Introduction to our energy saving technologies for metals plants
TMEIC introduces the following electrical energy saving technologies for metal mills:
Examples of an energy saving system for rolling mills and process lines
- Features
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- Providing optimal energy savings for complete rolling mills and process lines
- Providing an energy saving system which can be easily added to an existing mill
- Using a combination of PLC controllers and drives
- Applications
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- Energy saving using variable speed drive control
- Optimal cooling of drive motor
- Energy savings for miscellaneous power, lighting, and heaters (example: Stop while idling)
- Optimal operation using energy saving control model (example: heating furnace combustion control and mill pacing)
- Waste heat recovery
Examples of energy saving control for hot strip mills
- Furnace combustion control
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- Improved fuel consumption using furnace combustion control model
- Reduction of material heat emission using mill control model
- Improvement of power factor
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- Improving efficiency and power factor by applying GCT/IEGT main drives
- Monitoring power demand for the entire mill line
- Reduction of electric power rates by improving power factor
- Optimization of Ventilation cooling
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- Optimal control using variable speed control
- Main motor cooling fan
- Auxiliary motor cooling fan
- Electrical room ventilation cooling fan
- Applying Variable Voltage, Variable Frequency Control
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- Descaler pump
- Air compressor
- Heating furnace blower
- Conveyor system
- Energy saving operation
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- Energy saving control of miscellaneous power, lighting and air conditioning units
- Introduction of energy saving equipment
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- Applying high efficiency motors
- Applying high efficiency transformers
- Replacing DC motors with AC motors and variable speed drives
Energy saving control system for hot strip mill main motor cooling fan
- System Configuration
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In order to remove the heat generated in the main motor rotor and stator, cooling air is circulated through the unit cooler. The speed of the cooler fan motor is varied proportionally to the load of the main motor, thereby providing energy conservation.
- Typical plot of Fan Frequency and Motor Temperature
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Typical Change of Fan frequency and Motor temperature
This graph shows an example of controlling the main motor cooling fan speed so the temperature rise of the motor remains constant irrespective of the main motor load. By applying this technology, large energy savings have been realized as shown in the following table.
- Actual result
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Existing operation Energy saving operation Amount of energy saving Motor Specification [kWh/y] [kWh/y] [kWh/y] Rate Customer A 2,800,000 600,000 2,200,000 79% AC motor Customer B 9,800,000 2,000,000 7,800,000 80% DC motor 
This graph shows the power reduction by applying TMEIC's energy saving control system in a steel company.
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