Two steps to unlock the energy saving potential in your process plant

两步轻松释放食品饮料工厂节能潜力

The push for ever greater productivity combined with sustainability means that plant operators in the food and beverage industry need to reduce their electricity bills and their carbon footprint. Brith Isaksson, ABB Motion’s Global Segment Manager Food and Beverage, outlines a two-step process to unlocking the energy saving potential in a process plant. First, operators need to identify their major energy users. Then they can make fully-informed decisions to upgrade to high-efficiency solutions, including drives and motors, in the areas where they will make the greatest difference.

食品饮料行业的工厂需要在追求高生产力的同时兼顾可持续发展，这意味着企业要不断削减能耗并降低碳足迹。为此，ABB运动控制全球食品饮料行业经理Brith Isaksson提出了两步法来释放工厂的节能潜力。第一步，锁定主要耗能对象。第二步，根据相关数据制定科学的决策，在变频器和电机发挥重要作用的领域，升级高效解决方案。

The energy saving journey begins by identifying exactly what the main energy users are in a plant. This is where adopting the new generation of wireless smart sensors for motors and pumps can make a significant contribution. Because in addition to cost-effective plant-wide condition monitoring, smart sensors can worktogether with the energy monitoring capabilities of variable speed drives (VSDs) to collect a wealth of data to help analyse energy use.

节能之路应从准确锁定工厂中的耗能大户起步。这也是新一代无线智能传感器在电机和泵中大展拳脚的地方。除了实现高性价比的工厂级状态监测外，智能传感器还可结合变频器的能源监测功能来收集海量数据以分析能源使用情况。

There is also a growing portfolio of other energy optimization services that plant operatorscan employ to identify the energy saving potential in pump, fan and compressor applications. With actionable data, operators are then in the best position to optimize their processes to improve energy efficiency. 

此外，工厂还可借助其他丰富多样的能源优化服务来发掘泵、风机和压缩机的节能潜力。获得设备数据后，运营商即可轻松优化生产过程，提高能效。

The specific equipment using the most energy will vary from process to process. Typically, the high energy users are motors running pumps and fans, and especially compressors in refrigeration processes. As a general rule of thumb, focusing on pumping and cooling can optimize energy consumption and lower costs by up to 60 percent.

耗能最多的特定设备因工艺而异。通常，用来驱动泵、风机、尤其是制冷压缩机的电机是耗能大户。因此，根据经验法则，关注泵和制冷设备可以优化能耗并降低将近60%的成本。

Tackling the high energy users

解决耗能大户

Once an operator has an understanding of where they need to improve their energy efficiency, they can look at upgrading their equipment. In general, we find that most energy is wasted byinefficiently controlled and oversized motors in pumps, fans and compressors. In these applications motors are often oversized to cope with a maximum demand that rarely or never occurs. Also, when inefficient control methods such as dampers, vanes or valves are used, the motor runs at full speed and the flow is mechanically restricted.

一旦找准低能效的症结所在，运营商就可着手升级设备。通常，大多数能源被泵、风机和压缩机中低效控制和功率过大的电机所浪费。在这些应用中，电机往往选型过大，以应对很少或永远不会发生的峰值需求。同时，当使用风门、叶片或阀门等低效控制方法时，电机全速运行，而流量却受到机械限制。

A common example of inefficiency is when the flow of liquid through a pipeline is reduced by a valve. This is wasteful, because the pump motor keeps running at its nominal speed regardless of the demand.  Equally, motors operating refrigeration systems in a food plant often run 24/7 even though the load can vary significantly during the day.

一个常见的低效示例是通过阀门降低管道的液体流量。这会造成巨大的浪费，因为无论需求如何，泵电机都保持额定转速运行。同样，在食品厂中，尽管负载在白天可能会有比较大的变化，但是驱动制冷系统的电机始终全天候运行。

The key to saving energy is to use a VSD to give precise speed control. So that rather than running at full speed when it doesn’t need to, the motor is controlled to match the actual process demand.This is crucialbecause the speed of an electric motor is strongly tied to the power it consumes. Just a modest speed reduction yields significant energy savings. For example, a pump or a fan running at half speed consumes only one-eighth of the power compared to one running at full speed. That means that installing VSDs will usually show a fast return on investment through reduced energy bills.

节能的秘诀是使用变频器来精确控制电机转速。在无需全速运行时，通过变频器对电机进行调速控制，使电机的转速与实际生产需求相匹配。这一点至关重要，因为电机的转速与功耗息息相关。仅需适当降速即可节省大量能源。例如，半速运行时泵或风机仅消耗全速运行时1/8的功率。因此，安装使用变频器通常可显著降低能源开支，帮助客户快速获得投资回报。

Teaming drives with high efficiency motors

变频器与高效电机的“紧密配合”

To achieve the optimum energy savings, VSDs should be paired with the new generation of high-efficiency motors. For example, an upgrade to IE5 ultra-premium synchronous reluctance motors can offer up to 50 percent lower energy losses compared to IE2 motors used widely across the food and beverage industry.

为了达到最佳的节能效果，变频器应与新一代高效电机配套使用。例如，相比于食品饮料行业中广泛使用的IE2电机，升级到IE5超高级同步磁阻电机可以将能耗降低多达50％。

The IE5 level of efficiency is made possible by a design which combines the performance advantages of permanent magnet technology with the simplicity and service-friendliness of an induction platform.Additional benefits of IE5 motors are lower bearing and winding temperatures for enhanced reliability and long life. The design also creates less motor noise for a better working environment.

IE5的效率水平是通过将永磁技术的的性能优势与感应平台的简单性和服务友好性相结合实现的，IE5电机的其他优点是降低轴承和绕组温度、提高可靠性和延长使用寿命，该设计还可以降低电机噪音，改善工作环境。

IE5 motors can be used in a wide range of demanding food and beverage applications where they offer high efficiency across the whole speed range, even at partial loads. This makes them an ideal upgrade option for standard induction motors in pumps, fans and compressors as well as in more demanding applications like extruders, conches, winches, and conveyors.

IE5电机适用于各种高要求的食品饮料应用，即使在部分负载情况下，依然能在全转速范围内保持高效率，使之成为在泵、风机和压缩机的标准感应电机以及更高要求的应用，如挤出机、混凝土机、绞车和输送机等应用的理想升级之选。

Investing in energy savings generates early payback

节能投资回报快

CombiningVSDs with high-efficiencymotors can help the food and beverage industry to lower energy costs by up to 60 percent as well as reduce carbon dioxide emissions.The initial purchase price of a drive and motor package is just a few percent of the equipment’s energy costs over its lifetime. And in many instances the return on investment can come within months. This early payback can have a significant effect on profitability as well as helping the global food and beverage industry to meet its environmental objectives.

变频器和高效电机的结合使用，既可以帮助食品饮料行业降低多达60%的能源成本，又可减少二氧化碳排放。一套变频器和电机的初期购置价格仅为设备生命周期中能源开支的一小部分。因此，大部分情况下，仅需数月即可获得投资回报。这种快速回报不仅对企业的盈利能力产生重大影响，而且有助于全球食品饮料行业实现其环保目标。

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更多信息，请访问：

https://new.abb.com/drives/segments/food-and-beverage