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feature energy efficiency

Germany makes strides


into energy efficiency
For around two years the campaign “Energy efficient systems in industry and trade” has
supported willing companies in Germany with concrete system analyses. More than 50
companies from the chemical, pharmaceutical, paper, electric, plastics and metalworking
industries have optimised their pump systems based on intensive professional advice – often
with astonishing results, as World Pumps correspondent Hans-Jürgen Bittermann reports.

T
he German Pumps+Systems Cost reduction x 200 is associated with high energy
Association of the VDMA, consumption. Furthermore, the
in association with the An example from the consulting pumps were operated at or above
Deutsche Energie-Agentur (dena), projects that already has been their nominal power, resulting in a
presented preliminary findings of their realised is at Unilever Deutschland reduced lifetime.
campaign for energy efficiency earlier GmbH. The company produces
this summer. ‘Their controllers will soap products in Mannheim. Most The analysis showed a savings
get teary-eyed’, one auditor quipped of the 200 pumps on site are used as potential of 925,000 kWh. This
when he saw the results. The report process or circulating pumps. At the means an annual cost savings of
concluded that energy efficient pump centre of the energy analysis stood 74,000. Unilever has invested
systems reach returns on investment up the optimization of the process water 295,000, which will amortize in
to 50%. These results that have been and circulating pumps as well as the four years.
unearthed as part of a recent “energy re-cooling system.
efficiency” initiative in Germany. The following activities were
The following parameters were recommended to optimize the
Christoph Singrün, general manager examined: the power consumption of system:
of the VDMA says, ‘...We put the the pump, the flow rates and the head
focus on energy optimization of the as well as the main consumers. • No throttling of pumps by slide
complete system. Only that way can valves
such high cost savings be reached.’ The The analysis shows that all pumps • Using motor-driven slide valves
fact that the campaign concentrated in the re-cooling systems have been for the individual systems and
on the cross section technology ‘pump throttled in their flow rate by flaps integrate them into the controlling
systems’ ensures that the energy on the discharge side. The result process
efficiency activities can be transferred was that the pumps were operated • Fitting drives with control devices
to as many companies as possible. according to their performance • Using drives with variable speed
range with a low efficiency, which (frequency converter) to adjust
Table 1. Summary of the savings achieved by
Unilever in the first two years of the project.

Power consumption
2,470,000 kWh/year
before the activities

Power consumption after


1,545,000 kWh/year
the activities

Saving of energy 925,000 kWh/year

Percental saving of energy 37 %

Cost savings 74,000/year

Investment in Euro295,000

Payback period 4 years

Return on investment
21.4 % Figure 1. After the efficiency analysis the pumps at the Unilever plant in Mannheim use
(dynamised)
37% less energy as before – so the company saves 74,000 every year.

36 0262 1762/07 © 2007 Elsevier Ltd. All rights reserved WORLD PUMPS October 2007
feature energy efficiency

the duty points of the pump to customers (process heat for the beer
EFF1 much better the system requirements production, heating of cleaning circuits,
than EFF2 • Use of high efficiency motors etc).
In the two presented projects it (EFF1-motors)
was recommended to use high • Refitting or removing the flow The analysis shows that the
efficiency motors. What is the
advantage for the owner, if he uses
meters not being used. flow rates at low heat consumption
a high efficiency motor of class and during production stops, or for the
EFF1 instead of an EFF2-motor? tempering of the pipeline network,
The most important arguments for Cost-efficient brewing
are basically too high. Furthermore,
EFF1 motors are:
In the centre of the energy analyis at an additional savings potential of
• a better efficiency (reduces energy the Binding Henninger Brauerei stands approximately 15,000 could be
consumption and thus operating an optimised hot water pump system. achieved by reducing the thermal energy,
costs), These pumps provide hot water to 500 an annual savings potential of 26,500.
• a lower noise level (increases
comfort)
• a lower winding temperature
(prolongs lifetime and reduces
heat input into the environment/
the pumped liquid)
• in total it has a positive impact on
the environment.

But Hermann W. Brennecke,


president of the management
board of the Grundfos GmbH in
Germany, says, ‘We should not fool
ourselves: No responsible manager
in the industry or of a local
authority will make investments
only for environmental reasons.
What he needs, is a real economic
advantage in competition with
clear payback periods.’

Why should the owner invest in an


EFF1-motor? Because after only 72
days of continuous operation, the
energy costs reach the purchase
price of a 3 kW motor (Comparison
measurement on the basis of a
pump motor 3.0 kW / 3 x 400 V /
50 Hz of efficiency class 1 and 2).
From day 73 on, he saves money.
Says Brennecke, ‘Even a donated
EFF2-motor is too expensive in the
long run.’

