- Published: Friday, 01 August 2008 08:00
As awareness of the environmental repercussions of human behavior and the cost of natural resources increases, industries are beginning to take efficiencies to the next level. Here's a look at some recent developments aimed at reducing pollution and energy consumption.
HYBRID WHEEL LOADER
Volvo Construction Equipment has unveiled the L220F Hybrid wheel loader, which reportedly offers a 10% reduction in fuel consumption. The heart of the prototype system is an Integrated Starter Generator (ISG) coupled to a battery featuring more power capacity than a traditional lead acid battery. The ISG allows the diesel engine to be turned off when stationary and instantly restarted by rapidly spinning the engine up to optimum working speed using a burst of energy from the high-power battery. The ISG reportedly can overcome a diesel engine's traditional problem of low torque at low engine speeds by automatically offering a massive torque boost, as the ISG's electric motor offers torque up to 700 Nm from a standstill. As a result, the diesel engine can remain off for long periods when it would otherwise be idling. In addition, the operator does not need to over-rev the engine in order to get sufficient torque to work. The battery is replenished automatically, with the ISG acting as a dynamo/alternator.
DUST COLLECTION CARTRIDGE
The HemiPleat cartridge design promises valuable benefits to end users of dust-collection equipment. Pleating technology is the key to the HemiPleat's performance. Synthetic beads hold the pleats of the cartridge open with wide pleat spacing not found in competitive cartridges, which are packed too tightly to maximize media use, the company says. The wider spacing of the HemiPleat design exposes more media to the gas stream and results in lower pressure drop as well as improved cartridge release characteristics during pulse cleaning.
HemiPleat offers lower pressure drop through open pleat spacing and reduces energy costs through less compressed air consumption during cleaning applications. More media is available for filtration, for improved performance and longer life. The separation beads, not the media pleats, contact the inner cage, protecting the media from frictional damage.
Global Environmental Management Initiative has redesigned its Web site. GEMI is a non-profit organization of 37 leading companies dedicated to fostering environmental, health and safety excellence, and corporate citizenship worldwide through the sharing of tools and information.
Brad Rosenwald, vice president, safety, health and environment, Vulcan Materials, explains, ìGiven the constantly changing regulatory environment and challenges facing the industry, our SHE programs must continue to improve for the company to maintain its leadership position. Membership and participation in an organization of GEMI's caliber is a cornerstone in helping our company achieve this goal of continual improvement.î
The new site provides information about GEMI and the numerous environmental and sustainability Web tools and documents the organization has developed. This includes a search wizard and a members-only section that allows for multiple-login IDs.
Several interactive tools also are provided to help businesses develop sustainability practices. GEMI's BusinessandClimate.org Web tool provides information and guidance for businesses in all stages of the strategic planning life cycle for climate change. The site is organized into four planning stages: Assess Risks, Formulate Strategy, Implement Strategy and Review.
Also, the GEMI Water Planner helps companies address the water sustainability challenges that are impacting companies around the world. It is intended to guide a user through the process of taking a corporate sustainability strategy and converting it into a site or unit strategy for water.
Global Environmental Management Initiative, (202) 296-7449, http://www.gemi.org
Cummins' heavy-duty QSX engine has a fully integrated air intake to exhaust, after-treatment system to meet U.S. EPA Tier 4 Interim and European Stage IIIB off-highway emissions regulations in January 2011. The Tier 4 QSX increases displacement to 16 liters and incorporates the XPI high-pressure common rail fuel system to enhance power output and engine response.
Low emission levels are achieved with Cummins particulate filter exhaust after-treatment, which reduces particulate matter (PM) emissions by 90%. Cooled exhaust gas recirculation reduces NOx by 45%. The Tier 4 QSX also features a Cummins crankcase filter to eliminate blowby gas emissions.
Performance-enhancing Tier 4 technology brings a significant increase in QSX power output with an unrestricted top rating of 650 hp (485 kW) compared to 600 hp (447 kW) for the current Tier 3 QSX. Ratings will extend down to 400 hp (298 kW) to cover a broad range of heavy-duty applications. Peak torque is increased by 12% to 2,150 lb-ft (2,915 N.m) with faster torque delivery available across the engine rpm range.
Cummins XPI fuel system enables multiple injection events with high fuel-injection pressure across all engine rpm speeds to enable both cleaner combustion and improved engine response. The XPI fuel system is complemented by a Cummins turbocharger with sliding-nozzle design. The nozzle continuously varies the airflow boost to precisely match engine rpm and load demands.
The Cummins particulate filter replaces the muffler in the exhaust stream and offers equivalent noise-reduction qualities. The filter is especially strengthened against shock loads and vibration to meet the most severe off-highway operating conditions. The particulate matter collects on the filter and is gradually oxidized by catalytic passive regeneration.
Cummins Inc., http://www.cummins.com
New vibrating screen technology from Metso Minerals offers several environmental benefits. The company says producers can reduce the consumption of petroleum products, electrical power and structural steel. Dust emissions also can be reduced by eliminating multiple transition points.
New vibrator technology utilizes grease lubrication, which consumes far less petroleum than traditional oil-lubricated vibrators. The MV (Modular Vibrator) only requires a few ounces of grease per month. Traditional oil lubricated vibrators require several gallons of oil. The use of synthetic lubricants requires less grease and increases the lubrication interval to 200 hours. Further decreasing petroleum waste, the screens feature an auto-grease lubrication system. The company also says that the MV has 40 to 60% higher bearing life.
