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

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

Sep 18, 2022 278 likes •518 views

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)

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eg@lokalenergi.dk

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

ECEEE summer study 2007

Erik Gudbjerg

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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 ?

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eg@lokalenergi.dk

What is coating - introduction

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eg@lokalenergi.dk

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eg@lokalenergi.dk

Why ? - Case paper mill !

55 kW water pump , electricity price 8 Euro cent pr. kWh Plus reduced “down time”

Coated Uncoated Pump cost 7000 7000 Maintenance - sealing 4875 4875 Maintenance - wheel 4875 Electricity 360000 420000 Coating cost (twice) 10000 Total cost 15 years period 381875 436750 Lifetime economics

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Improvement during lifetime with planned maintenance ! Efficiency Drop % 5 10 15 Time (years) 5 10 15 20

Energy Loss Energy Loss Energy Loss Energy Loss

Energy saved with routine mechanical maintenance

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Further Savings

Efficiency Drop % 5 10 15 Time (years) 5 10 15 20

Energy Loss

Energy saved with routine maintenance and coating

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Conclusions Part 1

Slam Vand Vand Vand Vand Vand Chlor Vand Vand Environment ”NEW” USED NEW NEW NEW USED USED NEW USED Status 855 855 S2 855HT 855 HT 855 HT S2 855 HT 855 HT Coat 30 55 3 3 37 110 11 7,5 0,75

  • Sz. P 2 [kW]

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

  • Sz. P 2 [kW]

Hidrost C / gl C / gl C / gl C / gl C / gl C / gl C / gl C / gl Pump type 4 29 14 12 3 6 19 _ [%] 52 62 57 56 74 86 69 77 34 _after [%] 50 48 50 50 72 81 58 77 34 _before [%] 4060 1250 1950 1950 1950 2350 2950 2250 2850 Ns 1460 2915 2900 2900 1445 1325 1500 1450 2840 N [o/min] 15 75 18 18 30 37 14 19 6 p [mWC] 450 120 34 34 300 700 200 200 15 Flow [m 3/h] Ejby Water Dalum Paper mill Ny2 Projekt Ny1 projekt Holstebro Heat Supply Hjørring Heat Supply Holstebro Swimming Skagen Heat Product. Roskilde Hospital

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eg@lokalenergi.dk

Part 2 – Agricultural sector

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New versus new coated single ventilator

  • No difference in effieciency or performance
  • Low pressure/high flow axial construction
  • Need for special test-rig / used in the rest

20 40 60 80 100 120 140 160 180 200 2000 4000 6000 8000 10000 12000 14000

Flow m3/h Pressure [Pa], eta [%]

70 140 210 280 350 420 490 560 630 700

Power [W]

Pressure coat Eta Coat Pressure Catalogue Eta Catalogue Pressure No Coat Eta No Coat Power coat Power Catalogue Power No Coat

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0% 2% 4% 6% 8% 10% 12% 14% 16% 18% 20% 22% 24% 26% 28% 30% 2000 4000 6000 8000 10000 12000 14000 16000

Flow [m3/h] Overall eff.

30 60 90 120 150

Pressure [Pa]

Eta New Eta Used Pressure New Pressure Used

Tryk eta

Used versus new unit (channels & ventilator)

  • About 2 pct. points lost after 6 months
  • 7 percent reduction in efficiency
  • Furthermore Pressure loss about 5-10 Pa
  • 10 percent reduction in hydraulic performance
  • Coated wheel better avoids dust !
  • Coated wheel can easier be cleaned on location !
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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.

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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
  • n the need of air in general
  • The price of technology better match

energy-consumption for each ventilator

  • One example measured already:
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Industrial sector

71,0

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5000 10000 15000 20000 25000

Flow [m3/h] Pressure [Pa]

0,0 10,0 20,0 30,0 40,0 50,0 60,0 70,0 80,0

Overall Efficiency [%] Power [kW]

Pressure Without coating Pressure With coating Efficiency Without coating Power Without coating Power With coating Efficiency With coating

  • 4 percent higher efficiency
  • 7 percent higher hydraulic performance
  • Increased consumption, uncrontrolled !
  • High pressure & potential
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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
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Maintenance in general – is important !

No 2 throttle stop No 3 only van and channels No 4 throttle stop and throttle No 5 rectifier cross in the top No 6 all

0% 2% 4% 6% 8% 10% 12% 14% 16% 18% 20% 22% 24% 26% 28% 30% 2000 4000 6000 8000 10000 12000 14000 16000

Flow [m3/h] Overall efficiency

30 60 90 120 150

Pressure [Pa]

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

Tryk eta

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How and why !

Energyuse in centrifugal pumps

50 55 60 65 70 75 80 85 90 95 100 600 1000 1300 1900 2500 3100 3700 4800 6000

Specific velocity Ns SI Losses & efficiency % Mechanical Volumetrical Impeller friction Hydraulic Usable work

7 5 ,

H Q n Ns

  • =
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Performance, new pump – 2,2 kW

0,0 500,0 1000,0 1500,0 2000,0 2500,0 10 20 30 40 50 60 Flow [m3/h] p_diff [mbar] DESMI 01 - Datablad DESMI 01 - Fabrik DESMI 01 - Coating DESMI 02 - Fabrik DESMI 02 - Coating

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Efficiency, new pump – 2,2 kW

0,0% 10,0% 20,0% 30,0% 40,0% 50,0% 60,0% 0,00 10,00 20,00 30,00 40,00 50,00 60,00 Flow [m3/h] Total eff. DESMI 01 - Fabrik DESMI 01 - Coating DESMI 02 - Fabrik DESMI 02 - Coating

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Performance, small pump – 0,2 kW

Performance 3000 rev./min

0,0 200,0 400,0 600,0 800,0 1.000,0 1.200,0 0,00 5,00 10,00 15,00 20,00 25,00

Flow [m3/h] pressure [mbar]

New pump Coat impeller Total coat

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Efficiency, small pump – 0,2 kW

Overall efficiency

0,0% 5,0% 10,0% 15,0% 20,0% 25,0% 30,0% 35,0% 40,0% 0,00 5,00 10,00 15,00 20,00 25,00

Flow [m3/h]

  • Eff. [%]

New pump Coat impeller Total coat