Aus der Praxis für die Praxis 1 Increase of the energy efficiency of industrial plants Forced by increasing competitions manufacturing companies have to reduce their production costs permanently. According to ISO 50001 they are looking for energy savings projects. During the last 7 years there was an increase of electricity prices of about 50 %! Simply about 18 % during the last 2 years! And forecasts will show also rising prices in future (Figure 1). 50 Tribologie + Schmierungstechnik 63. Jahrgang 4/ 2016 * Christoph Baumann Hermann Mogler Mineralölgroßhandlung GmbH 74078 Heilbronn Hydraulic Oil - Increase Of The Energy Efficiency Of Industrial Plants C. Baumann* Figure 1: Overview of the electricity prices [1] Source: Statistisches Bundesamt, Wiesbaden www.destatis.de Durch die Verwendung von Hochleistungshydraulikölen können Einsparungen erzielt werden. Diese resultieren aus einer besseren Energieeffizienz sowie einer Steigerung der Produktivität. Weitere Vorteile sind die längere Lebensdauer des Öls und ein besserer Schutz der Komponenten. Bei der Auswahl des richtigen Öls ist es wichtig, speziell entwickelte Hydrauliköle entsprechend der Anwendung zu wählen. Unser Feldversuch hat gezeigt, dass die PAO basierende Formulierung nur ein Aspekt der Zusammensetzung ist. Das Auswahlkriterium muss die Leistungsperformance des Hydrauliköls sein. In einem Feldversuch in einer Blechbiegemaschine haben wir neben einer Energieeinsparung von 6,4 % eine Steigerung der Produktivität von 3 %, nachgewiesen. Schlüsselwörter Hydrauliköl PAO-Basis, Energieeffizienz, Produktivitätssteigerung, Feldversuch, Anlagenschutz, Ölstandzeit In summary it can be said that the usage of high performance hydraulic oil can achieve savings. The customer’s most serious arguments are energy efficiency and increased productivity. Additional benefits are the longer oil life and the better protection of the components. During the selection of the right oil, it is important to choose special designed hydraulic oil according to the application. Our field trial has shown that the PAO based formulation is only one aspect of the composition. But most important is the comprehensive performance of the lubricant. It should be the first choice for customers, due to the additional benefits. Such as system protection, longer oil drain intervals and the increase of the productivity. In the meantime the PAO based hydraulic oils have become a design element to the engineers. Smaller storage tanks in conjunction with longer oil drain intervals and higher pressure show them the need of such oils and the advantage that PAOs can handle higher oil temperatures. Keywords PAO based hydraulic oil, energy efficiency, increased productivity, Field trial, system protection, oil drain intervals Kurzfassung Abstract € / kWh T+S_4_16 02.06.16 12: 27 Seite 50 Aus der Praxis für die Praxis 2 Our Project - Energy saving by another hydraulic oil 2.1 The aim of the energy efficiency by selecting another hydraulic oil We had the aim to demonstrate the increase of the energy efficiency of industrial plants by selecting another hydraulic oil. To save energy with a synthetic based hydraulic oil. ► Better fluid performance ► Better viscosity index ► Less weight (see Figure 2, 3, 4) ► Better fluid performance Conventional hydraulic oils are a mixture of naphthenicand paraffinic-base-oils. PAO based hydraulic oils are characterized by a clean, wax-free structure. This molecular structure in connection with a special additive technology reduces the internal friction of these fluids. ► Better viscosity index In the past, multigrade hydraulic oils were sold as energy saving oils. This effect was achieved by increasing the VI, in conjunction with a reduction of the viscosity. Due to the used VI-Improver, this effect cannot be achieved over the entire oil life (shear stability). And VI-Improvers can reduce the air release of the hydraulic oil. ► Less weight The direct comparison shows about 50 gram per litre less weight of the PAO based Hydraulic oil (PAO density: about 830 kg/ m 3 ⇔ conventional oil 880 kg/ m 3 ). In the first instance, this is not much. But according to the machine pump capacity you have to pump much less weight of the oil! For example a bending machine has an all over pump capacity of round about 100 litres per minute (high pressure 22 litres per minute, low pressure 36 litres per minute and cooling circuit 47 litres per minute). An injection moulding machine has about 270 litres per minute. So you can see the following reductions of the weight you have to pump (Figure 5). Tribologie + Schmierungstechnik 63. Jahrgang 4/ 2016 51 Figure 3: oil samples Figure 2: Overview of a hydraulic system [2] Source: SHELL www.shell.de Mineral based HLP PAO based HLP Figure 4: VT-Diagram Shell Tellus S2 M 46 and Shell Tellus S4 ME 46 T+S_4_16 02.06.16 12: 27 Seite 51 Aus der Praxis für die Praxis 2.2 Our field trial to demonstrate the energy efficiency by selecting another hydraulic oil The first step in our field trial was to organize a data logger. Here we used the Kyoritsu KEW 6305 (Figure 6). The power consumption is measured at industrial plants permanently. The evaluation of the measurement can be done with the corresponding program KEW Windows (Figure 7). 