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ESL-IE-08-05-47

MEASURED SAVINGS OF DC TO AC DRIVE RETROFIT IN PLASTIC EXTRUSSION

Ricardo A. Sfeir, P.E.

Senior Electrical Engineer

BASE Energy, Inc.

San Francisco, CA

ABSTRACT This paper presents the potential electrical energy efficiency improvements for utilizing alternating current (AC) motors controlled by variable frequency drives (VFD) in place of direct current (DC) motors to drive plastic extrusion machines. A brief background on the extrusion process is presented along with typical extrusion machine electrical drive performance requirements. Motor performance characteristics and control strategies are described for both AC and DC machines. A case study is presented, where detailed electrical measurements were performed on two similar extrusion machines driven by a DC motor and an AC motor respectively. Electrical energy, demand, and cost savings are analyzed.

INTRODUCTION In the plastic extrusion process, extruders continuously feed resin into a heated barrel, where a screw conveys, compresses, melts the resin, and expels the melt through a die. After exiting the die, the melt is cooled (through air, chilled water baths, etc,) and solidified to the shape of the die. Although the extruder barrel is electrically heated, the resin melts mostly due to friction and compression forces of the screw acting on the resin (approximately 85% of the heat required to melt the resin is delivered through friction [1]). The only moving part in an extrusion machine is the screw. Melt quality is mostly controlled by heat that is delivered to the resin (through friction by the screw); therefore it is important to have a consistent and reliable screw drive system. If constant and sufficient heat is not delivered to the resin, the melt will be uneven; conversely if too much heat is delivered to the melt it would result in significant energy waste due to: 1) excess heat delivered to the melt and 2) added cooling load when the melt exits the die and is ready to be solidified. Traditionally DC motors have been used as screw drives due to their: Relatively constant torque throughout the speed range, and Simple design of motor drive system compared to an AC motor drive system However, with advances in AC motor drives (vector flux variable frequency drives) their dynamic response has improved dramatically, making them an attractive alternative to DC drive systems. Due to improved dynamic response and better motor efficiency of AC drives (compared to DC drives), extrusion machines using AC drives can run faster

than extrusion machines using DC drives, resulting in improved productivity and significant electrical energy savings. DC DRIVES Traditionally DC motors have been the preferred drive system for extrusion machines due to their relatively flat speed vs. torque profile. A typical speed/torque profile for a DC motor is shown in Figure 1 [3].

Increasing Terminal Voltage

Vt1 Vt2 Vt3 Speed Vt 4

Torque

Figure 1 Typical Speed/Torque Characteristics for a DC Motor Four curves are shown in Figure 1, each representing shaft speed with constant terminal voltage (at four different terminal voltages, Vt1, Vt2, Vt3, and Vt4. Increasing the motors terminal voltage will increase the motors shaft speed. Ideally the speed curves should be completely flat; however due to armature resistance, a change in torque will result in a slight change in speed (the curve slopes are exaggerated in this graph). These almost flat curves, which characterize DC motors, is one of the main reasons DC drive systems have been the preferred technology to drive extruder screws. DC motors are able to maintain a relatively

Proceedings from the Thirtieth Industrial Energy Technology Conference, New Orleans, LA, May 6-9, 2008.

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ESL-IE-08-05-47

constant shaft speed, regardless of any load torque variation, which helps control the quality of the melt inside the barrel (constant shaft speed results in constant heat delivered to the resin). AC DRIVES Unlike DC motors, AC motors have a torque profile that varies with shaft speed. Typical off-the-shelf AC (or induction) motors can be classified as Type A, B, C, or D, depending on starting current and their torque/speed characteristics. Some typical current and torque speed curves for induction motors are shown in Figure 2 [1].

measurements (instantaneous power measurements as well as current data logging) where performed on one of the extruders powered by a DC system and a similar extruder which had been retrofitted with the new VFD controlled AC motor. The current drawn for the AC and DC driven extruders for a period of one week is presented in Figure 3 below.
500 450 400 350
DC System AC System

Current (A)

