MITSUBISHI ELECTRIC Changes for the Better
Germany

Reduce energy costs for exhaust air appliances in metal recycling by half? Quite simply!

Frequency inverters for motors in the exhaust air treatment of metal recycling pay off. Energy savings of more than 50 % can be achieved here. This is because the energy consumption of applications such as pumps and fans depends heavily on the speed of the motor. If this is reduced by 20%, for example, energy costs can be halved. And this is also necessary due to high electricity prices and stricter environmental guidelines such as the Energy Efficiency Act (EnEfG) or the Technical Instructions on Air Quality Control (TA Luft).

The energy consumption of pumps and fans depends heavily on the motor speed
Energy Efficiency Act stipulates more efficient systems and fewer emissions
Reduce energy costs in exhaust air treatment by more than 50 % with frequency inverters

A calculation example: A fan is operated with a motor output of 110 kW. The assumed electricity cost is €0.1665 per kWh, with 250 operating days and 10 hours of operation per day. For simplification, it is assumed that the fan operates at an average of 80% of its maximum drive power.

With regulated speed, energy costs are reduced by approximately 49% compared to network operation (bypass) and around 41% compared to operation with a throttle. According to the calculation below, this results in an annual electricity cost savings of € 22.344 and € 16.392 respectively.

Working cycleWorking cycleEnergy costs / yearEnergy costs / yearEnergy costs / yearStandard values (typical) when operating a pump
Pump / Fan performance (%)Operating time (hours/day)Direct online operationWith throttleWith inverterOperating time (hours/day)
0 %0 h.0 €0 €0 €0 h.
10 %0 h.0 €0 €0 €0 h.
20 %0 h.0 €0 €0 €0,50 h.
30 %0 h.0 €0 €0 €1,20 h.
40 %0 h.0 €0 €0 €3,50 h.
50 %0 h.0 €0 €0 €5,00 h.
60 %0 h.0 €0 €0 €6,00 h.
70 %0 h.0 €0 €0 €5,00 h.
80 %10 h.45.788 €39.835 €23.443 €2,50 h.
90 %0 h.0 €0 €0 €0,30 h.
100 %0 h.0 €0 €0 €0 h.
TOTAL10 h.45.788 €39.835 €23.443 €

Improved operating performance, efficient filtration

The precise control of motor speed also improves the operating performance of the fans in exhaust air treatment. Even in low-load operation, power consumption is reduced by up to 60 percent. Precise control of the air flow ensures efficient filtration and wind separation is also optimized.

More energy efficiency thanks to catch function (windmill function)

Our frequency inverters have a catch function (windmill function) for both ventilation and sucktion. If, for example, a fan that is switched off is rotating. The inverter reads the speed of the motor before activating it. It then switches to the drive at the same speed to prevent an abrupt start, which would consume a lot of power and possibly cause a failure.

Frequency inverters for exhaust air treatment: the FR-F800 series

Maximum energy efficiency, fast speed control, simple commissioning and maximum flexibility - Mitsubishi Electric has developed a new generation of drive technology: the FR F800 series. It is specially optimized for motors in pumps, fans and compressors and has many innovative functions. For the best possible combination of efficiency and precise control.

High performance thanks to advanced PID controller

At the heart of the FR F800 series is an advanced PID controller that can be used to control fans, pumps and compressors without an external controller. The frequency inverters also have special functions that further increase efficiency: the specially developed AOEC (Advanced Optimum Excitation Control) optimization algorithm, for example, enables maximum energy savings even for loads that require a high torque to accelerate or decelerate.

Intelligent energy optimization in standby mode

Similar to the start and stop function in motor vehicles, the FR F800 series drives can switch all unused circuits to standby mode to reduce energy consumption so that only 24 V control voltage needs to be applied to maintain control. A restart takes place within one second, so there is no impact on system availability. The energy savings can be read online or directly on the display of the device.

The FR-F800-E has a 100 Mbit Ethernet TCP/IP Basic connection as standard. It also offers extended options for remote monitoring and parameterization as well as simple integration into existing network environments.
The FR-F846-E2 frequency inverter is the IP55 standalone version of the proven FR-F800 series. Among other things, it enables the detection of mechanical faults, the auto-tuning of IM and PM motors, the cleaning of pumps and fans as well as the smooth restart at the lowest speeds.

Further applications in the recycling process

With our energy-saving and flexible drive technology for shredders and conveyor belts, you can further optimize your recycling process.

Low-voltage frequency inverter and medium-voltage frequency inverter for driving the shredder

  • Reduce load peaks
  • Reduce wear
  • Problem-free conversion

Low-voltage frequency inverter for driving conveyor belts

  • Consistent speed
  • Overload capability
  • Simple installation

I will be happy to advise you personally

Simply contact me via the contact form or directly via LinkedIn.

Thomas Droth, Business Development Manager Mitsubishi Electric

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