Hannover Fair showcases technologies in energy efficiency | Automation.com

Hannover Fair showcases technologies in energy efficiency

February 2, 2009 - Energy efficiency is a well-established concept in the mechanical and plant engineering sectors. Streamlined processes and modern machinery can pave the way to significant reductions in energy consumption. The special display "Energy Efficiency in Industrial Processes" at HANNOVER MESSE 2009 (20 - 24 April) will focus on the key issues.

Visitors to Hall 26 will be able to get to grips with the many possibilities for pruning back energy consumption. Numerous reference projects, selected from various sectors of industry, will be on display. A program of live presentations will illustrate the energy-saving potential of 'smart' industrial processes - processes that save time, cut costs and prolong machinery life cycles.

Energy saving will also be high up on the agenda at all the 13 trade shows that make up HANNOVER MESSE 2009. A shuttle bus will ferry visitors from the "Energy Efficiency" display directly to exhibitors of relevant products and systems. In addition, a printed Tour Guide will list all those exhibitors whose products and services are dedicated to boosting energy efficiency.

The replacement of obsolete drive systems would save up to 27.5 billion kilowatt-hours of electricity
Werner Blass, Managing Director of the Electric Power Transmission Section of the German Electrical and Electronics Federation (ZVEI), confirms that the "special display Energy Efficiency in Industrial Processes will give manufacturers of electric drives an excellent opportunity to demonstrate their capabilities. In standard applications such as pumping, ventilation, handling, conveying, air conditioning and refrigeration there is considerable scope for reducing energy consumption. The replacement of obsolete drive systems would save 27.5 billion kilowatt hours (KWh) of electricity per year. This is equivalent to 11 percent of total annual industrial power consumption - or €2.2 billion euros. Such an investment would pay for itself in two to three years."

"Pump tuning" cuts energy costs by up to 60 percent
Pumps account for more than 30 percent of total electricity consumption in trade and industry. For this reason pump systems will figure prominently at the "Energy Efficiency" display. Energy costs make up around 45 percent of the total costs incurred during a pump's life cycle. Servicing and maintenance are also expensive items. An important realization is that pumps often do not have to operate at full power all of the time. On the basis of more than 70 fact-finding missions to industrial enterprises the German Energy Agency (dena) estimates that optimized pump systems can generate annual savings of between €2,500 and €50,000 - or even €100,000 in some cases. The average potential saving is around 30 percent. In one extreme case it would be possible to slash energy costs by more than 90 percent.

Matching pump performance to actual demand
KSB, a leading manufacturer of pumps, valves and related systems, will be one of the contributors to "Energy Efficiency". Daniel Gontermann, Head of KSB's Automation Competence Center: "At HANNOVER MESSE 2009 we will be presenting PumpDrive, our speed control for centrifugal pumps. This demand-dependent system can achieve energy savings of up to 60 percent. It is designed for application in building installations, industry, as well as water extraction, treatment and transport.

Reduced energy consumption, noise emissions and heat losses
Rexroth will be taking the wraps off a smart variable-speed pump drive which generates the precise flow volume required at any given time. In other words, the pump speed is reduced significantly during pauses in the processing cycle and when the hydraulic system is not operating at its full load. As soon as higher power output is required, the speed of the dynamic and responsive motors is increased instantaneously. This minimizes energy consumption (by up to 45 percent), noise emissions (by up to 15 decibels) as well as the transfer of heat to the hydraulic oil (by up to 60 percent).

"Our energy-efficient automation solutions give machine manufacturers an immediate competitive edge - above all, as end users are in a position to achieve substantial energy savings. Our strategy is to combine mechanical components and smart electronic control systems in order to create ready-to-install mechatronic subassemblies. These modules have an immediate impact on energy efficiency - and are relatively easy to design," explains Dr. Karl Tragl, Executive Vice President Sales, Bosch Rexroth AG.

EC fans consume up to 70 percent less energy than their conventional counterparts
Sustained reductions in energy consumption are a prime development goal for ebm-papst, a leading international manufacturer of electric fans and motors. At HANNOVER MESSE 2009 ebm-papst will showcase its product portfolio in Hall 14, as well as at the "Energy Efficiency" display in Hall 26. The focus will be on so-called EC fans, which consume up to 70 percent less energy than their conventional counterparts.

Modern fans could render four European power stations superfluous
Hans-Jochen Beilke, Chairman of the ebm-papst Group, outlines the potential savings as follows: "Europe needs no fewer than eight power stations just to supply energy to electric fans. Four of these power stations could be dispensed with completely if electronic control technology were introduced on a wide scale."

ebm-papst will also take the opportunity to present its new HyBlade axial fans. The blades are constructed of a lightweight plastic material moulded around a resilient aluminium core. This innovative hybrid design delivers clear benefits: two thirds less power consumption; 50 percent less perceived noise; and a significantly reduced ecological impact over the product life cycle.

"HANNOVER MESSE is a very important trade show for our company. In our role as a producer of low-energy fans and motors we have decided to stage an additional product presentation at 'Energy Efficiency in Industrial Processes'," Hans-Jochen Beilke explains.

Systems monitoring pays dividends
According to a study by Rockwell Automation, servicing and maintenance account for between 15 and 40 percent of production overheads. These costs could be cut by half with the help of advanced diagnosis and condition monitoring systems. During HANNOVER MESSE 2009 Festo will present its GFDM system for the continuous monitoring of the pressure, flow and cycle consumption in pneumatic systems. GFDM provides the basis for implementing condition-oriented maintenance procedures. It also detects leakages immediately, thus allowing the plant operator to take effective countermeasures.

A further highlight at HANNOVER MESSE 2009 will be Festo's bionic jellyfish "AirJelly" and "AquaJelly". The purpose of the AirJelly is to demonstrate the potential for optimizing automated motion systems.

Dr. Eberhardt Veit, CEO of Festo AG: "Mechatronics, miniaturization, piezo technology and systems technology play a key role in boosting energy efficiency - not only in new sectors such as photovoltaics, but also in conventional mechanical engineering."

Demand-oriented compressed air systems cut energy consumption by as much as 30 percent
According to the Fraunhofer Institute the 60,000 compressed air installations in Germany consume 14 billion kilowatt-hours (kWh) of electricity every year. This is equivalent to five percent of total industrial electricity requirements. Against this background BOGE KOMPRESSOREN will be presenting its AIReport monitoring system, which tells the user precisely how much electric power is needed in order to generate one cubic metre of compressed air. Ultrasound measuring devices are then deployed to detect leaks. After just one week the system determines which specific combination of compressors is the most cost-effective and demand-oriented. Jürgen Hütter, Head of product marketing at BOGE KOMPRESSOREN: "The potential energy savings are immense - in the region of 30 percent."

In addition, BOGE will be unveiling a new compact piston compressor that delivers completely oil-free compressed air. In other words, lubricating oil is now superfluous - together with the regular monitoring and replenishment of oil levels. In addition, the new compressor helps to save energy. As Jürgen Hütter explains, "Downstream air treatment is less complicated. The pressure losses attributable to filters and air dryers are much lower. Consequently, less energy is required for compression purposes. The deployment of an oil-free piston compressor not only ensures additional safety and reliability - it also pays for itself in terms of substantially reduced energy costs."

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