300 250 200 150 100 50 0 4/16

4/17

4/18

4/19

4/20

4/21

4/22

4/23

Figure 2 Current and Torque Characteristics for Different AC motor Classification The large torque variations with respect to shaft speed shown in Figure 2 is one of the main reasons that historically DC drive systems have been the preferred technology for plastic extrusion machines. New variable frequency drive technology (vector flux variable frequency drives) are able to overcome the torque/speed shortcoming of induction motors with a tighter control strategy. Vector Flux VFDs continuously monitor the motors rotor position and speed, which are fed to the VFD microprocessor to determine and control the motors actual speed, torque and power [2]. Due to this closed loop control strategy, Vector Flux VFDs are capable of operating induction motors in a similar way to DC motors offering the following performance improvements over traditional VFDs: Better control of motor speed, torque, and power Quick response to load changes Ability to provide 100% torque at zero speeds ENERGY SAVINGS (CASE STUDY) A plastic extrusion facility had recently replaced an existing DC drive system in one of their reclaim extruders with a VFD controlled AC drive system. The AC retrofit resulted in a significant reduction in total electrical energy consumption as well as an increase in product throughput. Detailed electrical

Figure 3 Current draw for DC Driven Extruder and AC Driven Extruder Some interesting features shown in Figure 3 are: The AC extruder requires less current (thus less power) to operate than the DC extruder. On average the AC drive draws approximately 210 A, while the DC drive draws approximately 286 A. Although the Reclaim department works 24 hours per day, not all extruders operate all the time. From Figure 3 it is estimated that the average utilization factor (UF, the ratio of machine run time to production hours) for the DC driven extruder is 0.55, while the UF for the AC driven extruder is 0.76. Production load decreases towards the weekends as is evident by the DC driven extruder coming offline. Since replacing the DC drive system with an AC drive system resulted in a productivity improvement, comparing the electrical energy consumption before and after the retrofit requires normalizing the energy consumption versus product throughput rate (pounds/hour, lbs/hr). Table 1 compares the performance/energy consumption of both the AC and DC driven extruders. Data collected and presented in Table 1 was measured, calculated based on measurements, or collected from information given by plant personnel.

Proceedings from the Thirtieth Industrial Energy Technology Conference, New Orleans, LA, May 6-9, 2008.

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TABLE 1 RECLAIM EXTRUDER ENERGY SPECIFICATIONS Extruder Drive System DC AC Average Current Draw (A) 286* 210* Utilization Factor 0.55* 0.76* Average Prod. Rate (lb/hr) 2,400** 2,800** Operating Hours (h/yr) 8,760 8,760 Nominal Power (hp) 400 300 Input Power (kW) 209 160 Energy Intensity (kWh/lb) 0.08710 0.0571702 Total Production (lb/yr) 11,538,157 18,617,114 Annual Energy(kWh/yr) 1,004,945 1,064,343 * Measured values. ** Based on conversation with plant personnel. Anticipated Savings The electrical energy savings will be calculated by comparing the electrical energy consumption of the DC driven reclaim extruder with that of the AC driven reclaim extruder, while considering the product throughput of each extruder. The annual amount of product processed, P, by a reclaim extruder can be calculated as follows: P = TP H UF Where, TP = H = UF = extruder throughput, lb/hr (from plant personnel) Reclaim Department operating hours, hr/yr utility factor, fraction of time the extruder operates, no units (measured) Eq. (1)

The energy intensity, EID, for DC driven extruder can be calculated as follows: EID = EID = (209 kW)/(2,400 lb/hr) 0.08710 kWh/lb

The energy intensity, EIA, for the AC driven extruder can be calculated as follows: EIA = EIA = (160 kW)/(2,800 lb/hr) 0.05717 kWh/lb

The electrical energy savings, EES, can be calculated as follows EES = P x (EID EIA) Where, P = total amount of product processed by the DC extruder during one year, lb energy intensity of the DC drive system, 0.08710kWh/lb (measured) energy intensity of the AC drive system, 0.05717 kWh/lb (measured) Eq. (3)

EIC = EIP =

The electrical energy savings, EES, for replacing the DC drive system with an AC drive system can be calculated as follows: EES= EES= (11,538,157 lb)(0.08710 kWh/lb 0.05717 kWh/lb) 345,337 kWh/yr