Energy + Award 2008


To promote the development and
use of high-efficiency circulation
pumps, the EU-project “Energy +
Pumps” has launched a European
competition, focusing on high
efficiency pumps. Three different
award categories are open for
applications: The best energy-
efficient circulator, the best
electricity-saving condensing
boiler and the best campaign
to promote these products will
receive the European “Energy +
Award”. Registration deadline
for all entries is 15th December
2007. The laureates will receive
their prizes within an award
ceremony in March 2008 at the
international trade fair “Mostra
Convegno” in Milan. Contact:
www.energypluspumps.eu

WORLD PUMPS October 2007 www.worldpumps.com 37


feature energy efficiency

The following activities were re-


commended to optimize the system:

• Replacement of the two existing


600 m³/h pumps
• Use of high efficiency motors
(EFF1-motors)
• Using frequency converters for
the operation with variable speed
• Hydraulic adjustment of the hot
water pipeline network
• Temperature-dependent adjusting
of the overflow lines for tempering
the pipeline network to the
required minimum
• Adapting other large-scale consumers
to load-dependent flow metering.
Figure 2. Professor Dr. Dieter-Heinz Figure 3. “At the advices we put the focus
Hellmann, member of the managing on the energetic optimization of the
Control speed to save board at KSB, estimates that in the complete systems. Only that way such high
energy companies of the chemical industry the cost savings can be reached.“ Christoph
proportion of speed controlled pumps Singrün, general manager of the VDMA
The examples of Unilever and has grown from small 2% to 20% in the association pumps+systems.
Henninger Brauerei show once last five years.

again that in existing pump systems


an adjustment to the required pump
performance is, in many cases, still 90% of the electrical nominal Hellmann referred to other advantages
made by means of conventional power at a flow rate of 60%. At that the energy efficient control of
methods such as using throttle the same flow rate of 60% a speed pump systems offers with regard to their
valves or by-pass lines. These controlled pump reduces its power lifespan:
techniques lead, in part, to enormous consumption to less than 30%. His
energy losses. Professor Dr. Dieter- clear conclusion: ‘For pump systems • Due to the always low speed
Heinz Hellmann, a member of the with recurrent fluctuating operation level at part load operation the
managing board at KSB, gives a or operation at part load the use of a mechanical components such
simple example. A pump system demand-dependent speed control is as shaft, bearings and seals are
controlled by throttle still uses particularly energy efficient.’ stressed in a lesser extent.
• Frequency converters start and stop
smoothly. By this way the whole
Table 2. Results of energy-saving efforts at Binding drive section is preserved and
Henninger Brauerei. the pump system is mechanically
stressed in a lesser extent. As in
Power consumption before the
case of energy optimized pump
activities 263,000 kWh/year
systems, fewer wear parts have
Power consumption after the to be replaced, and the periods
activities 139,000 kWh/year between the maintenance works
will be prolonged. Not only are
Saving of energy 124,000 kWh/year the energy costs falling, so are the
costs of servicing the equipment.
Percental saving of energy 47 %

Savings of thermal energy 365,400 kWh/year But there is one question left. If
the arguments for speed control
Savings of energy costs 11,500/year and energy efficiency are so clear
and coherent, why are so many
Cost savings by thermal energy 15,000/year
companies in Germany so resistant to
Total cost savings 26,500/year changing their methods? Probably the
dilemma is based among others on the
Required investment in Euro 84,000 traditional division of work. Normally
the planner is not responsible for the
Payback period 3 years operating costs, and the purchasing
Return on investment (dynamised) 31.1 %
derpartment still looks only at
ostensibly low prices.

38 www.worldpumps.com WORLD PUMPS October 2007


feature energy efficiency

Figure 4. According to Dr. Horst Dieter Figure 5. ‘Even a donated EFF2-motor


Elsner, CEO of the Wilo AG, the US- is too expensive in the long run.’
companies look keenly at the LCC Hermann W. Brennecke, president
(life-cycle-cost) of a pump. German of the management board of the
manufactures should unconditionally Grundfos GmbH in Germany.
take this chance.

Dr. Horst Dieter Elsner, CEO of the employing them. Only if energy
Wilo AG, sees this phenomenon is correspondingly expensive will
often with American companies, such investments pay off in an
who are often criticized because adequately short time. Now this
of their excessive waste of energy. moment has come. The results of
However, there is a growing the consulting projects in Germany
awareness of the benefits of analysing show that an increase in energy
lifetime costs, at least in case of efficiency pays for small and middle
industry managers. According to size companies as well as for large-
Elsner’s observations, the American scaled groups – and this applies to
companies look keenly at the LCC all sectors. ‘The companies being
(Life-cycle-cost) of a pump. In his advised can not only reduce their
opinion the products of American energy consumption and energy
pump manufacturers are not state costs considerably, they can also
of the art when it comes to energy gain high returns on investment’,
efficiency and speed control. says Stephan Kohler, the general
German pump manufacturers manager of the dena. ■
should unconditionally take this
opportunity to fill a market need. CONTACT:
Hans-Jürgen Bittermann
Pressebüro bitpress
A lot is happening in Germany, Goethestraße 10 A
and even the traditional chemical 67245 Lambsheim
Tel.: 06233-352030
industry is moving slowly towards Fax: 06233-352031
energy efficiency. Hellmann bitpress@t-online.de
estimates that in the chemical www.bit-press.de
industry the proportion of speed VDMA Fachverband Pumpen +
controlled pumps has grown from Systeme, Ulrike Mätje, Lyoner Straße
2% to 20% in the last five years, 18, 60528 Frankfurt
Tel.:+49 69 6603-1296
with the present trend ‘increasing Fax: +49 69 6603-2296
more and more’. ulrike.maetje@vdma.org

Deutsche Energie-Agentur GmbH


At first, high efficiency motors, (dena), Immo Zoch, Chausseestrasse
complex control devices and speed 128a, 10115 Berlin
Tel.: +49-30-726165-771
controlled pump drives cost money Fax: +49-30-726165-699
– and that deters companies from zoch@dena.de

WORLD PUMPS October 2007 www.worldpumps.com 39