A PUNCH Power 200 flywheel unit was used with a TYRON 2000 XL 2.0 hybrid mobile shredder from Haas Recycling Systems. The generator was downsized from an 800kVA to a 550kVA generator, achieving a fuel savings worth £22,500 per year and CO2 savings of over 40 tonnes. The optimum flywheel configuration was achieved using power capping mode set at 250 kVA.
The TYRON 2000 XL 2.0 hybrid mobile is an industrial shredder, manufactured by Haas Recycling Systems of Germany. As a hybrid system, it relies on 280 kW electrically driven motors to power it’s two shredding shafts. This power can be provided by mains, or by a diesel generator where grid power is not available.
Figure 1. The Haas Tyron 200 XL 2.0 Hybrid Shredder
In this case study CRJ services, the UK agents for Haas Recycling Systems, arranged a test to confirm what level of generator downsizing could be achieved by using a PUNCH Power 200 flywheel system alongside a diesel generator. A successful test would reduce the size of generator required, offering their customers cost savings on generator rental and fuel usage, as well as reduced CO2 emissions.
The test took place at the new Geminor waste processing facility in Hull, UK. This facility is capable of producing 150,000 tonnes of refuse derived fuel (RDF) per year and shredding is a key step in that process. Geminor typically power their TYRON shredder from grid power, but for this test the grid was disconnected.
When diesel is used, the TYRON shredder typically requires an 800 kVA generator to power the machine. The load cycle of these machine is highly dynamic – high power is required as material is loaded into the shredder, with a period of low power requirements as the next load of material is prepared. Such dynamic load cycles are well suited to downsizing with the PUNCH Power 200 flywheel.
The PUNCH Power 200 flywheel system stores energy from the diesel generator during periods of low load, and can rapidly supply both real and reactive power when needed. This allows operators to reduce the size of the diesel generator required. The customer then makes three savings: Firstly, saving on the rental cost of smaller generator. Secondly, the lower fuel costs associated with a smaller generator and finally they save CO2 emissions due to lower fuel usage. The combination of these factors makes the PUNCH Power 200 environmentally friendly and economically attractive
For this test Sunbelt Rentals UK, power solution provider to CRJ, supplied a 550 kVA Himoinsa Stage V diesel generator, a PUNCH Power 200 flywheel system along with appropriate cables and connectors. The electrical system was commissioned by the team from King Power Solutions.
Figure 2. The shredder, generator and flywheel systems connected
The PUNCH Power 200 flywheel system was set up using current clamps. These clamps detect the current being drawn by the shredder and allow the flywheel to inject power in response to that demand. The PUNCH Power 200 was set in “power capping mode”. This mode allows the user to set a threshold, and if the demand from the load exceeds that threshold then then flywheel will inject power to cap demand. For example, if the power cap is set at 400 kW, and a load of 450 kW is detected then the flywheel will inject 50 kW of power.
With the system set up, the team from Geminor began loading waste into the shredder. Settings were adjusted to lower the power capping level down to 250 kW. This resulted in the flywheel making larger and more frequent energy injections, which in turn better levelled the load on the generator. The entire test lasted just over 60 minutes. Data from the PUNCH Power 200 system was downloaded at the conclusion and is displayed in figure 3.
Analysis of the data showed that the system worked flawlessly. The mean power usage across the most active part of the test was 150 kW, whilst peak power and current demand were experienced during the machines start up cycle. The flywheel successfully levelled the load applied to the generator by supplying energy during periods of high demand and harvesting energy during periods of low demand.
Load levelling a stage V generator offers benefits to DPF regeneration, SCR (AdBlue) usage, and generator servicing requirements.
Figure 3. Data on power, frequency, voltage and flywheel speed for the duration of the test
Based on the worst-case power demand, fuel savings were calculated at 6 litres per hour resulting in fuel savings of £22,500 per year. This fuel saving results in a direct reduction in CO2 of just over 40 tonnes – equivalent to taking almost 30 cars off the road for a year. To calculate a net benefit, the lower cost of generator hire should also be added, as should the cost of hiring the flywheel system.
Punch Flybrid would like to thank all parties involved in making this groundbreaking test happen.