Energy saving in flour milling

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					Digital Re-print - January | February 2012
                       Energy saving in flour milling

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     FEATURE                                                                                                                                                                                                                                                                        FEATURE

                                                                                                                                                        Pneumatic conveying (negative pressure)      controllable through extraction scales, can be
                                                                                                                                                    in a system where ground stock product is        taken under control by extraction tracing and
                                                                                                                                                    carried, while volume of air moved changes,      reporting through recording correct data.
                                                                                                                                                    static pressure varies with the square of the        In new generation mills where the
                                                                                                                                                    speed, required power with the cube of           number or the size of windows is reduced in
                                                                                                                                                    speed.                                           order to prevent contamination, the choice
                                                                                                                                                        In summary, when volume of moved air         with the lighting control and the energy
                                                                                                                                                    is reduced by 20 percent, fan speed is also      efficient armature has gained importance.
                                                                                                                                                    reduced at the same ratio, whereas power             To calculate milling capacity in the way
                                                                                                                                                                                                                                                        About the author:
                                                                                                                                                    consumption is down by 50 percent.               not to run the plant at time zones with high-
                                                                                                                                                                                                                                                        Mr Tuncay Lamci is General
                                                                                                                                                        In pneumatic systems, removing vibration     est energy cost and if demand is available, to
                                                                                                                                                                                                                                                        Manager of Integrated
                                                                                                                                                    by mechanic balance, setting product and         increase capacity, they must be carefully ana-
                                                                                                                                                                                                                                                        Machinery Systems (IMAS)
                                                                                                                                                    stock speed by a right system design and using   lysed since the latter will enable faster return

 Energy saving in flour milling
                                                                                                                                                    minimum and wide angle elbow, optimising air     of investment and if needed, be decided            More information:
                                                                                                                                                    volume to be absorbed by clacks, setting fan     immediately without delay.                         IMAS Integrated Machinery Systems
                                                                                                                                                    speed can be taken as first steps of a 10-20         It should not be forgotten that the way        2 Organize Sanayi Bologesi Lalehan,
                                                                                                                                                    percent saving in pneumatic system power.        to compete in global markets and succeed           Cad No:61, 42300, Turkey
  by Mr Tuncay Lamci, General Manager of IMAS Integrated Machinery Systems, Turkey                                                                      Conveying with blowers (positive pres-       is through establishing energy efficient, effec-
                                                                                                                                                                                                                                                        Tel: +90 332 2390141
                                                                                                                                                    sure) is an expensive conveying method           tive and lifetime systems, by considering
                                                                                                                                                    that consumes same or more power than            operating costs rather than investment costs.
                                                                                                                                                    pneumatic conveying. Amount
                                                                                                                                                    of power to be used changes
                                                                                                                                                    according to, correct design of

