Energy savings Dust Collectors
Energy savings on Dust Collectors with Mac Pulse Valves
The world keeps increasing the demand for energy and governments are doing everything to decrease this. This should help to make the world more sustainable and also helps to save on energy costs. MAC Valves has designed Pulse Valves for Dust Collectors that help with the energy saving by reducing the need for compressed air. These energy savings will be explained after this.
Introduction to MAC Pulse Valves
Many of our customers are already aware of the benefits that the MAC Pulse Valves have as alternative to the much used diaphragm valves. When we started with these valves in 2009, there were some major advantages:
• No leaking rubber diaphragms because of the use of the rubber bonded spool design
• No unexpected leakages
These issues with diaphragm valves caused a lot of unscheduled maintenance because of the lost of pressure and lots of maintenance to replace diaphragms at sites that are difficult to reach.
The diaphragms have an expected lifetime of about 1 million cycles. This means that in applications where the valves shift frequently the diaphragms already tear before they have to be replaced during scheduled maintenance. By replacing the diaphragm valves with our Mac Pulse valves, which have a much longer lifetime, the following results are accomplished:
• Less unscheduled maintenance
• Longer interval between scheduled maintenance
Easy interchange on excisting Dust Collectors
When we first started with MAC Valves on Dust Collectors, we started with excisting valves from our range. The disadvantage of this was that the excisting Dust Collectors had to be adjusted to fit our valves. After the big interest from customers, a special line of MAC Valves has been designed. These are easier to install on existing Dust Collectors to replace the diaphragm valves. We have two different options:
• MAC Pulse Valve with Mac Base Plate that fits onto excisting piping
• MAC Pulse Valve with an adapterplate to fit onto the diaphragm valve body
See the picture on the right to see a MAC Pulse Valve with an adapterplate that mounts onto an excisting body of a diaphragm valves.
MAC Valves already designed many different adapter plates for the valves found in the field. To replace for instance Asco, Goyen, Mecair, Turbo and other brands.
After these valves were released many customers in both the Netherlands and in the rest of the world have changed to using the MAC Pulse Valves.
By using the valves on different sites and the many years of experience in the field, it turned out there were even more advantages in comparison with the diaphragm valves.
As you are accustumed of MAC Valves, the Pulse Valves are the fastest shifting valves available on the market. The MAC Pulse Valves have an orifice of 3/4 inch up to 2 1/2 inch (larger sizes are in develelopment), but still shift at high speed. In comparison with the diaphragm valves this will have the following major advantages:
• The flow of the valve is energizing faster, therefore the impactspeed is higher
• The Mac Pulse Valves are de-energizing faster, therefore they use less air per pulse
The comparison can be seen in the following graph:
Because of the high impactspeed of the flow, the MAC Pulse Valves have a better cleaning effect. Because it is usually normal to have still some dust on the bags, the better cleaning brings up the following possibilities:
• Adjust the pressure of the compressed air
• Change the intervaltime between two pulses
As you can imagine, these adjustment bring big advantages in the consumption of compressed air. And help with the energy savings you like to accomplish.
Air is free, compressed air definately not
Compressed air is expensive, compressed air at 8 bar cost roughly 1,5 cent per m3. This is ofcourse depending on the efficiency of the compressor. For big orifices, like the valves used on Dust Collectors (3/4 inch upto 3 inch), it means the cost can get high. Beside that the leakages are even more expensive. With leakages a lot of compressed air is lost into the atmosphere. For instance a leakage at 7 bar of 1,5 inch (38 mm) in diameter, this will cost around € 1000 a day. Therefore diaphragms that tear, outside the cost of maintenance, also cost a lot in terms of energy. An energy saving is therefore desirable.
When a Pulse Valve in a Dust Collector is able to pulse less, it means that the valve will also use less air during the day. Also the air consumption of the Mac Pulse Valve is less per pulse than a diaphragm valve. Because of that, the Dust Collector will use less air, even with the same amount of pulses.
Return on investment
Our representative could come around to show you, according to your data, how much you can safe with our solution. All your technical specification from the Dust Collector will come back and we’ll show you how much you can safe. This file also gives us the possibility to show you a ROI (return on investment) to quantify the saving.
From our experience at customers, the average ROI is within 12 months. We even have plenty of examples where the ROI is even within 6 months.
The examples from the industry are wide available and more keep coming. Our representative will gladly talk to you about this. Unfortunately, many of the companies we help are not eager to share the savings they have accomplished. This way they can keep the advantage over the competition.
Luckily there are still companies that agreed to share the information with other companies. These have been made publicly with the approval of the companies and they agreed to work with us on public videos.
Below we’ll discuss three recent examples and what their experience is with the MAC Pulse Valves.
JD Norman, UK
At JD Norman in England they have different Dust Collectors with diaphragm valves. The video below will show you a good view of how the situation was before the MAC Pulse Valves and also after the installation. The diaphragm valves were pulsing every 10 seconds with a pulse time of 1 second. With that setting the flow of the dust through the filter was only 12 km/hour. After installation of the MAC Pulse Valves, because of the more efficient pulse, they had the following result: Every valve now has a pulse every 300 seconds and also a pulse time of only 0,3 seconds, and also the flow of the dust through the filter was raised to 30 km/hour. This resulted in a better cleaning result with fewer and shorter pulses. They went from 2 million pulses per valve to about 70 thousand pulses per valve per year.
Cemex is one of the biggest groups in the world for supplying raw materials for the building industry. They have plants all around the world, for instance for producing cement. Cemex is originally a Mexican company and the headquarter is located near the Mexican distributor of MAC Valves, this distributor is Grupo Kopar. Cemax has tested the MAC Pulse Valves at different locations. Every year Cemex makes a plan for future investments, and as many companies energy savings are the main goal. Therefore after the succesful tests with the MAC Pulse Valves they made this the number one priority for the complete group. See below the video and the press release done by Cemex.
Carpet Pad manufacturing, USA
At this production facility for carpets the maintenance department had issues with the cleaning effect of the diaphragm valves for different type of carpet. The Dust Collectors were clogged and then the Dust Collector had to be cleaned by hand, which took them about 4 hours. Because of the high speed of the flow by the MAC Pulse Valves, this wasn’t an issue anymore. In the below video you can see someone from maintance that the quality of the pulses explains. In the same video you can also see a recording inside the Dust Collector where you can clearly see the difference in the pulse for a diaphragm valve and a MAC Pulse Valve.
These are just a few companies that were willing to work with MAC Valves to spread the information towards the competition. Many times they do it to help other companies that also have a hard time to find ways to reduce the use of energy.
We would like you to invite us to explain you the differences and the benefits again and more clear. We also would like to help you to set up a test, because we would like to prove to you how much success you can achieve.