Measurement Report for Synchronous Motor in Floatation Cellule
Project Summary Information:
After being extracted from underground and ground in mills to produce granules, the minerals such as lead, zinc and chrome need to be subjected to floatation process in tanks that contain water and chemicals. In these tanks, the minerals are separated from soil and rise to the surface in the form of foam; after which they are collected and undergo purification process to produce pure minerals.
In the scope of the project for achieving energy savings at the floatation facility, a trial run was carried out in order to determine the applicability and the advantages of EMF-brand Synchronous Torque Motors as mixer motor at A Plant. The asynchronous electric motors used in the current system were replaced with torque motors. With this application, a considerable saving wa achieved in the electric motors used for the cellules.
The existing asynchronous motors are 18.5 kW and 970 rpm motors, which run at a speed of 220 rpm by means of pulleys.
Our suggested motor is an SQM160-200 type 9.9 kW motor, which can run at any speed from zero to 270 rpm. Thanks to its powerful initial startup capability, it is not necessary to select a high kW as is the case for asynchronous motors.
Summary Information about the Activities Carried Out:
Total 8 cellules in cellule group 80-87 of Balya floatation facility were measured for the purposes of the trial. It is known that there is a different load on the motor at each cellule.
Therefore, 4 torque motors were subjected to trial alternately at the cellules with high load and at the cellules with low load. During the first month (792 hours), 4 EMF synchronous torque motors were run under high load at cellules 80-83. During the following month (792 hours), 4 EMF synchronous torque motors were run under low load at cellules 84-87.
During these periods, the consumption values of both the synchronous and asynchronous motors were measured, and these are summarized in the table below.
Summary Results
Results of the measurements obtained from the motors according to the data gathered during the trials carried out
Project Summary Information:
After being extracted from underground and ground in mills to produce granules, the minerals such as lead, zinc and chrome need to be subjected to floatation process in tanks that contain water and chemicals. In these tanks, the minerals are separated from soil and rise to the surface in the form of foam; after which they are collected and undergo purification process to produce pure minerals.
In the scope of the project for achieving energy savings at the floatation facility, a trial run was carried out in order to determine the applicability and the advantages of EMF-brand Synchronous Torque Motors as mixer motor at A Plant. The asynchronous electric motors used in the current system were replaced with torque motors. With this application, a considerable saving wa achieved in the electric motors used for the cellules.
The existing asynchronous motors are 18.5 kW and 970 rpm motors, which run at a speed of 220 rpm by means of pulleys.
Our suggested motor is an SQM160-200 type 9.9 kW motor, which can run at any speed from zero to 270 rpm. Thanks to its powerful initial startup capability, it is not necessary to select a high kW as is the case for asynchronous motors.
Summary Information about the Activities Carried Out:
Total 8 cellules in cellule group 80-87 of Balya floatation facility were measured for the purposes of the trial. It is known that there is a different load on the motor at each cellule.
Therefore, 4 torque motors were subjected to trial alternately at the cellules with high load and at the cellules with low load. During the first month (792 hours), 4 EMF synchronous torque motors were run under high load at cellules 80-83. During the following month (792 hours), 4 EMF synchronous torque motors were run under low load at cellules 84-87.
During these periods, the consumption values of both the synchronous and asynchronous motors were measured, and these are summarized in the table below.
Summary Results
Results of the measurements obtained from the motors according to the data gathered during the trials carried out
Evaluation of the Results:
It was observed that the amount of the energy saved in one month at the measured cellules was 6,441.31 kWh, when EMF Torque Motors were used for 792,3 hours instead of the 8 Asynchronous motors used at Balya Plant. The average financial return of the savings in 10 years will be around 60,360 TL.
List of advantages when asynchronous motors are replaced with torque motors
A. Our EMF torque motors with approximately 7 kW power will be used instead of the existing 18,5 kW motors, so;
C. In order for the establishment to obtain the most efficient production data, the cellule mixing speeds can be tested at different rpm's with E torque motors and drivers, and a contribution can be made to the production quality and amount.
D. During the initial startup, our motors do not cause dust, noise, do not impact the grid thanks to their smooth startup, do not strain the mechanical system and do not slip, as is the case in asynchronous motors.
E. Since our motors do not operate with belt and pulley system, there is no wearing and maintenance-demanding parts. They are completely maintenance-free.
F. If desired, our motors can be ordered as water-resistant in insulation class IP55 or IP66 instead of IP54.
G. Contributions in terms of occupational health and safety:
Dust : Since our motors do not have fans and cooling, they do not circulate the air, which leads to dusting and product waste by causing the product to take-off.
Noise : Our motors do not have belts and flywheels, and they operate at low decibels without noise.
Wastes : Our motors do not produce worn belt wastes, they are environment friendly.
Risk : While synchronous motors turn at 1000 rpm, our motors turn at 220 rpm and operate with low risk (the ball-bearing life is extended at the same ratio)
H. Besides all these advantages, thanks to our high efficiency, the government provides grant supports of 25% of the project cost and above for the energy efficiency projects to be carried out with our motors.
It was observed that the amount of the energy saved in one month at the measured cellules was 6,441.31 kWh, when EMF Torque Motors were used for 792,3 hours instead of the 8 Asynchronous motors used at Balya Plant. The average financial return of the savings in 10 years will be around 60,360 TL.
List of advantages when asynchronous motors are replaced with torque motors
A. Our EMF torque motors with approximately 7 kW power will be used instead of the existing 18,5 kW motors, so;
- All cable cross-sections will decrease at the same ratio.
- The double cables needed for star-delta operation will be replaced with a single cable.
- Thanks to their drivers, our motors eliminate the need for compensation investment.
- The reactive energy is at minimum level.
C. In order for the establishment to obtain the most efficient production data, the cellule mixing speeds can be tested at different rpm's with E torque motors and drivers, and a contribution can be made to the production quality and amount.
D. During the initial startup, our motors do not cause dust, noise, do not impact the grid thanks to their smooth startup, do not strain the mechanical system and do not slip, as is the case in asynchronous motors.
E. Since our motors do not operate with belt and pulley system, there is no wearing and maintenance-demanding parts. They are completely maintenance-free.
F. If desired, our motors can be ordered as water-resistant in insulation class IP55 or IP66 instead of IP54.
G. Contributions in terms of occupational health and safety:
Dust : Since our motors do not have fans and cooling, they do not circulate the air, which leads to dusting and product waste by causing the product to take-off.
Noise : Our motors do not have belts and flywheels, and they operate at low decibels without noise.
Wastes : Our motors do not produce worn belt wastes, they are environment friendly.
Risk : While synchronous motors turn at 1000 rpm, our motors turn at 220 rpm and operate with low risk (the ball-bearing life is extended at the same ratio)
H. Besides all these advantages, thanks to our high efficiency, the government provides grant supports of 25% of the project cost and above for the energy efficiency projects to be carried out with our motors.
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