Variable Frequency Drives
Opportunities in Agriculture
Presented by
Robin Priestley
Rockwell Automation
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Market Drivers
Cost Volatility
• Reduce costs
• Maintain Competitive
Advantage
• Predictability of prices
Supply Scarcity
• Resource constraints
• Energy reliability and
availability
Government Regulations
• Compliance to current and
future regulations
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Sustainability
• Corporate initiatives
• Brand protection
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World-wide energy
consumption will
increase over
50%
BY 2035
SOURCE: LNS RESEARCH
On plant floor
50%
of the energy
consumed is by
electric
motors.
Reduce speed 20%,
save 50% energy
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More Than Just Electricity
 Water
 Mega Liters consumed, Discharged
 Gallons of Water per unit of Product Produced
 Air
 Air Flow,
 Pressure,
 kWh’s consumed
 Gas
 Gas Consumption
 Electricity
 Demand Management
 Load Profiling
 Power Factor Control
 Steam
 Mass, Energy, Net Steam,
 Heat Differential,
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WAGES (Water, Air, Gas, Electric & Steam)
 Drives can impact each of these
 AND….
 Animal heath
 Regulatory compliance
 Assist in branding
 Clearly improve OEE
 “Green” Initiatives
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Animal Health
 Air quality and temperature control
 Coordination
 Intake
 Exhaust
 Circulation
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Animal Health
 What did we learn
 YEILD
 Energy Cost
 Freezing and Icing
 Automatic Damper
Control
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9
Regulatory Compliance
I am specifically not saying there is an out of
control devil attempting to make our lives
miserable
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Regulatory Compliance
Emissions
Regenerative Thermal Oxidizer
“intelligence”
Stink bait
Aerobic Digestion
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Regulatory Compliance
 Consumption
 Water
 Aquifer management
 Maximize the effectiveness of irrigation
Pressure, flow, reduced
atomization
 Quality
IDAHO Arsenic
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Regulatory Compliance
Shear USE!
EVIL CHEMESTRY
Continuous move, chemigation
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13
Branding
Drive use promotes “family values”
 Sustainability
 Reduced energy consumption
 LEEDS Certification
 Environmentally Friendly
 ROHS complient
 Soy based lubricants
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 Reduced Carbon Footprint
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OEE Improvements derived
from hard and soft costs
Reduced
Resource consumption (water)
GPM, MGD (dopey davenport)
Energy consumption
Environmental impact
 Spills, river & aquifer levels
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OEE Improvements derived
from hard and soft costs
Reduced
 Maintenance
 Gears, Belts
 Pumps (seal water, cavitation, bearing,
filters & Wye Gate management
 Piping
 Pressure & Hammer
 Three phase vs single phase motors
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16
“Green” Initiatives
 Properly applied: Great marketing spin on financially prudent profit
opportunities
 Drives on…
 Irrigation
 Combustion
 Drip
 Mixing
 Pivot
 Conveying
 Flooded canal
 Vacuum pumps
 Fans
 Wells
 Blowers
 Total Mix Ration
 Contaminant dilution
 Continuous Flow Crop Drying
 Combustion
 Single to three phase conversion
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17
Top Energy Management Challenges
Drives can report
their
consumption!
Technology related
LNS Research Industrial Energy Management Research, 2013
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Energy Management Maturity Curve
Three Stages Most Companies Experience
Energy
Optimization
• Energy no longer just
“cost of doing business”
Energy
Efficiency
• Energy Monitoring in
place
• Energy cost allocated
across all departments
Energy
Awareness
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• Continuous Improvement
for energy is ongoing
• Energy Awareness
program in place
• Energy is viewed as Cost
of goods sold (COGS)
• Initiatives to reduce energy
usage in place
• Energy cost savings
programs - Demand
Response and Load
Shedding are in place
• Energy usage associated
with production is
understood and monitored
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19
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Variable Speed
 Takes advantage of change in
fan curve
 Affinity laws where:
N = Fan Speed
Q = Flow (CFM)
P = Pressure (Static Inches of
Water)
HP = Horsepower
Q1 N1

Q2 N 2
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P1  N1 

 
P2  N 2 
2
HP1  N1 

 
HP2  N 2 
3
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Variable Speed Curves
 Dramatic energy savings
100
100
%
Pressure
%
Power
% Flow
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100
100
% Flow
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Variable Inlet Vane
 Modify fan curve to change air
flow
100
100
%
Pressure
%
Power
% Flow
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100
% Flow
100
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Pump / System Curves
100
Pump
Curve
Total Head
in Feet
System
Curve
1000
2000
U.S. Gallons per Minute
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Variable Speed Pump
100
Speed #1
Total Head
in Feet
Speed #2
1000
2000
U.S. Gallons per Minute
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Example Savings - VFD for
Electronic Throttling
80% Flow, 1360 GPM
Valve Operation Versus Reduced Speed Operation
240
220
30
40
50
60
70
200
Total Head (FT)
180
160
75
Throttled Operating
Point
78
80
Energy Savings
140
Reduced Speed
Operating Point
1400 RPM
120
100
80
60
40
20
Pump Output =
Power
Head (Ft.) x Flow (GPM) x Specific Gravity
3960
0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
1800
Flow (GPM)
Typical 100 HP Pump Application
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Fan, Pump and Regen Energy
Calculator
http://www.ab.com/drives/energy_savings/index.html
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Time for Tools!!!!!
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Rev 5058-CO900E
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Questions?
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29
For more information:
http://discover.rockwellautomation.com/energy
Jan Pingel
Product Manager, Energy Intelligence
[email protected]
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30
PUBLIC INFORMATION
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Robin Priestley
Power Control Manager
[email protected]
563-343-8862
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Rev 5058-CO900E
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