The TS (Triple Slope) screen produces 20 to 30% higher capacity using less horsepower than conventional vibrating screens. The TS utilizes the MV vibrator, which is designed to lower operating costs, the company says. For example a TS3.3 (6- ◊ 20-foot) screen may do the job of an 8- ◊ 20-foot TD conventional screen, depending on application factors. The TS screen performs with a single 30-hp motor while the conventional 8- ◊ 20-foot TD screen requires two 30- or two 40-hp motors. The MV vibrator design eliminates wasted weight found in the traditional vibrator, saving electricity.
Metso Minerals, http://www.metsominerals.com
NATURAL GAS VEHICLES
Kenworth Truck Co. is expanding with liquefied natural gas (LNG) vehicles with its T800 LNG trucks under an exclusive agreement with Westport Innovations Inc., Vancouver, B.C. Kenworth will use Westport's LNG fuel system technology adapted for the Cummins ISX 15-liter engine.
The Kenworth LNG factory installation coincides with the Ports of Los Angeles and Long Beach announcement to approve a new $1.6 billion Clean Truck Superfund. The fund will be used to replace many of the 16,800 Class 8 trucks serving the ports with LNG-powered vehicles. The ports also have introduced a progressive ban that will remove all pre-2007 trucks by 2012. Westport's LNG fuel system reportedly is the only alternative fuel technology currently qualified for financial support under the ports' Clean Truck program.
The Kenworth T800 serves a variety of applications ranging from linehaul tractors with the luxurious 86-inch Studio AeroCab sleeper to severe-service off-highway dump trucks and urban pickup and delivery vehicles. The Westport engine is fueled with LNG ó a safe, cost effective, low carbon, low emissions fuel. The Westport LNG system is available with 400- and 450-hp ratings and up to 1,750 lb-ft torque for heavy-duty port, freight and vocational applications. LNG fuel tanks can be configured to suit customer range requirements. In addition, trucks are eligible for federal tax credits in the United States.
Kenworth Truck Co., http://www.kenworth.com
Westport Innovations, http://www.westport.com
GreyStone offers three models of dewatering screens ó the DS-488 (4-ft ◊ 8-ft), DS-6010 (5-ft ◊ 10-ft) and DS-7212 (6-ft ◊ 12-ft) ó to handle a variety of capacities and efficiently dewater up to 225 tph. Screens eliminate the need to air dry concrete and masonry sands. Hence, there is no water runoff, an increasing environmental concern in local communities. The GreyStone dewatering screen cuts moisture down to 10%, providing salable material in less than a day.
GreyStone's high-frequency separator allows producers to easily adjust bed depth, table tilt and vibrator variables in order to remove up to 50% of the water from material. One of the greatest benefits of this dewatering screen is its ability to adapt to each plant's unique material by combining the adjustable motor force in conjunction with the adjustable bed tilt.
The dewatering screen utilizes two vibrators that initiate a linear motion, driving particles in an uphill, downhill or horizontal direction, so water is strained down through the sand bed and below the screen deck. The urethane deck, with a º-mm aperture, allows the user to dewater a broad range of particle sizes. It can handle up to 14 inches of material depth, making use of the bottom thin layer of material as a secondary ìscreen,î allowing the deck to preserve fines smaller than 200 mesh.
GreyStone, (402) 564-9505, http://www.greystoneinc.com
Thermo Fisher Scientific has eliminated mercury from its tilt sensor. It also has incorporated probes and controls to enhance stability, sensitivity and performance. Specially developed to address environmental concerns and meet government regulations, these new units are easy to install and available with various probe assemblies.
The new Ramsey mercury-free tilt sensor is actuated when material causes the probe to tilt at an angle of 15 degrees or more from its vertical position. The internal sensor has a 360-degree design and is precisely positioned so that, regardless of the direction of tilt, its normally closed contacts will open at 15 degrees. A hanger assembly allows the probe to be placed in the optimum position for each individual process.
The standard probe uses a rugged iron housing with a nickel chrome finish, for abrasion resistance. In addition, the fully potted internal electronics provide excellent impact resistance, the company reports. Typical applications include high-level detection in bins and vessels in a variety of materials, plug detector for chutes or transfer points, level control in volumetric batching, motion control for stackers and loading spouts, crash probes for tripper cars, and starvation or no-flow detector for belt and vibratory feeders.
Thermo Fisher Scientific, http://www.thermo.com/bulk-handling
As environmental issues grow more acute, operators must account for every liter of oil consumed and transported. By extending oil life, contractors can finish jobs without transporting new lubricants in and old lubricants out, avoiding paperwork, transportation and labor. The extension of service intervals helps reduce the impact of rising fuel and lubricant costs.
Hydraulic filters offered by CTI can increase change intervals from 500 hours to 2,500 hours, the company reports. Complete hydraulic oil changes are only required at 20,000 hours after installation of an ultra-fine bypass filter. Lube oil filter extends filter service intervals from 250 hours to 1,500 hours and oil change intervals from 250 hours to 7,500 hours.
The bypass filter removes greater-than one-micron solid particulate and moisture contaminants. Through the virtual elimination of all contamination, additive depletion is delayed. The company says the CTI system removes 99% of particulates down to the one-micron level.
Cleantechnics International, (877) 855-6702, http://www.ctifilters.com