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Water Treatment System and Equipment

Water treatment project at INTEL worth millions

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An Oregon state board has approved $120 million in publicly issued bonds to help finance a $600 million water treatment project at Intel.

In Oregon, a state board has approved $120 million in publicly issued bonds to help finance a $600 million water treatment project at Intel. According to Oregon Live, the state’s business development department plans to supplement that with $30 million from its own bonding authority.

According to state officials, Intel may request even more in the future. The company said they are trying to balance support for Oregon’s largest corporate employer against growing needs for bonding authority to help finance homebuilding to address the state’s housing crisis.

The tax-exempt bonds, known as industrial development bonds, cost the state little or nothing. It’s Intel, not the state, that is responsible for repaying them.

However, Oregon has limited private bonding authority. Officials with Business Oregon, the state’s economic development department, said they limited a request while they assess a potential request for bonds to finance housing construction.

According to Oregon Live, semiconductor production is a water-intensive process, as machines clean layers of material between each step in manufacturing. Intel uses nearly 3 billion gal of water each year at its manufacturing campus. According to Hillsboro officials, the project could reduce the company’s water use by a third.

Intel representatives told Oregon private bond committee members that in addition to conserving water, the project will enable additional manufacturing capacity in Oregon.

The company said it plans to expand its Oregon manufacturing site, beginning in 2019. According to OregonLive, Intel is talking with contractors and tradespeople about building a new, multibillion-dollar factory in Hillsboro.

“To continue innovating and manufacturing in Oregon, Intel is investing in adaptable waste management systems,” Intel said in a written statement Tuesday. “The support of Business Oregon and the Oregon Private Activity Bond Committee to finance this project will help further economic development, environmental sustainability, and support the state’s small businesses through Intel’s supply chain impacts.”

In addition to the $120 million for Intel, the Private Activity Bond Committee voted to allocate nearly $115 million for housing, including $37.5 million for a first-time homebuyer program.

According to Oregon Live, the committee also approved as much as $15 million for a renewable energy program at the Port of Morrow.

I manage the editorial affairs for MONETA Tanıtım, which produces specific publishing, specially for the sphere, Turkey industry. We work for content development through digital and print media, with a new generation, dynamic publishing intellection.

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Water Treatment System and Equipment

Drive solutions for sewage plants – We keep our slate clean

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In the field of water treatment, the drive technology is decisive for the availability and efficiency of pumping and fan stations. NORD DRIVESYSTEMS offers branch-optimised solutions that are characterised by great operational reliability, long service life and high axial and radial load capacities.

Completely unobstructed operation is just as essential as high efficiency in sewage plants. For drive units which operate continuously, energy costs are a very important factor. In addition to the operation of aeration systems, it is mainly the pumps which are the significant factors for electricity consumption in sewage treatment plants. NORD DRIVESYSTEMS combines energy-efficient motor technology and almost loss-free gear unitsas well as frequency inverters with energy-saving functions for its drive solutions, ensuring top reliability and economic efficiency. Additionally, the service and maintenance friendly drive units by NORD reduce down times and thereby increase the efficiency and plant availability.

Even with the extreme environmental conditions, like moisture, dust and dirt, to which the drive units for waste water treatment and outdoor applications are often exposed to, drive technology by NORD is perfectly prepared. Double covers, IP66 brakes, increased corrosion protection through multiple coat painting, overload protection, stainless steel shafts and reinforced output shaft extensions are only a few examples for the high level of protection that is offered by NORD units.

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Water Treatment System and Equipment

Submersible geared motors solution for state-of-the-art wastewater treatment plant

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Conducting an effective and up-to-date wastewater treatment service is challenging. When a plant in the Netherlands needed to renovate its systems in one of its post-sedimentation tanks, it chose Bauer Gear Motor to provide a durable, submersible solution.

Delfluent Services BV is a consortium of specialised companies working on wastewater treatment facilities in The Hague, Netherlands. One of the plants, located in Houtrust, covers 5 hectares and, on average, can treat nearly 79,000 cubic metres of waste water a day.

The treatment process at Houtrust begins with the removal of large, solid material. Subsequently, the wastewater goes through pre-sedimentation tanks, activated sludge, biological treatment and post-sedimentation tanks.

The wastewater treatment plant was originally built in 1967 and needed to be refurbished to be in line with current environmental regulations. Included in the maintenance project was the replacement of a gear unit that was used to drive the chainwheel in one of the sedimentation tanks. The original equipment gear had always required a high degree of maintenance, demanding the tank’s basin be emptied twice a year to carry out regular services. This level of ongoing maintenance resulted in production losses and high maintenance costs. Delfluent chose to use the refurbishment as an opportunity to upgrade the system to a solution that could be easily maintained.

