AEL Intelligent Blasting cuts energy consumption by 500 kWh per hour

Wednesday, January 9, 2019
AEL Intelligent Blasting cuts energy consumption by 500 kWh annually

This 720 Mtpd nitric acid plant in South Africa saves 3.6 M Rand annually on operating costs, thanks to an upgrade from direct-on-line operation to VLT® drive control of electric pumps and motors.

For many years, motors and pumps in the process cooling water (PCW) system operated direct-on-line. With the upgrade, AEL Intelligent Blasting aimed to improve efficiency and reliability by introducing AC drive motor control. They chose VLT® AQUA Drive FC 202 and VLT® HVAC Drive FC 102 drives from Danfoss, based on their ability to ensure stable operation despite unreliable mains power supply. These drives offer Automatic Energy Optimization and kinetic back-up features to support highly efficient and reliable plant operation.

The remarkable payback time of only 18 months reflects the vast improvement in process cooling water efficiency enjoyed by AEL Intelligent Blasting.  

“The drives were selected based on the kinetic back-up feature, which is valuable to us because of our unstable electricity supply and a lot of small voltage dips causing our facilities to trip out. With this feature we can keep the plant online without any issues, therefore saving millions,” explains Johan Engelbrecht, AEL Nitrates MV Electrical Engineer.

Other case studies related to pumps

  • if (isSmallPicture) { } else if (isBigColumns) { } else { }
    VACON® 1000 MV drives power deep pumping at Los Gatos mine

    MEXICO: Faced with the challenge of pumping stagnant water from depths of more than 400 meters, the Cerro Los Gatos mine opted for medium-voltage variable speed pump control using the VACON® 1000 drive from Danfoss. Drives were delivered and installed in the record time of 14 weeks from factory acceptance test.

  • if (isSmallPicture) { } else if (isBigColumns) { } else { }
    Danfoss efficiencies help South African farmer to free up energy and achieve production goals

    SOUTH AFRICA: In recent years, South African energy security has been constrained and while macroeconomic steps are in progress to correct this, the continuing unreliability of the country’s electricity supply, together with escalating costs, can affect farming in several ways. This includes operations planning, spoiling of produce, and erratic irrigation schedules. The Development Bank of Southern Africa recognizes South Africa as being a water-scarce country, so energy efficiency in assisting with irrigation is critically important.

  • if (isSmallPicture) { VLT® Midi Drive for precise actuator control } else if (isBigColumns) { VLT® Midi Drive for precise actuator control } else { VLT® Midi Drive for precise actuator control }
    VLT® Midi Drive for precise actuator control

    With its compact and temperature-resistant design, the drive integrates easily into actuators from Schiebel Antriebstechnik GmbH, providing high-precision flow control.

  • if (isSmallPicture) { Italcementi enjoys optimized process performance in all conditions } else if (isBigColumns) { Italcementi enjoys optimized process performance in all conditions } else { Italcementi enjoys optimized process performance in all conditions }
    Italcementi enjoys optimized process performance in all conditions

    Italcementi chose the VLT® AutomationDrive FC 302 to ensure optimized process performance in their harsh environments.

  • if (isSmallPicture) { 80 kW power savings at Kolomela mine } else if (isBigColumns) { 80 kW power savings at Kolomela mine } else { 80 kW power savings at Kolomela mine }
    80 kW power savings at Kolomela mine

    Back-channel cooling in VLT® AutomationDrives reduces substation heat load enabling use of a smaller air-conditioning system with lower power consumption. 

  • if (isSmallPicture) { 30% energy reduction for Yamana Gold } else if (isBigColumns) { 30% energy reduction for Yamana Gold } else { 30% energy reduction for Yamana Gold }
    30% energy reduction for Yamana Gold

    VACON® AC drives improve the operation of underground ventilation and pumping systems and cut energy consumption of many application processes.