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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

2© Hitachi, Ltd. 2011. All rights reserved.All Rights Reserved, Copyright © GIPC 2011

1. Background and Objective


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%


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)


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


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


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


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


2. Evaluation & Results


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


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


Raw Mill Fan

C ( )Operation data

Raw Mill Fan

Current data (10days)

rren

t (A

) Average:75A

Operation = 7,500hr/y (assumption)

Cur


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(%)


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)


Preheater FanPreheater Fan

Preheater Fan

Rated specification- Power : 800kW- Voltage : 6000V- Current : 95.7A- pf : 0.85- Speed : 1450rpm


Preheater Fan

C t d t (10d )

Preheater FanOperation data


Average:83A

rren

t (A

)

Operation = 8,000hr/y (assumption)

Cur


weeks

Preheater FanPower consumption Characteristics of input power of fan*

Preheater Fan


= √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[%]



Flow rate[%]94.7%


Flow rate (%) = 94.7(%)

Preheater FanPreheater FanEnergy saving estimation


2) Inverter driven- Speed rate (%) = 94.7 (%)- Shaft power (kW) = Rated Shaft Power (kW) * Average Speed rate (%)^3 p ( ) ( ) g p (%)


= 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)


Cement Mill Air FanCement Mill Air Fan

Cement Mill Air Fan

Rated specification- Power : 400kW- Voltage : 6000Vg- Current : 48A- pf : 0.85- Speed : 980rpm


Cement Mill Air Fan

C ( )Operation data

Cement Mill Air Fan


Average:40A

rren

t (A

)

Operation:68%hr = 6,000hr/y (assumption)

Cu


days

Cement Mill Air FanPower consumption Characteristics of input power of fan*

Cement Mill Air Fan


= √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[%]



Flow rate[%]90.2%


Flow rate (%) = 90.2 (%)

Cement Mill Air FanCement Mill Air FanEnergy saving estimation


2) Inverter driven- Speed rate (%) = 90.2 (%)- Shaft power (kW) = Rated Shaft Power (kW) * Average Speed rate (%)^3


= 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)


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


*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.


3. Experience of Hitachi Inverter


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


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


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


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)


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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