The original supplier had designed a solution which employed a single stage bevel gearbox fully submerged in the water. A connection tube was used to connect the gearbox to the rest of the power train, positioned above the water level. The tube connected to a pre-stage gearbox and an overload coupling, with a 0.55 kW motor driving the application.

In order to replace the existing motors and gears, Delfluent contacted Bauer Gear Motor, worldwide supplier of high quality, reliable geared motors, and part of Altra Industrial Motion Corporation.

Bauer has a proven track record of developing geared motors for challenging conditions and was particularly suited to help design a replacement to the original equipment. In particular, Bauer produces IP68-rated versions of its motors, which are fully submersible and impervious to water and dust ingress.

To provide the optimal service, Bauer conducted the replacement operations with its strategy partner Vos Gekas & Boot (VGB), expert in rotating equipment, including pumps – a supplier familiar to the wastewater treatment facility where the activity took place.

The solution provided by Bauer consisted of a drive belonging to the BK series of bevel geared motors (type BK70G20X-82W/DHEU09SA4/SP) that can operate continuously underwater. This motor series is available with power ratings between 0.03 kW-75 kW and operates at 110-690 V and 50/60 Hz.

From two one-stage gears, Bauer moved to a multi-stage geared motor. The bevel gearbox range can withstand torque of 80 Nm up to 18,500 Nm and gear ratios of 3.67-108.60 for two-stage gears or 7.29-441.3 for three-stage gears. In this way, the equipment was simplified, making future maintenance easier.

In addition, by removing the gear, the tube and the coupling, Bauer reduced the oscillations in the system and provided a more energy efficient solution.

Specific advantages of the BK series, besides IP protection against dust and water, include simple and cost-effective installation, high energy efficiency, robustness and durability, low maintenance requirements and low running costs.

This particular application runs at a set speed and so there was no need for a variable speed drive that might prove advantageous in other situations. Using a lower power-rated 0,37kW IE2 direct on line (DOL) motor offered the most energy efficient and cost-effective solution for this application.

Ferry Spaans, Project Leader, Innovation Projects at Delfluent Services BV, commented: “Our main goal at Delfluent is to develop, refurbish and manage wastewater treatment plants in The Hague. The wastewater treatment plant in Houtrust has been operating for 50 years and has been renovated three times since then. Now, thanks to Bauer, we can continue providing an optimal service, treating the waste water flow from the homes and companies in The Hague with an innovative solution.”

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Water Treatment System and Equipment

Bauer Motors deliver cost-effective and greener wastewater treatment

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The treatment of water and wastewater is an essential task to protect our water resources
and reduce our impact on the environment. However, the energy resources required to carry out
such treatment processes also have an impact on the environment; not to mention an impact on
the wallet as energy prices continue to rise.
As a result, many wastewater treatment plants are actively pursuing a campaign of
improved energy efficiency. Bauer Gear Motor optimised the energy use of a plant in
Bayreuth, Germany, reducing the environmental burden and the energy costs with an
innovative geared motor solution for the plant of the future.
Although this example relates to a sewage treatment works, the processes and equipment
involved are very similar to those used in commercial and industrial water treatment
applications. As such, the benefits in efficiency, reliability and operating costs can also be
applied here.


The municipal wastewater treatment plant in Bayreuth, Germany, wanted to optimise the
motors powering the plant in order to improve its energy efficiency and lower its energy
consumption costs.
The original system, built in 1999, was composed of multiple 1.5 kW Direct On Line
(DOL) asynchronous induction motors running at 50 Hz. The motors were supplied by Bauer
Gear Motor (Type BF50-35A/D09LA4-TF-D) and had been running without any failures since
their installation. However, as their energy efficiency couldn't reach the levels of the latest
technology, it was decided to retire the existing system and specify a hi-tech alternative.
As the original equipment supplier, Bauer Gear Motor, part of Altra Industrial Motion
Corporation, was invited to suggest a solution that would continue to operate with the same
level of reliability whilst delivering cutting-edge energy efficiency. Bauer's credentials as a
leader for innovative, energy efficient geared motor solutions made it an ideal partner for the
project.
Harald Bezold, Chief Machine Operator at the municipal wastewater treatment plant,
commented: "We were content with the original Bauer solutions, developed when the
wastewater treatment plant was first built. However, after 19 years of service, we felt that
intelligent investment could help us to improve our operations. As part of the renovation we
knew it was essential that we considered the environmental impact of our processes. Our target
is to provide the best water management service, at minimal costs, with minimal impact on our
surrounding environment.

