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SUPPLEMENT SUSTAINABILITY IN MANUFACTURING
VFD BRINGS A NEW LEVEL OF SUSTAINABILITY TO INDUSTRIAL AND AGRICULTURAL SECTORS
A cutting-edge yet user-friendly variable frequency drive has been launched by WEG. The ADV200-SP has been designed specifically for isolated or hybrid solar-powered water pumping systems, bringing a new level of efficiency and sustainability to the agricultural and industrial sectors. The new drive combines the capability of the existing ADV200 inverter and WEG’s
extensive experience in solar and pump applications via photovoltaic (PV) panels. It converts the electrical energy supplied by the PV panel into mechanical energy which is converted into hydraulic energy by the pump. Leveraging the synergy between its inverters and solar technology, WEG has also
developed a groundbreaking software application that optimises the operation of solar pump systems. At the heart of this innovation is the company’s MPPT dynamic search algorithm, which ensures that the ADV200-SP Drive continuously adapts to varying irradiation and temperature conditions, maximising system load at maximum output power. Not only can the drive accommodate different plant configurations, but it also offers a power range from 1.5 to 400kW, making it suitable for a wide range of plant dimensions. To provide comprehensive support for pump protection and operation, the ADV200-SP incorporates
several specialised features within its software, including radiation sensor management, auto start and stop functionality, tank level control, dry run protection, flow and pressure loop control, etc.
WEG
NEW HYDROGEN COMBUSTION TECHNOLOGY UNVEILED
In partnership with Crosstown H2R, Sulzer has unveiled revolutionary hydrogen combustion technology designed for the aeroderivative, industrial, and power generation gas turbine fleet, positioning the installed gas turbines for a sustainable, emission-free, future. By integrating an advanced micromixer into the existing
combustion system, this technology represents a step forward from conventional burner types. The upgrade, which can be carried out during scheduled overhauls, involves replacing the existing burner and preparing the entire combustion system to accommodate the new component, making the turbine capable of flexibly using multiple fuels – e.g. from 100% natural gas to 100% hydrogen. Hydrogen, with a combustion flame speed around seven times faster than natural gas, necessitates a combustion system upgrade. A key technology is the burner, which ensures seamless handling of any level of hydrogen fuel. The overall upgrade integrating the new burner ensures reliable and efficient operation. The new solution, slated for its first commercial implementation in the second half of 2024, is a
testament to both companies' commitment to advancing greener energy solutions. Sulzer
www.sulzer.com
www.weg.net SUSTAINABLE
TITANIUM POWDER FOR ADDITIVE MANUFACTURING
6K Additive’s titanium powder (Ti-6AL-4V) has been independently certified by Scientific Certification Systems (SCS) Global Services, a global third-party auditing and certification organisation, for achieving a minimum 95% post-consumer recycled titanium content. The SCS Recycled Content Certification
evaluates products made from pre-consumer or post-consumer material diverted from the waste stream. This certification measures the percentage of recycled content for the purpose of making an accurate claim in the marketplace. 6K Additive is said to be the world’s the first
producer of AM powder made from sustainable sources and offers a full suite of premium powder, including nickel, titanium, copper, stainless steel, aluminium alloys, and refractory metals such as tungsten, niobium, and rhenium. The company leverages its UniMelt production-scale microwave plasma process to precisely spheroidise metal powders while controlling the chemistry and porosity of the final product with zero contamination and high throughput production capabilities. “We’re seeing a big increase from
customers asking for not only data, but third-party validation from their suppliers regarding sustainability, and having a recognised certification from a global sustainability organisation like SCS is exactly the type of confirmation they are seeking,” said Frank Roberts, president of 6K Additive. “Our proprietary technology for processing titanium and refractory metals at scale is a benefit to our customers and the environment by recycling scrap streams back into premium powders.”
6K Additive
www.6kinc.com/6k-additive/
AN ENERGY EFFICIENT WAY TO CLEAN AUTOMOTIVE COMPONENTS
At BMW Group’s Steyr site, the optimisation of production lines and machinery for the manufacturing of core engine components like crankshafts and crankcases, cylinder heads and housings for the latest generation of electric drives, has been on the agenda for several years. This also includes the cleaning machines for these. Although the company began equipping the pumps of the cleaning machines with variable frequency drives in 2016, it was found that the electrical heating systems of the machines running in three-shift operation caused a high rise in electricity consumption. A project to determine the energy
savings potential of replacing the previous electric heating system with a heat pump was therefore put into action. Due to the excellent cooperation the company has with Ecoclean, it was asked to become general contractor on the project. The solution is tailored to BMW Steyr. On the roof
of the transfer system there is a tank holding 2,000 litres of clean water that is supplied to the cleaning process at 56˚C. The required electrical heating system had a power draw of 39kW. Cooling of the vacuum pumps and control cabinet was effected by a cold water circuit. Cooling water is provided at a supply temperature of 16˚C and returns at a temperature of 22˚C. This ‘warm water’ serves as an energy source. It is supplied to the heat pump (power draw 11.2 kW) where it is heated to 65˚C. The heat transfer to the hot water supply of the cleaning machine is effected by a plate heat exchanger. A new circulating pump (power draw 1.2 kW) delivers the heated process water to the hot water tank of the cleaning machine while a second new circulating pump (also with 1.2kW
32 DESIGN SOLUTIONS - SUPPLEMENT DECEMBER/JANUARY 2024
power draw) returns the water that has been cooled to 16˚C to the cold water circuit. This solution reduces the energy consumption from 39kW to 13.6kW. With a defined production time of 5,760 hours per year, this adds up to more than 146 MWh. Furthermore, another 23 MWh are saved in cold water generation. Due to the saved current of a total of 169 MWh, the annual operating costs for cleaning have been reduced by approx. 19,000 Euros. In addition,
significantly fewer CO2 emissions are emitted into the environment, in this case the savings
amount to approx. 34 tons of CO2. “It has been a good decision to involve Ecoclean as prime contractor for energy-efficient projects. We are very happy with the results and their support, and will continue our cooperation,” said Gerhard Fuchs, who is in charge of the processes and is energy officer in the Steyr works.
Ecoclean
www.ecoclean-group.net
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