Bre­del pumps save up to 80 per­cent en­ergy con­sump­tion

DEMM Engineering & Manufacturing - - PUMPS & VALVES - WWW.WMFTG.COM

• En­ergy ef­fi­ciency and CO2 re­duc­tion i s now a board l evel com­mit­ment. • Cor­rect pump se­lec­tion i s vi­tal i n the drive to­wards a greener f uture. • A sin­gle Bre­del pump i s sav­ing one man­u­fac­turer around £ 2700 a year i n elec­tric­ity costs com­pared with an AODD pump. Bre­del pumps says i t saves UK man­u­fac­tur­ers £ 2700 per pump/per year i n elec­tric­ity, com­pared with AODD pumps – Equat­ing to an 80 per­cent re­duc­tion i n en­ergy con­sump­tion.

To­day, all man­u­fac­tur­ing and process plants see en­ergy ef­fi­ciency as a ma­jor pri­or­ity on their agen­das. En­ergy has be­come a board l evel com­mit­ment be­cause it i s driven by l eg­is­la­tion i n both the EU and the UK, and also be­cause it ’s an ex­pen­sive over­head. Nearly all plants run pumps of some kind, and with­out the nec­es­sary en­ergy man­age­ment they can make for hefty elec­tric­ity bills that can i mpact the bot­tom l i ne and re­duce com­pet­i­tive­ness.

KNOWL­EDGE IS POWER

Ac­cord­ing to the BPMA ( Bri­tish Pump Man­u­fac­tur­ers’ As­so­ci­a­tion), pumps ac­count for around 10 per­cent of the world’s elec­tric­ity con­sump­tion, while an alarm­ing t wo- thirds of pumps use up to 60 per­cent more power than nec­es­sary.

Cor­rect pump se­lec­tion i s there­fore crit­i­cal i n con­trol­ling en­ergy con­sump­tion, and not j ust the brand, but the cor­rect pump tech­nol­ogy, the size of pump and drive for the ap­pli­ca­tion. Only this will en­sure the short­est pay­back times and al­low plants to max­imise the re­turn of their i nvest­ment. Quick ROI i s also a great way to en­sure board l evel buy- i n.

LOOK BE­YOND THE PRICE

When con­sid­er­ing the ac­qui­si­tion of a new pos­i­tive dis­place­ment pump, many en­gi­neers get se­duced by a cheap pur­chase price. How­ever, there are far more sig­nif­i­cant sav­ings to be made over the life­time of a pump i f fac­tors such as en­ergy ef­fi­ciency are more care­fully con­sid­ered. In fact, tests and cal­cu­la­tions have shown that Bre­del heavy duty hose pumps can save up to 80 per­cent i n en­ergy costs per pump i n com­par­i­son with AODD pumps.

One re­cent ex­am­ple high­lights j ust how much can be saved by mak­ing more i nformed pump pur­chases. At a Mid­lands based pack­ag­ing com­pany that was an es­tab­lished user of AODDs (air op­er­ated dou­ble di­aphragm pumps), a prospec­tive en­quiry l ed to a very wel­come boost to the bot­tom line by switch­ing to Bre­del hose pumps f rom Wat­son- Mar­low Fluid Tech­nol­ogy Group.

LIKE-FOR-LIKE COM­PAR­I­SON

A di­rect com­par­i­son was drawn be­tween their ex­ist­ing AODD pump and the Bre­del 50 hose pump. At 29 rpm, the flow rate at 50 Hz is 5,000 l/ hr. The AODD pump air con­sump­tion at this flow rate (at 6.9 bar pres­sure) is equal to 35.34 CFM.

Ex­trap­o­lat­ing the math­e­mat­ics fur­ther, 35.34 CFM (based on 4 CFM per kW max­i­mum gen­er­a­tion) is equal to 8.83 kW. Hence, with elec­tric­ity cost­ing £0.10 per kW/ hr, the cost of run­ning the AODD pump per hour is £0.88. The duty cy­cle of the pumps for this client’s ap­pli­ca­tion is 16 hours run­ning per day, five days per week, 48 weeks a year – which equates to an­nual run­ning costs in elec­tric­ity of £ 3379. In re­al­ity this fig­ure is likely to be even higher be­cause of the air sys­tem leak­age suf­fered by most man­u­fac­tur­ing sites.

Us­ing the same pa­ram­e­ters, the Bre­del 50 draws just 1.75 kW, so the run­ning cost per hour is £0.175. Based on iden­ti­cal hours of oper­a­tion, the an­nual run­ning cost in elec­tric­ity is £672, de­liv­er­ing an im­pres­sive sav­ing of £2707 per year, per pump. The com­pany has in­stalled three Bre­del hose pumps, de­liv­er­ing an im­pres­sive sav­ing of £8121 per year, thereby re­duc­ing their en­ergy con­sump­tion by 80 per­cent.

Added to this, there is a re­duc­tion in CO2 emis­sions of over 12500kg per year, per pump based on the 2015 DEFRA con­ver­sion ra­tio of 0.46219kg of CO2 per kW hour of en­ergy used.

IM­PRES­SIVE SAV­INGS

Fac­tor­ing in the pur­chase price of the Bre­del 50, the pay­back pe­riod is just 2.1 years, af­ter which the pumps have a pos­i­tive ef­fect on the bot­tom line.

“For this client, the pay­back pe­riod was even shorter as the cal­cu­la­tions shown do not in­clude com­mon is­sues as­so­ci­ated with AODD pumps for this type of ap­pli­ca­tion – such as break­down costs and lost pro­duc­tion time,” says An­drew Ed­wards, a sec­tor spe­cial­ist at Wat­son- Mar­low. The client also con­sid­ered the re­duced com­pressed air re­quire­ment, which re­sulted in less wear and tear on the com­pres­sor.

Th­ese ef­fects were par­tic­u­larly com­mon at the man­u­fac­turer in ques­tion be­cause the prod­uct be­ing pumped from bulk tanks to day con­tain­ers is starch, which is quite abra­sive and be­comes even more abra­sive when sheared.

Abra­sives are known to wear AODD pump parts, such as ex­pen­sive end caps and man­i­folds. Fur­ther­more, the ball check valves of air op­er­ated dou­ble di­aphragm pumps can be dis­torted by the wear, to the point they reach a size that they can ex­trude through the pump. If this oc­curs the re­sult can be a con­tam­i­na­tion of the process or cre­at­ing a block­age in the pipework sys­tem.

LESS MAIN­TE­NANCE

Pre­vi­ously, the man­u­fac­turer had to main­tain the AODD pumps ev­ery 2-3 weeks, and not just to re­place nor­mal wear parts like di­aphragms, but high cost com­po­nents. What’s more, the fail­ures were un­pre­dictable, caus­ing line stop­pages, process dis­rup­tion and yet more costs.

In short, in­dus­trial man­u­fac­tur­ers can be­come far more en­ergy ef­fi­cient and max­imise process up time by switch­ing to Bre­del pumps.

Ul­ti­mately, the ex­am­ple de­scribed shows that switch­ing to Bre­del pump tech­nol­ogy can im­prove en­ergy ef­fi­ciency and en­able plants to in­crease prof­itabil­ity and re­main com­pet­i­tive in to­day’s fierce mar­ket­place. Ben­e­fits ar­rive not just in the shape of en­ergy sav­ings, re­duced car­bon emis­sions and leg­isla­tive com­pli­ance, but in demon­stra­ble greener cre­den­tials as part of a com­pany’s cor­po­rate re­spon­si­bil­ity ini­tia­tives.

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