Drives cut the cost of fan power

Large inverter drives fitted on exhaust fans at asphalt coating plants achieve payback in record time.

One of the largest building materials suppliers in the UK is benefiting from higher efficiency operation and ECA paybacks to achieve a short ROI on the fitment of large inverter drives supplied and commissioned by Wyko.

The drives are fitted on exhaust fans at six of the company's UK asphalt coating plants, calculated savings predict a payoff period of just over a year and a half for the largest of the drives, a 150kW unit.

The drives have replaced mechanical damper controls and in a system of this type deliver a 40% reduction in absorbed motor power while maintaining an equally effective airflow.

Start up and shut down processes are also smoother and speed control more precise, extending the life of the motors and ensuring process consistency.

There are three sizes of fans in use on the coating plants and each have different estimated payoff periods, ranging from 1.5 to 2.2 years.

The three sizes are 55, 110 and 150kW.

Calculations are based on an average airflow rate of 90%, with the motors on an average 75% load for 10 hours a day, 6 days a week, and 50 weeks a year.

Cost per kilowatt-hour varies, but averages out at GBP 0.04/kWh, motor power factor is 0.9.

As the original motors have been retained, motor efficiency remains at 90%.

Jim Conner, Wyko Corporate Account Manager comments: "Energy costs and environmental issues now, more than ever, are playing a major part in the operating cost of an efficient site".

The products and services designed to address these matters range from inverters and soft-starts through to energy related site surveys, aimed at identifying the most efficient use of these products and the savings to be gained.

Pumps, fans, dryer drums, mixers and crushers are all key areas for drive and control products.

There are benefits over and above energy saving aspect of the upgrade that are also being felt.

The majority of the asphalt produced is consumed in major construction and building projects such as roads and other infrastructure projects, however a growing trade is with localised contractors involved in small-scale projects who prefer to collect their material direct from company plants.

With the added frequency of order collections, plant flexibility is essential and reliability is even more important.

Demand is also growing for specialist materials that are designed for specific end uses such as sports surfaces, decorative areas, industrial and commercial parking areas, which include precise control of the coating process.

These products include innovative new lines such as cold-mix materials, coloured asphalt and low-noise road surfaces.

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