En­ergy ef­fi­ciency of dif­fu­sion pumps in­creased

DEMM Engineering & Manufacturing - - PRODUCT WATCH - www.demm.co.nz/reader- en­quiry #171110a

Dif­fu­sion pumps do not have any mov­ing parts – their prin­ci­ple of op­er­a­tion is based on steamed pro­pel­lants, thus en­abling ex­tremely re­li­able and low-main­te­nance op­er­a­tion. In ad­di­tion, they are ro­bust and of­fer an ex­cel­lent cost/per­for­mance ra­tio for high vac­uum gen­er­a­tion. For decades, these prop­er­ties have made them the “work­horse” in in­dus­trial ap­pli­ca­tions. Many sup­pli­ers considered this tech­nol­ogy to be ma­ture and ac­cord­ingly the tech­ni­cal de­vel­op­ment came to a stand­still, states Ley­bold.

The vac­uum sup­plier says it has recog­nised the po­ten­tial to raise this es­tab­lished tech­nol­ogy to a con­tem­po­rary level and has sig­nif­i­cantly re­duced the en­ergy con­sump­tion of the es­tab­lished DIP and newly de­vel­oped DIJ dif­fu­sion pump se­ries, with the aid of in­tel­li­gent tech­nolo­gies and in­no­va­tions. Ley­bold now pro­vides a num­ber of op­ti­mised mod­els and ac­ces­sories that are f lex­i­ble and can be im­ple­mented world­wide into the rel­e­vant dif­fu­sion pump ap­pli­ca­tions. The new DIJ fam­ily con­vinces with an op­ti­mised hous­ing de­sign, of­fer­ing con­nec­tions for both ANSI f lange and ISO f lange com­po­nents as well as var­i­ous elec­tri­cal con­nec­tion vari­ants. The new five- stage noz­zle sys­tem of the DIJ se­ries has been es­pe­cially im­proved for the pres­sure range from 10-2 to 10- 3 mbar.

Through de­sign changes and mod­ern con­trol ele­ments, the man­u­fac­turer was able to re­duce the en­ergy con­sump­tion of the dif­fu­sion pumps by an av­er­age of more than 30 per­cent – with­out sac­ri­fic­ing per­for­mance. In ad­di­tion, there are f ur­ther i mprove­ments i n terms of ser­vice­abil­ity and i nte­gra­tion i nto the cus­tomers’ sys­tems.

The l ow­er­ing of the en­ergy re­quire­ment has a pos­i­tive ef­fect i n all ar­eas of ap­pli­ca­tion. Even rel­a­tively l ow i ncreases i n ef­fi­ciency of i ndi­vid­ual vac­uum com­po­nents can l ead to i mproved en­ergy bal­ances, and no­tice­able re­duc­tions i n op­er­at­ing costs for cus­tomers and users over the en­tire ser­vice life of the plants and equip­ment.

Ley­bold says the great­est sav­ings po­ten­tial was achieved by se­lect­ing an im­proved heat­ing sys­tem and ad­just­ing it to pro­duce the pro­pel­lant steam. In ad­di­tion, en­ergy is saved by an op­ti­mized ar­range­ment of the heat­ing ele­ments in the boiler room, the loss­free en­ergy trans­mis­sion and the ther­mal in­su­la­tion.

In ad­di­tion to these struc­tural ele­ments, the op­tion of an in­te­grated en­ergy reg­u­la­tor re­duces the power con­sump­tion of the dif­fu­sion pump. Their use is par­tic­u­larly use­ful be­cause a high heat­ing power does not lead au­to­mat­i­cally to a higher suc­tion ca­pac­ity. Dur­ing a t yp­i­cal pro­duc­tion cy­cle, the full heater power must only be used dur­ing the ini­tial heat­ing up of the pumps boiler room. In the fol­low­ing process phases, the nec­es­sary en­ergy sup­ply can be con­trolled ex­actly with the set­tings of the con­trollers.

For this, sensors in the boiler room mea­sure the oil and heater tem­per­a­ture. As soon as the op­ti­mum is reached, the heat­ing out­put is low­ered. The power con­sump­tion is adapted to the re­quire­ments at the re­spec­tive op­er­at­ing point by means of the en­ergy reg­u­la­tor, op­er­at­ing man­u­ally or via a PLC. The mea­sured pump data is stored inside the reg­u­la­tor. It can be eas­ily in­te­grated into the cus­tomer’s own process con­troller and can be ex­ported and eval­u­ated via an USB port.

De­pend­ing on the pro­pel­lant f luid – min­eral oil or sil­i­cone oil – the op­ti­mum tar­get tem­per­a­ture in which the liq­uid de­vel­ops its re­spec­tive max­i­mum per­for­mance is ad­justed at the dig­i­tal en­ergy reg­u­la­tor. Com­pared to the en­ergy con­sump­tion of un­reg­u­lated stan­dard pumps, Ley­bold states that en­ergy sav­ings of up to 50 per­cent are pos­si­ble, de­pend­ing on the process cy­cle.

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