Energy efficient Vacuum Systems for Furnace Industry and Metallurgy

Innovation in vacuum technology today is characterized by increases of efficiency and cost
reductions in energy demand. Specially designed vacuum systems offer substantial customer
benefits. Oerlikon Leybold Vacuum informs about these advantages on occasion of the
Thermprozess / METEC exhibition at Düsseldorf.

(firmenpresse) - The highest priority for vacuum pumps and systems certainly is the reliable delivery of the
required vacuum levels. The trouble-free operation of the vacuum system is a must. The
growing pressure to save energy is not allowed to restrict the productivity of the plant. Still,
vacuum pumps and systems must be designed following the “state of the art” regulations.

Fighting against global warming and increasing greenhouse gas concentrations, the
regimentation of CO2 emission are the justification for the European Commission to set up
the European Directive 2005/32/EC. This and several amending directives describe a
framework of eco-design requirements for energy using products asking for increased
efficiencies. New standards and norms have been written and others have been updated
which now need to be considered in new product engineering projects. Furthermore,
energy costs are rising constantly and will continue to rise in the future.

Considering these aspects the design of modern furnaces has changed recently. New
designed vacuum furnaces are operating much more efficient than older furnaces. Also
modern steel degassing plants use more and more mechanical vacuum systems instead of
energy-wasting steam ejector systems. Also here, modern vacuum pumps and pump
systems, designed to support these energy saving attempts, have proven their capabilities.

High reliability can be reached by using traditional technologies as e.g. oil-sealed rotary
piston or rotary-vane pumps, roots blowers and diffusion pumps, but also also more
modern technologies such as dry screw pumps already have a proven track record to work
most reliable even under harshest conditions. Today’s standard dry pumps are screw
pumps with variable pitch rotor design. Continues compression along the rotor length
minimizes the energy demand. Older technologies with constant screw pitch or even dry

pumps based on multiple stages of roots- or claw type rotors, have significantly higher
power consumption due to design and pumping principle. But even the plurality of today’s
screw-pumps with variable pitch differs a lot from each other. Most pumps of the 600 m3/h
class demand app. 10 kW power at typical furnace operation pressures below 1 mbar,
which is a clearly higher value as those of a comparable rotary-vane pump.

The DRYVAC pump series of Oerlikon Leybold Vacuum are optimized with regard to the
mechanical rotor design, the electrical motor concept and by selection of a perfectly
matched build-in frequency converter.The achieved result in energy saving is substantial,
as the pump only consumes 6.9 kW at 1 mbar, is even more energy efficient than a rotary-
vane pump and therefore is the new bench mark for power consumption in the market. The
build-in frequency converter also offers potential for additional savings and higher process
control. Many process steps do not require “full-power” suction speed, especially during
operation at rougher pressures, e.g. during carburizing.

Soft start and ramping functionality can be realized with the variable frequency drive.
Chamber pressure can be controlled by varying the rotational speed. The customer can
even realize a process specific “standby condition” considering certain valve positions to
save for example the volume of supplied Nitrogen. Next to these environmental issues, the
modern design of the DRYVAC eliminates sensitive components as shaft- seals or
couplings which clearly increase robustness and reliability of the pump.

Modern designed pumps improve the energy consumption, but several measures can also
improve the situation with traditional pumps. Oil-sealed pumps and roots-pumps need to be
equipped with newest standard IE2-motors and can be operated with frequency converters
to deliver just as much suction speed as required. Oil-diffusion pumps can be equipped
with innovative control-systems which can identify the actual power demand and regulate
the power supply of the heaters accordingly. These measures diminish the power
consumption of a diffusion pump by more than 30 per cent.

Today, all modern vacuum technology options should be considered for choosing the right
vacuum solution. Modern system solutions are robust, highly reliable, environmental
friendly and cost efficient.

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Unternehmensinformation / Kurzprofil:
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Bereitgestellt von Benutzer: PRSchulz
Datum: 24.06.2011 - 17:46 Uhr
Sprache: Deutsch
News-ID 430189
Anzahl Zeichen: 5044

Kontakt-Informationen:
Ansprechpartner: Oliver Schulz
Stadt:

Hürth

Kategorie:

Chemikalien

Meldungsart: Unternehmensinformation
Versandart: Veröffentlichung
Freigabedatum: 24.06.11

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