Application Case Study - Supply Air Fan for Formaldehyde Plant | Amtech Electronis

Are you fed up with frequent plant tripping due to power fluctuations in air supply fan? Try our highly reliable Axpert VFD system.

In the industrial process, methanol vapor together with a large excess of air is passed over the catalyst in a tubular reactor at 350-450 °C. The heat of reaction is removed by a liquid which surrounds the tubes. After cooling to 100 °C, the gases from the reaction are scrubbed with H2O in a bubble column.

By adjusting the amount of water, the concentration of the formaldehyde solution can be varied between 37 and 50 wt%.

The methanol conversion is roughly 95-99% and the formaldehyde selectivity reaches 91-94%. The formaldehyde formation occurs practically as a pure methanol oxidation. A mixture of 18-19 wt% Fe2O3 and 81-82 wt% MoO3 is employed as catalyst. Under carefully controlled conditions, it is overfed into the catalystically active iron(Ⅲ)-molybdate. Excess MoO3 is frequently added in order to make up for losses resulting from formation of molybdenum blue. This compound goes to the cooler end of the catalyst bed where it lowers both the catalystic activity and selectivity. Cr and Co oxide can be used as promoters.

Previous system:

• The plant is old and used old generation VFD.

Limitation of previous system:

• There were stoppages of the plant due to frequent power fluctuations resulting in heavy energy & production losses.
• The system required frequent maintenance.

Challenges:

• To reduce the maintenance cost due to frequent power fluctuations.
• To get the desired production which was affected due to power fluctuations.

Solutions:

• Axpert-Eazy Series 4Q, 690 V VFD is used to control the speed as per the air flow requirement resulting in saving of maintenance & energy cost.
• VFD is designed in such a way that it can continue the operation during power fluctuations up to 70% power dip for 200 msec.

Benefits:

• There is a production gain of approximately 2 % & energy saving of 2 % (10 % Saving compared to old plant) after installing new VFD.
• Maintenance requirement is now very less.
• Enhanced life of the equipment due to easy & smooth operation
• Adequate protection of the motor.

AMTECH POWER PRODUCT OVERVIEW

Retrofitting of Jeumont AVR with DECS 100

In one of our enquiries for our BPCL, Haldia customer, their present system was Jeumont make AVR controller Mounting Plate for DG set with Engine of Green Power (MWM) make and Alternator of Anglo Belgian Corporation make. The problem observed was that one of the Jeumont AVR controller failed to build the generator voltage, so there was need to replace the existing system.

According to the Excitation Current and Excitation Voltage at the site, we provided DECS 100 (1A+1M) Mounting Plate. The payback period for the system is pproximately 6 Months. Failure of excitation system directly result in loss of generation. The new system has advance features for fault diagnosis and rectification which makes it

easy and fast for restoration. Hence generation loss can be saved.

Lot of challenges were faced in the implementation of the new system. Here,?

1. Thorough understanding of input-output configuration is necessary for upgrading to DECS 100 from Jeumont AVR system, as in old system many complex wiring of all system and compare with customer side relay panel for different commands.
2. All function wires were from relay panel and synchronizing panel in old system, so with new DECS 100 Mounting plate, all wires had to be checked for the input, output and logic wires.
3. Lot of reverse engineering work required. More wire had to be tracked for new system like power and control logic wiring.
4. At the time of both DG synchronized condition set the droop setting value as per site requirement and testing trail for more time.
5. BESTCOM software knowledge is necessary as DECS 100 is programmable.

Advantages of new system:

1. Microprocessor-based design provides high functionality and performance.
2. Powerful 7-amp, PWM power stage provides high field forcing for increased system response.
3. THD-tolerant design offers reliable operation with nonlinear loads.
4. Integrated generator and exciter protection ensure proper system operation.
5. Rugged, potted design for exceptional reliability in the harshest environments.

PRODUCT OVERVIEW: Axpert-i-Sine Multi-Functional AHF

Amtech Electronics is a leader in design and manufacturing of Power Electronics product like Variable Frequency Drive, Regenerative Drive, Soft Starter, Active Harmonic Filter, Static VAR compensator, Heater controller and customized power supplies. We at Amtech, feel proud to support “Aatmanirbhar Bharat” campaign as all our products are designed, developed and manufactured in our state-of-the-art facility at Gandhinagar, Gujarat. We are continuously investing in R&D to remain ahead in technology to have an edge over competitors in the business we are. In this article, we will have a overview of our flagship product Axpert-i-Sine Series Active Harmonic Filter in Power Quality Business segment.?

To find out more on the harmonic spectrum of different loads, visit https://www.activeharmonics.com/download/Harmonics-Spectrum-for-non-linear-loads.PDF

Amtech offers range of products, solutions and services for power quality improvement, energy conservation, enhanced operational efficiency and reliability improvement.

Axpert-i-Sine Series AHF is Multi-Functional Active Harmonic Filter, designed with intelligent control algorithm dynamically changes the switching frequency to optimize the performance and efficiency. The performance is less affected by supply voltage harmonic distortion. It provides selective harmonic attenuation up to 51st order.

Amtech offers AHF in 2-level as well as 3-level technology. The AHF is available in both 3- Phase, 3-Wire as well as 3-Phase, 4-Wire configuration. Whenever there are single phase non-linear loads like computers, there is an accumulation of triplen harmonic current in neutral. Our 3-Phase, 4-Wire Active Harmonic Filters are the best choice for such applications.

Our AHF is equipped with a user-friendly control panel, which has self-explanatory full parameter names, easy navigation of parameters and functional keys. It also simultaneously displays 8-selectable parameters on single screen.

The AHF is available in different ratings from 30…600 A. Above 600 A requirement, multiple units will be connected in parallel. Up to 40 units can be connected in parallel.

Some of the unique features are,

• Control method Digital Fast Fourier Transform with Proportional Resonant controller
• Harmonic order selection - Global / Selective compensation from 3rd to 51st order with settable amplitude
• Harmonic attenuation ratio up to 97 % at rated current
• Automatic power factor improvement / Load balancing between line-to-line up to the unutilized capacity of filter
• Priority selection for compensation between Harmonic rejection, power factor improvement and load balancing
• 39 uSec reaction time
• Less than one power cycle transient response time
• Efficiency better than 97.5 %
• AHF can start automatically at power ON condition in local and serial mode.
• Adjustable auto restart up to ten times for fault like overcurrent fault, timed overcurrent fault, adjustable overcurrent fault, DC bus overvoltage fault, DC bus undervoltage fault, earth fault, temperature fault, external fault with individual enable or disable.
• Metering - THDv, Line Frequency, DC bus voltage, PF, DPF, kW, kVA, kVAR, kWH, MWH, VL-L, Filter current / Load current / Source current for each phase, THD of Load and Source

current / Source current for each phase, THD of Load and Source We offer complete solution for the harmonic problems. Today, we have so many success stories to share with you as our products are performing up to the mark in the field.

For more information, contact

[email protected] or [email protected]

"Amtech - Your Trusted Partner for Technology and Service"

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