special test-rig / used in the rest 80 280 60 210 40 140 20 70 0 0 0 2000 4000 6000 8000 10000 12000 14000 Flow m3/h Pressure coat Eta Coat Pressure Catalogue Eta Catalogue Pressure No Coat Eta No Coat Power coat Power Catalogue Power No Coat eg@lokalenergi.dk

Used versus new unit (channels & ventilator) 30% 150 28% 26% • About 2 pct. points lost after 6 months 24% 120 eta 22% • 7 percent reduction in efficiency 20% 18% 90 Pressure [Pa] • Furthermore Pressure loss about 5-10 Pa Overall eff. 16% • 10 percent reduction in hydraulic performance 14% 12% 60 Tryk 10% 8% 6% 30 • Coated wheel better avoids dust ! 4% 2% • Coated wheel can easier be cleaned on location ! 0% 0 0 2000 4000 6000 8000 10000 12000 14000 16000 Flow [m3/h] Eta New Eta Used Pressure New Pressure Used eg@lokalenergi.dk

Conclusion agricultural sector  No start potential – axial, low-pressure fans  A lot of potential during lifetime / 7% after 6 months!  A lot of potential in possible more accurate dimensioning / 10% loss of hydraulic performance after 6 months!  A lot of additional potential by focusing on maintenance in general  Still expensive technology according to energy-consumption for each ventilator. eg@lokalenergi.dk

Industrial sector Assumed start potential – radial, high-  pressure fans / larger hydraulic losses due to friction in the ventilator housing Several types of use with a lot of  potential during lifetime! A lot of additional potential by focusing  on the need of air in general The price of technology better match  energy-consumption for each ventilator One example measured already:  eg@lokalenergi.dk

Industrial sector 5000 80,0 4500 71,0 70,0 4000 60,0 • 4 percent higher efficiency 3500 Overall Efficiency [%] Pressure [Pa] 50,0 • 7 percent higher hydraulic performance 3000 Power [kW] 2500 40,0 • Increased consumption, uncrontrolled ! 2000 30,0 • High pressure & potential 1500 20,0 1000 10,0 500 0 0,0 0 5000 10000 15000 20000 25000 Flow [m3/h] Pressure Without coating Pressure With coating Efficiency Without coating Power Without coating Power With coating Efficiency With coating eg@lokalenergi.dk

Next Step  Development in ventilaton for agricultural use – coatings & in general New research projects about industrial ventilators   Dissemination for end-users as energy service.  Further research regarding coating material according to the application  Penetration among OEM’s eg@lokalenergi.dk

eg@lokalenergi.dk

Maintenance in general – is important ! 30% 150 28% 26% 24% 120 eta 22% No 2 throttle stop 20% Overall efficiency No 3 only van and channels Pressure [Pa] 18% 90 No 4 throttle stop and throttle 16% No 5 rectifier cross in the top 14% Tryk No 6 all 12% 60 10% 8% 6% 30 4% 2% 0% 0 0 2000 4000 6000 8000 10000 12000 14000 16000 Flow [m3/h] eta måling 3 eta måling 4 eta måling 5 eta måling 6 eta måling 2 pressure måling 2 pressure måling 3 pressure måling 4 pressure måling 5 pressure måling 6 eg@lokalenergi.dk

How and why ! Energyuse in centrifugal pumps 100 95 Losses & efficiency % 90 85 Mechanical 80 Volumetrical 75 Impeller friction 70 Hydraulic 65 Usable work 60 n Q � Ns = 55 0 , 7 5 H 50 600 1000 1300 1900 2500 3100 3700 4800 6000 Specific velocity Ns SI eg@lokalenergi.dk

Performance, new pump – 2,2 kW 2500,0 2000,0 p_diff [mbar] 1500,0 1000,0 500,0 0,0 0 10 20 30 40 50 60 Flow [m3/h] DESMI 01 - Datablad DESMI 01 - Fabrik DESMI 01 - Coating DESMI 02 - Fabrik DESMI 02 - Coating eg@lokalenergi.dk

Efficiency, new pump – 2,2 kW 60,0% 50,0% 40,0% Total eff. 30,0% 20,0% 10,0% 0,0% 0,00 10,00 20,00 30,00 40,00 50,00 60,00 Flow [m3/h] DESMI 01 - Fabrik DESMI 01 - Coating DESMI 02 - Fabrik DESMI 02 - Coating eg@lokalenergi.dk

Performance, small pump – 0,2 kW Performance 3000 rev./min 1.200,0 1.000,0 800,0 pressure [mbar] 600,0 400,0 200,0 0,0 0,00 5,00 10,00 15,00 20,00 25,00 Flow [m3/h] New pump Coat impeller Total coat eg@lokalenergi.dk

Efficiency, small pump – 0,2 kW Overall efficiency 40,0% 35,0% 30,0% 25,0% Eff. [%] 20,0% 15,0% 10,0% 5,0% 0,0% 0,00 5,00 10,00 15,00 20,00 25,00 Flow [m3/h] New pump Coat impeller Total coat eg@lokalenergi.dk