Case Study - Energy Saving For Fume Exhaust System Blower In 4HI Cold Rolling Mill.

Motor Rating : -

3-ph AC Induction motor of 50 HP, 415 V, 1460 RPM.

Previous System : -

  1. Star Delta starter for motor operation
  2. Belt pulley system for power transmission to fan.

Observation : -

  1. Blower fan kept working continuously at a constant speed.
  2. Blower fan working at full speed irrespective of fumes generated or not at rolling mill.

Process Study and Exprimentation : -

  1. Fume generation was very low during first pass rolling.
  2. No fumes generation during coil handling.
  3. Actual rolling duration at full and hence maximum fume generation takes place only 60% of the total duration of mill operation.
  4. Manual control of inlet valve of blower fan was impractical.

Present System : -

  1. AC electronics speed variable drive installed.
  2. Drive operation studied & software designed accordingly, optimise the power consumption during idling of mill.
  3. Further optimisation done to reduce the power consumption in accordance with fumes generation.

Merits of New System : -

  1. Smooth start resulting in increased life of motor and mechanical system.
  2. Energy saving due to speed / voltage variation during idling of the mill.

Cost Benifit Analysis : -

  1. Previous System (Without Drive) -
  2. Present System (With Drive) -
  3. Energy Saving per year -
  4. Investment -
  5. Saving in Rupee Terms / Year -
  • Speed=50 Hz, Kw (Consumption)=30
  • Speed=0-20-45Hz, Kw (Consumption)=15
  • 15 Kw X 20 X 300 = 90,000 KwH
  • Rs. 1,50,000 /-
  • 90,000 X 4 = 3,60,000 /-
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