ONI-PowerSave, for a
plus in energy efficiency

Use of physical system connections

Cooling water circuits are usually required to have different water quantities and pressure ratios, depending on the system situation. In order to ensure a demand-oriented and energetically adapted supply, regulated supply pumps are therefore often used. For the recooling of these cooling water circuits, which supply machines and systems, glycol-free, self-draining free coolers are often used. The particular advantage of this system technology lies in its high efficiency combined with very low energy consumption. However, these recooling circuits require special safety equipment in the hydraulic installation against the background of high operational safety even at low outside temperatures. In addition, minimum water volumes and pressure conditions must be observed.

In any case, this means the suitable selection of a feed pump with a defined performance spectrum that has a resulting power consumption at the operating point. The newly developed ONI-PowerSave technology makes it possible to reduce the power consumption for the system circuit pump in the recooling circuit by approx. 30 % using physical system connections and a special hydraulic circuit.

Optimization of existing components

In concrete terms, the energy-saving circuit consists of additionally installed, hydraulically active components and speed control for the free cooler circuit pump used. After activation of the energy-saving circuit, the pump output is readjusted and in a few seconds the water volume flow returns to the originally set value. All safety-related functions in the system hydraulics remain unaffected. If one considers that the recooling circuit is required over the entire year in accordance with the operating times of the company, this also results in correspondingly high savings rates in relation to the annual electricity consumption.

If, for example, a pump with a power requirement of 10.5 kW is used as a basis, this is reduced by approx. 3 kW to 7.5 kW after activation of the energy-saving circuit. Taking into account an operating time of 6,000 hours, this results in electricity savings of approx. 18,000 kWh and an amortisation period which is usually less than two years! A much higher saving and a shorter amortisation time is achieved if times are run in partial load operation over the course of the year. Since plastics processing companies in particular have to live with a high energy input and are therefore interested in improving efficiency also in connection with energy management according to ISO 50001 or EN 16247, this technology is a sensible and economical supplement in terms of energy optimisation.