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Home Focus Pumps & Compressors

Energy-efficient wastewater treatment

3. April 2020
in Pumps & Compressors, Water & Waste Water
Energy-efficient wastewater treatment Bauer Gear Motor

Picture: Bauer Gear Motor

The assets at Bayreuth sewage treat­ment plant oper­ate almost con­tin­u­ous­ly. When the time came to replace a motor at the site, oper­a­tors seized the oppor­tu­ni­ty to spec­i­fy an opti­mum replace­ment. Bauer Gear Motor was ready to offer an inno­v­a­tive per­ma­nent mag­net syn­chro­nous motor (PMSM) solu­tion that pro­vid­ed improved effi­cien­cy and increased cost-effectiveness.

In any indus­try, secur­ing effi­cien­cy is impor­tant. For crit­i­cal infra­struc­ture such as waste­water treat­ment plants, where duty require­ments are con­tin­u­ous, it is even more so. There­fore, select­ing an opti­mum geared motor to effi­cient­ly meet these duty require­ments can deliv­er a win­ning com­bi­na­tion of cost-effec­tive­ness and increased envi­ron­men­tal pro­tec­tion. This is exact­ly what Bauer Gear Motor, a lead­ing brand of Altra Indus­tri­al Motion Corp., has enabled for an eccen­tric screw pump at Bayreuth sewage treat­ment plant in Germany.

Bear Gear Motor is a world leader in tech­nol­o­gy for geared motors – always ahead of the curve in terms of deliv­er­ing high per­for­mance and effi­cien­cy dri­ves. Since the found­ing of the busi­ness in 1927, it has focused on pro­vid­ing opti­mum motor and gear­box solu­tions – allow­ing oper­a­tors to access appli­ca­tion reli­a­bil­i­ty while safe­guard­ing return on invest­ment (ROI) and over­all ener­gy consumption.

This is of per­ti­nence for the water treat­ment sec­tor. At Bayreuth, the eccen­tric screw pumps are required to oper­ate almost con­tin­u­ous­ly 365 days of the year. Over such duty require­ments, an improp­er motor can gen­er­ate exces­sive costs for oper­a­tors. Spec­i­fy­ing an over­sized motor, match­ing it to incor­rect com­po­nents, miss­ing the oper­at­ing point or improp­er gear selec­tions can have a debil­i­tat­ing effect on long term ener­gy effi­cien­cy. Spec­i­fy­ing an opti­mum dri­ve solu­tion for this appli­ca­tion, in con­junc­tion with the pump man­u­fac­tur­er, was the chal­lenge pre­sent­ed to Bauer by plant operators.

As is to be expect­ed of a glob­al tech­nol­o­gy leader, Bauer had a solu­tion. Work­ing with the pump man­u­fac­tur­er, Bauer dis­cov­ered that the installed 15kW IE3 asyn­chro­nous motor (ASM) could be down­sized to a 5.5 Kw IE3 dri­ve with PMSM technology.

A down­sized motor obvi­ous­ly pro­vides improved ener­gy effi­cien­cy, but the design of Bauer PMSM dri­ves home the advan­tage. An excep­tion­al­ly effi­cient rotor design fea­tures spe­cialised per­ma­nent mag­nets, which pro­vides pow­er sav­ings and improved envi­ron­men­tal cre­den­tials com­pared to tra­di­tion­al motors. Heat loss­es from the rotor are elim­i­nat­ed and total loss­es reduced by 25%, which results in con­sis­tent motor effi­cien­cy improve­ments of over 10% com­pared to com­peti­tor dri­ves. These char­ac­ter­is­tics ensure high effi­cien­cy even across var­ied duty requirements.

Oth­er eccen­tric screw pumps at the plant were still oper­at­ing ASM vari­ants, which allowed Bauer and oper­a­tors to con­duct a direct com­par­i­son. Oper­at­ing both ASM and PMSM vari­ants at a con­stant speed of 25Hz, the PMSM was found to deliv­er con­tin­u­ous ener­gy effi­cien­cy across the curve, espe­cial­ly at low load. When speed was var­ied, the PMSM was still more effi­cient under par­tial load. At low speed and load, the PMSM achieves 85% effi­cien­cy com­pared to 65% for the ASM. This illus­trates the wide par­tial load oper­a­tion and speed range offered by the inher­ent­ly effi­cient PMSM.

Ben­e­fits to the appli­ca­tion are many. Eccen­tric screw pumps oper­ate at dif­fer­ent speeds and oper­at­ing points depend­ing on require­ment, which suits the wide par­tial load oper­a­tion and speed range offered by the PMSM. Fur­ther­more, this range offers a high­er over­load capa­bil­i­ty, which is advan­ta­geous if anoth­er pump fails on-site and the same duty require­ments are spread across few­er pumps. If installed motors pro­vide greater over­load capa­bil­i­ty, this require­ment is eas­i­ly met, pro­tect­ing uptime. A high start­ing torque is anoth­er inher­ent fea­ture, which is impor­tant when pump­ing flu­ids. Down­siz­ing the motor also eas­es future main­te­nance, as the small­er motor can be eas­i­ly replaced if the need aris­es. Con­nect­ing cables were also half the thick­ness of the ASM equiv­a­lents, also reduc­ing costs while ensur­ing eas­i­er han­dling and maintenance.

How­ev­er, the prin­ci­ple ben­e­fits to oper­a­tors was increased effi­cien­cy across all duty require­ments. A min­i­mum 10% over­all effi­cien­cy improve­ment extend­ing over year­ly oper­at­ing cycles deliv­ered con­sid­er­able cost sav­ings of up to € 9.000 per pump per year and envi­ron­men­tal advan­tages on top. As well as reduc­ing ener­gy bills, oper­a­tors could eas­i­ly meet tar­gets for CO2 emis­sions, which are tight­en­ing in all aspects of indus­try. This matched with the inher­ent per­for­mance and reli­a­bil­i­ty of the PMSM, means the oper­a­tors reached the goldilocks zone of effi­cien­cy cre­at­ed by an opti­mum motor designed for var­ied duty requirements.

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