Markus Kutny, Business Development Manager for Bauer, added: "We conducted a site
review and audit of the existing equipment. We put an inverter on one existing piece of
equipment, to measure the behaviour of this application. With this data we were able to make a
calculation for the customer, to show the benefits of the permanent magnet synchronous motor
(PMSM) technology. The theoretical values, savings and behaviour were simulated and
presented to the customer. In addition to achieving the environmental and performance targets,
we were able to create a system that adheres to the most recent Industry 4.0 standards. As such,
we added an unprecedented level of motor control to the site."
The initial request from the client was to replace the original motors with IE3 induction
motors – this is what is typically seen as the standard energy efficient solution' in the water
industry. However, as a result of Bauer’s assessment of the facilities, it became evident that the
wastewater treatment plant could further benefit from the specification of PMSMs running at
the same frequency, 50 Hz.
The benefit with PMSMs was not only the energy savings; they also have the advantage
for the customer to control all gearmotors direct from the office via "ProfiNet Bus system". A
further huge benefit proved to be, that with the intelligent inverter duty and bus system, the
service technicians can monitor the performance of the motors and immediately see on the
monitor if any application isn´t running well.
The IE3 PMSM technology consumes less energy and requires lower power ratings for
the same torque load than equivalent IE3 induction motors. When the system is running under
partial load, the asynchronous motor has a drastically reduced efficiency level compared to
PMSMs under the same conditions. More precisely, Bauer measured the required power for
this application and found that it was lower than the actual running motor power and so they
were able to reduce the motor size from the initial 1.5 kW down to 1.1 kW while maintaining
the same performance.
Furthermore, according to the customer's measurement after the applications were fitted
with the new motors, the replacement of induction motors with PMSM alternatives running at
50 Hz could save over 93.000 kW/h per year. Assuming an energy price of € 0.20 kW/h, a
reduction of 93.000 kW/h translates into over € 18,600 saved in a single year.
Another proposal was to use an inverter duty motor to reduce the line frequency without
influencing the mixing behaviour. The result was, that for starting the mixing process the
frequency of 50-60 Hz was required. After the wastewater was in motion and the sludge was
suspended in the water, the speed could be reduced to 34 Hz. This reduction of speed with the same mixing result and the same treatment quality, offered a potential saving of over 260.000
kW/h in energy consumption and € 52,000 in annual energy costs.
The reduced energy consumption of PMSMs compared to standard induction motors are
an intrinsic consequence of their design. While induction motors require an electric current in
the rotor to create the induction that turns the rotor and produce torque, PMSMs rely on a
permanent magnet to make the rotor spin. When compared to similarly rated induction motors,
PMSM technology has been shown to offer performance improvements of as much as 40% in
some water treatment applications. As such, many PMSMs will pay for themselves in a matter
of months.
As part of the design process Bauer’s engineers were required to ensure that the new
motors would fit within the footprint of the existing motors. This would ensure that the original
mountings and gearboxes would not need to be replaced – helping to minimise project costs.
Furthermore, as they were to be located outdoors, it was essential that the new motors were
equipped to survive inclement weather as well as the general hazards faced in such an
environment. Therefore, Bauer opted for motors adhering to IP65 ratings and the associated
inverter in IP66, which ensure protection from dust ingress and from high pressure water jets
from any direction.
To make the combination of motor and variable-frequency drive effective, single
inverters mounted directly on the motors (EtaK2.0 geared motors) were preferred to connecting
all the inverters in series. In this way, if one unit were to fail, it wouldn't affect the other geared
motors, which would continue to work, minimising plant downtime and maintenance costs.
In addition, the new solution provided by Bauer simplified the system and reduced the
equipment required. The built-on inverters in the EtaK2.0 eliminated the need for shielded
cables in the plant and powered the motors in a decentralised way, so inverters in control
cabinets would not be needed. In this way, maintenance activities were reduced, which resulted
in additional cost savings.
The EtaK2.0 also provides additional communication and control capabilities. More
precisely, the built-on inverters send a constant flow of data to the programmable logic
controller (PLC) via the widely used PROFINET industrial ethernet standard connection. This
enabled the condition of each unit to be monitored remotely, without the need for physical
inspection.
In this way, the wastewater treatment plant could benefit from an automated network and
be ready for Industry 4.0 and the Industrial Internet of Things (IIoT). Furthermore, by enabling

higher control capabilities, signs of failure could be detected in an easier and quicker way,
while minimising maintenance activities and costs.
Harald Bezold continues: "When we approached Bauer's engineers we told them that we
wanted to future-proof the site by ensuring that the solution operated on the newest technology
as standard. By creating an automated network we are now able to precisely monitor the
performance data of the motors to ensure that they are operating efficiently at all times."
By working closely with the engineers on site at the Bayreuth municipal wastewater
treatment plant, Bauer was able to understand the demands of the application and use its
industry expertise to deliver a solution that's at the forefront of environmental engineering and
industrial communications. Not only did the technology provide measurable improvements in
energy efficiency and productivity, it was managed in such a way that no re-engineering was
required and disruption was kept to a minimum.
With this project, Bauer proved that energy efficiency improvements can not only reduce
the costs for generating, transmitting, and distributing energy from power plants to the end
facility, but can also substantially reduce operating and maintenance costs.

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