Enhanced reliability in harsh environments
New resources, compounds and all sorts of active ingredients are continuously being developed to meet the ever-growing demand of all industries and for various uses in everyday life. Using the best-available technologies is standard practice for chemical reactors, distillation, precipitation, drying, milling, granulation, hot melt extrusion and associated processes in heavy and harsh environments and industries.
The specifications for refrigeration and control in chemical and pharmaceutical production processes for instance, are rigid. Only approved products for certain pressure ranges and harsh environments can be used. No wonder the demand for Danfoss expertise and quality products has continued through the years, and even during a worldwide Covid pandemic. Danfoss drives has continuously ensured high levels of reliability and safety, a long service life and high performance and energy efficiency.
Efficient supply, refining and transportation of the valuable raw materials kept at accurate temperature levels always can be achieved with refrigeration solutions from Danfoss. And, when it comes to the best-available technology for AC motors, the industry recognizes the benefits of speed control using AC drives.
Danfoss offers you its widespread experience and expertise in refrigeration and in controlling the speed of AC motors in all main chemicals sectors: petrochemicals, basic inorganics, polymers, specialty, and consumer. Our range of refrigeration equipment and AC drives is designed to fulfil the demands of the chemical industry where safety has the highest priority.
Optimized processes, less downtime
Process-control improvements with speed control of motors and proven energy savings in various applications have increased the output and reliability of processes and reduced carbon emissions.
The high protection class and conformal coating of printed circuit boards in Danfoss AC drives enhance protection against environmental pollution, aggressive gasses, moisture, and dust. These drives also reduce heat loads and air conditioning requirements with their superior heat management performance. This results in increased drive lifetime, reduced maintenance, reliable operation in harsh environments, less downtime, and a low cost of ownership.
Quality chemical plants powered by quality drives
For your chemical plant to run at its absolute best, you need drives that enable peak performance. Designed with decades of industry expertise, Danfoss quality AC drives deliver best-in-class reliability and robustness. Their leading energy efficiency lowers your total cost of ownership and makes a positive contribution to reaching the world’s climate goals. Further, predictive, and condition-based monitoring are built into our drives to give you the intelligence you need to future-proof your systems. The Danfoss drives product line, is fully compatible with any motor or system, so you are free to run the optimal system for your plant.
Reliability & Robustness
Aggressive gases can damage components at a chemical plant, while cooling air contamination can cause PCB tracks and door seals to decompose. Knowing your drives are reliable and durable enough to handle the rigors of chemical production is therefore key. It is comforting to know that Danfoss drives have as a minimum, conformal coated circuit board as a standard, with the option of a reinforced conformal coating, high IP ratings, are ATEX compliant and can withstand high ambient temperatures of up to 50°C.
All Danfoss drives offer simpler and more cost-efficient solutions and can be used with 150m shielded or 300m unshielded cable starting from 1.5 kW without any additional output filters for motor connections. This saves on initial investment, makes additional space requirement obsolete, lowers total loses in the system and provides full output torque on the motor shaft by avoiding voltage drop over the filter. Fitted with predictive and condition-based monitoring capabilities embedded into the drives, ensures system uptime, extends the lifetime of your applications, and helps to future-proof your system.
Danfoss AC drives are highly energy efficient, helping increase plant ROI and reduce TCO. They have excellent back channel cooling, reducing the need for air conditioning, as well as smart tools that lower energy use and application wear. Higher power density also means you can say goodbye to oversized drives, whilst at the same time lowering your energy consumption.
AEL Intelligent Blasting cuts energy consumption by 500 kWh per hour
This 720 Mtpd nitric acid plant in South Africa saves 3.6M Rand annually on operating costs, thanks to an upgrade from direct-on-line operation to VLT® drive control of electric pumps and motors.
For many years, motors and pumps in the process cooling water (PCW) system operated direct-on-line. With the upgrade, AEL Intelligent Blasting aimed to improve efficiency and reliability by introducing AC drive motor control. They chose VLT® AQUA Drive FC 202 and VLT® HVAC Drive FC 102 drives from Danfoss, based on their ability to ensure stable operation despite unreliable mains power supply. These drives offer Automatic Energy Optimization and kinetic back-up features to support highly efficient and reliable plant operation.
The remarkable payback time of only 18 months reflects the vast improvement in process cooling water efficiency enjoyed by AEL Intelligent Blasting.
“The drives were selected based on the kinetic back-up feature, which is valuable to us because of our unstable electricity supply and a lot of small voltage dips causing our facilities to trip out. With this feature we can keep the plant online without any issues, therefore saving millions,” explains Johan Engelbrecht, AEL Nitrates MV Electrical Engineer.