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X. Agnello J. Naveen et al.
Working of Variable frequency drive (VFD)
In Cement Industries, three phase induction motors are used because of its robust
characteristics and simple maintenance. Rotating direction and speed of the three
phase induction motor can be changed using Variable Frequency Drive (VFD) which
is happening in recent years. The advantages of VFD are that they are energy saving,
consumes less current for starting of motor, thermal and mechanical losses are less
on motors, maintenance is not required often, has high power factor and a low KVA.
The PLC controls and monitors VFD and VFD acts as a conciliator between 3
phase induction motor and the PLC. A conveyer is connected to the induction motor
and cell sensor input is connected uniformly across the conveyer. The sensor input
is connected to the PLC. This processes the input according to the ladder logic
programming and initiates corresponding output to the VFD.
1. VFDs taken in line for energy conservation and optimization (More than 65 Nos
of VFDs Installed for Fans, Pumps etc.)
2. VFD for Compressors (HAG–Hot generator Coal Blower)
3. Continuous monitoring of false air in each section and reduction activities (Raw
mill circuit −7% including seal Air and Kiln 3.8%)
4. All major drives like Process Bag filter Fans, PH Fans, Coolers Fans; Kiln etc.,
are running in VFD
5. Expert Optimizer (EO) implemented for Raw Mill, Cement Mill, Coal Mill and
Pyro.
6. Automated and flow meters connected to it on consumption.
7. Direct current (DC) is changed into alternative current (AC)
Explanation of Cost Analysis using ROI and CBR for VFD
The Table 1 shows, Variable frequency drive (VFD), the return on investment
in conventional technology (non-renewable energy) was (−96.54%) and cleaner
technology Variable frequency drive (VFD) was (−61.9%) for Rs. 1 investment.
On comparing the two technologies recorded loss. In terms of cost benefit ratio
conventional technology (non-renewable energy) (0.115) and cleaner technology
(VRM) Special Power Reduction in OPC (0.564). Where the conventional technology showed higher benefit. Though loss in ROI and cost-benefit ratio, the cleaner
technology would still provide benefit through energy saved to an extent of 80,000
kwh per year and Rs. 2.46 lakh per year.
2.9 False Air Reduction
Process of False air reduction
The false air which has been escaped from the equipment can be collectively
infiltrated and reused by the keeping the temperature and pressure in a minimum
level of maintain if this temperature is recycled in that process is called has false air
reduction (Udara et al. 2014).
X. Agnello J. Naveen et al.
Working of Variable frequency drive (VFD)
In Cement Industries, three phase induction motors are used because of its robust
characteristics and simple maintenance. Rotating direction and speed of the three
phase induction motor can be changed using Variable Frequency Drive (VFD) which
is happening in recent years. The advantages of VFD are that they are energy saving,
consumes less current for starting of motor, thermal and mechanical losses are less
on motors, maintenance is not required often, has high power factor and a low KVA.
The PLC controls and monitors VFD and VFD acts as a conciliator between 3
phase induction motor and the PLC. A conveyer is connected to the induction motor
and cell sensor input is connected uniformly across the conveyer. The sensor input
is connected to the PLC. This processes the input according to the ladder logic
programming and initiates corresponding output to the VFD.
1. VFDs taken in line for energy conservation and optimization (More than 65 Nos
of VFDs Installed for Fans, Pumps etc.)
2. VFD for Compressors (HAG–Hot generator Coal Blower)
3. Continuous monitoring of false air in each section and reduction activities (Raw
mill circuit −7% including seal Air and Kiln 3.8%)
4. All major drives like Process Bag filter Fans, PH Fans, Coolers Fans; Kiln etc.,
are running in VFD
5. Expert Optimizer (EO) implemented for Raw Mill, Cement Mill, Coal Mill and
Pyro.
6. Automated and flow meters connected to it on consumption.
7. Direct current (DC) is changed into alternative current (AC)
Explanation of Cost Analysis using ROI and CBR for VFD
The Table 1 shows, Variable frequency drive (VFD), the return on investment
in conventional technology (non-renewable energy) was (−96.54%) and cleaner
technology Variable frequency drive (VFD) was (−61.9%) for Rs. 1 investment.
On comparing the two technologies recorded loss. In terms of cost benefit ratio
conventional technology (non-renewable energy) (0.115) and cleaner technology
(VRM) Special Power Reduction in OPC (0.564). Where the conventional technology showed higher benefit. Though loss in ROI and cost-benefit ratio, the cleaner
technology would still provide benefit through energy saved to an extent of 80,000
kwh per year and Rs. 2.46 lakh per year.
2.9 False Air Reduction
Process of False air reduction
The false air which has been escaped from the equipment can be collectively
infiltrated and reused by the keeping the temperature and pressure in a minimum
level of maintain if this temperature is recycled in that process is called has false air
reduction (Udara et al. 2014).