Modernization of fan drives – reduction of energy consumption by 9,868 MWh
Modernization of fan drives in an industrial facility brought savings of nearly 10,000 MWh per year. The use of frequency converters and precise speed control allowed for reduced energy costs and CO2 emissions, eliminating losses associated with flow throttling.
The challenge
Fans used in industrial processes – especially in high-dust environments – are among the most energy-intensive auxiliary devices. In many facilities, their control is carried out by throttling airflow with dampers, which is a simple but highly energy-inefficient solution. This was also the case for a manufacturing company struggling with high energy costs associated with dust extraction systems.
Analysis showed that in many units, the duct opening was closed up to 60% for most of the operating time, yet the power consumption by the drives remained almost unchanged.
Our approach
During a site inspection, DB Energy experts conducted detailed measurements of airflow and energy consumption at different levels of throttling. Based on this, fan operating characteristics were developed and potential effects of modernization were estimated.
It was crucial to understand the actual process needs of the facility and tailor a solution that would allow precise control of the equipment without generating energy losses.
Solution
A modernization of 9 fan drives was proposed and implemented using frequency converters allowing smooth speed regulation. Instead of throttling airflow with dampers, control is achieved by adjusting the motor speed to the actual airflow demand. Before each modernization, flow measurements were carried out under different operating conditions to optimally select parameters.
The investment included both the purchase and installation of the frequency converter systems as well as installation work and operational testing.
Results
Overall, the modernized drives accounted for an average annual electricity consumption of 25,085.603 MWh. Thanks to the implementation of intelligent speed control, consumption was reduced by 9,868.927 MWh per year, representing nearly 40% reduction. Investment costs were approximately 3.5 million PLN, and the payback period was exceptionally short, considering the scale of achieved effects.
Conclusions
Modernization of fan drives is one of the most effective actions in improving the energy efficiency of auxiliary systems. Replacing flow throttling with speed regulation eliminates unnecessary energy losses and allows equipment operation to be adapted to actual process needs.
The example of this industrial facility shows that even a relatively simple investment in frequency converter systems can bring savings measured in thousands of megawatt-hours per year, reducing both operational costs and CO2 emissions.
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