The total amount of product, P, processed through the DC driven extruder can be estimated as follows: P P = = (2,400 lb/hr)(8,760 hr/yr)(0.55) 11,538,157 lb/yr

The electrical energy savings of 345,337 kWh/yr for retrofitting the DC driven extruder with an AC drive system would reduce the electrical energy consumption by approximately 34% over the existing DC drive system. The average demand savings for replacing the DC drive system with and AC drive system in the Reclaim Extruders is calculated as follows: DS = EES / H Where, Eq. (4)

The energy intensity, EI, which is the average amount of energy required to process one pound of plastic through a reclaim extruder can be calculated as follows: EI = kW / TP Where, kW = TP = average extruder input power, kW (measured) extruder throughput, lb/hr (from plant personnel) Eq. (2)

EES= H =

annual electrical energy savings, kWh/yr reclaim department operating hours, h/yr

The demand savings, DS, for replacing the DC drive with an AC drive in can be calculated as follows: DS = DS = (345,337 kWh/yr)/(8,760 h/yr) 39 kW

Proceedings from the Thirtieth Industrial Energy Technology Conference, New Orleans, LA, May 6-9, 2008.

Table of Contents
ESL-IE-08-05-47

The estimated electrical energy cost savings, EECS, that can result from replacing the DC drive system with an AC driven system can be calculated as follows: EECS = EES (ave. electricity unit cost) EECS= (345,337 kWh/yr)($0.10/kWh) EECS = $34,534/yr IMPLEMENTATION STRATEGY Retrofitting a DC driven extruder machine with an AC system will require replacing the DC motor and motor drive with an inverter-duty induction motor and vector flux variable frequency drive. Additionally, motor characteristics and production profile will need to be programmed into the vector flux variable frequency drive. The implementation cost for replacing a DC drive with an AC drive system for the above case study can be itemized as follows1: 300 hp premium efficiency motor (inst.) ........... $26,300 300 hp variable frequency drive (inst.) .............. $46,050 Engineering (25% of above costs)...................... $18,088 Total .................................................................... $90,438 Therefore the annual cost savings of $34,534 would payback for the implementation cost of $90,438 in approximately 2.6 years. CONCLUSION New advances to (vector flux) variable frequency drives bring traditional induction (AC) motors as an attractive alternative to traditional DC drives in plastic extrusion machines. Due to higher energy efficiency of AC motors versus DC motors and the improved controls strategy of vector flux variable frequency drives (which allows plastic extruder machines to run faster), AC drive system retrofits can result in a significant electrical energy saving and productivity improvement, by lowering the energy intensity (kWh/lb) of extrusion machines. It is expected that an AC retrofit will result in an energy intensity reduction of approximately 34%. In the above case study, the AC retrofit of the extrusion machine saved approximately 345,337 kWh/yr, equivalent to $34,534/yr, resulting in a simple payback of 2.6 years. (5)

REFERENCES [1] White Paper: Induction Motors - Constant Frequency /Constant Voltage Variable Frequency / Variable Voltage in the Reliance Website: http://www.reliance.com/prodserv/motgen/b7097_2.h tm (accessed on 02/29/2008) [2] Understanding Variable Speed Drives (Part 2), March 1, 1995, Solomon Turkel, EC&M Web Site: http://ecmweb.com/mag/electric_understanding_varia ble_speed_4/ (accessed on 02/29/2008) [3] Principles of Electric Machines and Power Electronics, 2nd Edition, P. C. Sen, John Wiley & Sons, 1997 [4] Extrusion Processes Application Solution, Electric Rockwell Automation, Reliance www.reliance.com/prodserv/standriv/appnotes/d7741 .pdf (accessed on 02/29.2008) [5] Standard Handbook for Electrical Engineers, 15th Edition, McGraw-Hill, 2007

Installed costs are estimated from manufacturers literature and RS Means Electrical Cost Data 2007

Proceedings from the Thirtieth Industrial Energy Technology Conference, New Orleans, LA, May 6-9, 2008.