52 Tribologie + Schmierungstechnik 63. Jahrgang 4/ 2016 Figure: 5 Pump capacities - less weight during work Figure 7: Kyoritsu KEW Windows program Figure 6: Kyoritsu KEW 6305 Data Logger There are also existing test to demonstrate the benefit of Oils: ► Single Tests / Simulation Tests Air release, filterability, TOST, … A single test only cannot evaluate the performance of hydraulic oil. ► OEM Tests / Test series Demonstrate the performance of the oil in an experimental environment. ► EUROMAP 60 Demonstrate the performance of the oil in an experimental environment. But the general conditions are nearly to the production conditions. - Consumption comparison of injection moulding machines regardless of the type of drive systems - Determination of energy consumption decoupled from tools and processes - The creation of opportunities to represent the energy consumption value of injection moulding machine as brochure worth. ► Field trials The best trial to show the performance of the products! Our experience shows that we have to prove the savings in the customers system by field trials. T+S_4_16 02.06.16 12: 27 Seite 52 Aus der Praxis für die Praxis It is very important that the connection of the data logger is not interrupted during the complete test. The interruption could cause false results! The next step is to find a customer where you can do the test. That sounds easy but you have to solve several problems: ► Automatized production ► Same conditions during the complete test ► Identical work pieces ► Logging of the production and manufacturing defects Then you have to persuade the customer to get the machine. The very good connection from the distributor’s sales manager to the customer supports this. Tribologie + Schmierungstechnik 63. Jahrgang 4/ 2016 53 Figure 9: Result of the field trial Figure 10: Extract of the result of the field trial Figure 8: Work piece of the automatized bending process You can argument as follows: ► The selection of Hydraulic oil is generally based on DIN 51524 or ISO 11158. Both represent a minimum requirement of industrial standards. ► You have to explain the benefits of the high performance Shell Tellus S4 ME 46. In this case, we used the technical data sheet with the several approvals. 2.3 First test run - not automatized bending machine The first results we could get in a not automatized bending machine! So we did the measurement only by a collection of the data of the stood consumption. According to the not automatized process it was not possible to compare production data’s. In this process we demonstrated a reduction of the power consumption of 1,25 % (conventional hydraulic oil ISO VG 46: 2.569 W ⇔ Shell Tellus S4 ME 46: 2.537 W) The customer’s subjective opinion had been a quieter running of the machine! We explain this quieter running with the extremely good air release of the Tellus S4 ME. By this result we got the permission to test again in an automatized machine. 2.4 Second test run - automatized bending machine The second test run we had in an automatized bending machine. The customer produces boxes (steel sheet: 1DC01) (Figure 8): An important factor to the test run is the flawless production. In this system we had a perfect process of 50 boxes. The work process starts when a robot takes the sheet to the bending machine. The robot holds and moves the sheet during the bending process. And finally places the finished box on a pallet. T+S_4_16 02.06.16 12: 27 Seite 53 Aus der Praxis für die Praxis Our first steps of the field trial were as follows: 1. Measurement with the OEM’s hydraulic oil 2. Change of the oil and no change of the filters! By using the old filters, we had the same conditions in the test machine during both trials. 3. Measurement with the Shell Tellus S4 ME 46 PAO based hydraulic oil. (see Figure 9, 10) The results: We demonstrated an energy saving of 1,51 % and an increase of the productivity of 1,91 %! Due to the change of the oil this customer confirmed an annual saving of 4.072 EUR. 3 Evaluation of the results 3.1 Energy savings According to the loss of weight and the better fluid performance of the Shell Tellus S4 ME 46 we felt sure to demonstrate this energy savings. By the evaluation of this result, we recognized that the customers benefit in EUR is only small in this machine. Because the electricity demands for this working process is very low. 3.2 Increase of productivity At the beginning of our field trial we had not observed this benefit. But for the customer this is the more economical item. This can help to optimize working processes. 3.3 Results According to several information’s we wanted to demonstrate a better result. ► Shell product information (117320): - Energy savings: up to 6,4 % - Productivity increase: up to 3 % [3] Source: SHELL www.shell.de So we asked the OEM of the bending machine and got the information that they use a full synthetic PAO based UTTO with a VI > 160. According to the IR of an Oel- Check analysis it seems to be the OEM’s UTTO. One significant deviation has been tested: the used oil’s VI is only 150. r Related to this application we have demonstrated a better performance with SHELL Tellus S4 ME 46 against the OEM’s PAO based UTTO! The most important factor for the selection of the right oil is the comprehensive performance of the lubricant. The Shell Tellus S4 ME 46 is developed for industrial hydraulic applications. References [1] Source: Statistisches Bundesamt, Wiesbaden www.destatis.de Daten zur Energiepreisentwicklung - Lange Reihen von Januar 2000 bis Oktober 2014 [2] Source: SHELL www.shell.de Shell Tellus S4 ME [3] Source: SHELL www.shell.de product information Shell Tellus S4 ME (117320) 54 Tribologie + Schmierungstechnik 63. Jahrgang 4/ 2016 Anzeige Nutzen Sie auch unseren Internet-Novitäten-Service: www.expertverlag.de mit unserem kompletten Verlagsprogramm, über 800 lieferbare Titel aus Wirtschaft und Technik T+S_4_16 02.06.16 12: 27 Seite 54