             e all know that milling is an       percent for mechanical conveying. For this        conveyed with the remainder due friction,        conveying line, periodic mainte-
             energy-intensive sector. Energy     reason, we will study energy savings under        loading and discharge losses.                    nance and cleaning of blowers,
             is the largest operating expense    three main titles:                                    Chain transfer systems require regular       reduction of number of blowers
item after raw material costs. When lifetime       • Methods of saving in motors                   oiling, whereas belt transfer requires regular   by connecting lines required in
costs are examined, we face amounts                • Conveying systems                             check, setting and replacement.                  the same area, dimensions and
exceeding investment expenses.                     • Automatic control and energy                      The right choice of often used V-belts       speed of air locks to be used,
                                                     management                                    according to the pulley groove, synchronised     and distances between blades.
    For example, if we assume the invest-                                                          replacement of multiple belts of the same            The most convenient meth-
ment cost of a flour mill of 200t/day capacity   Methods of saving in motors                       brand, parallelism of the pulleys, tension of    od should be chosen among
reaches five million TL (two million EUR)           Reducing the external load on motors,          the belts are important parameters for the       conveying systems.
and its life time would be 20 years on           such as reducing air volume absorbed by           energy cost.                                         For example, with a 10
average, then the annual depreciation cost       the pneumatic system or preventing leaks              Reduction of motor losses, definition        tonne per hour capacity; while
will be 250,000TL (100,000 EUR). The             from compressed air system would thereby          of size of motor being used in relation to       a mechanic system consumes
annual energy cost of such a company will        reduce motor load, which must be consid-          the duty, choice of lowest motor for full        0.8kW of power for 20m verti-
be around 500.000TL (200,000 EUR), twice         ered as the first step for the saving.            load, high efficient motor choice rather         cal conveying, this consumption,
the depreciation cost.                              The fact that efficient machines are cho-      than a standard one at replacement would         which is 4.7kW in pneumatic
    Departing from this fact, the fastest        sen according to the targeted production          therefore reduce losses and enhance saving       conveying, reaches 5.0kW in
way to reduce production costs is to have        tonnage and they are used at full capacity        opportunity.                                     blower conveying.
                                                                                                       A high efficiency motor of 90kW EFF1             In aspiration system, by
                                                                                                   type running 18 hours per day and 300 days       correct dimensioning, getting
                                                                                                   per year at a plant, would yield 2500TL          required airflow speed, prevent-
                                                                                                   (1000 EUR) of energy saving in a year with       ing loss and leaks and by using
                                                                                                   actual energy costs.                             manometer filters tracking filter
                                                                                                       Reducing the speed of motors means           cleanness and avoiding unneces-
                                                                                                   reduction in energy expenses.                    sary energy expenses is possible.
                                                                                                       For example, in pneumatic systems
                                                                                                   required air quantity for the transport of       Automatic control and
                                                                                                   stock product varies with the ambient and        energy management
                                                                                                   seasonal conditions; setting motor speed by          In the aim of avoiding a
                                                                                                   using variable speed drive would provide         general misunderstanding in the
                                                                                                   energy savings and would therefore return        milling industry, it is needed to
                                                                                                   the investment cost.                             re-emphasise on the purpose of
                                                                                                                                                    using automatic control in the
                                                                                                   Conveying systems                                system and its benefits.
focus on energy costs right after raw mate-      would reduce additional loads in motors              We will study conveying systems as four           Automation systems while
rial cost.                                       and gears resulting from the system through       types: Mechanical conveying, negative pres-      they enhance system reliability
    It would be possible to get energy saving,   bearing condition and oil check in line with      sure pneumatic conveying, positive pressure      through level measuring, flow
through having maximum capacity usage in         manufacturer’s advice.                            pneumatic conveying and dust collectors and      measuring, scale equipments
overall process by 5-10 percent, using high          The choice with motor drive arrange-          aspiration.                                      and failure warning switches
efficiency motors and total efficient main-      ment is of paramount importance.                     Examples of mechanical conveying can          and also thanks to the correct                                                 HALL 13
tenance by 2-5 percent, optimising air flow          For example, as the friction losses will be   be given as bucket elevators, screw and          start and stop timing, they avoid                                        STAND B71-C62
and avoiding leaks in conveying systems by       lesser with direct drive methods, they will       chain conveyors, in which some of the sav-       unnecessary operations and
10-20 percent.                                   work efficiently compared to chain or belt        ing opportunities are use of products with       make power saving independ-
    While the process uses 50 percent elec-      coupled systems. For bucket elevators, about      proper bearings where the friction in these      ent of operator mistakes.
tric energy for milling and grinding, 30         80 percent of the input power is directly         machines are at minimum, regular protective          The capacity, which can be
percent is used for pneumatic conveying, 11      attributable to the weight of material being      maintenance, product choice at right capacity.

                                                                                                                                                                                               AD_SEA_ipakima.indd 1                                                                  31/01/2012 08:46
22 | January - february 2012                                                                                 Grain &feed millinG technoloGy         Grain &feed millinG technoloGy                                                                                     January - february 2012 | 23

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Description: We all know that milling is an energy-intensive sector. Energy is the largest operating expense item after raw material costs. When lifetime costs are examined, we face amounts exceeding investment expenses. For example, if we assume the investment cost of a flour mill of 200 t/day capacity reaches 5 million TL (2 million EUR) and its life time would be 20 years in average, then the annual depreciation cost will be 250,000 TL (100,000 EUR). The annual energy cost of such a company will be around 500.000 TL (200,000 EUR), twice the depreciation cost.