Test runs successfully completed at swb Erzeugung AG & CO KG

SET successfully completed the 35-day test run periode at swb Erzeugung AG in Bremen, Germany with SETCON® SE6 recently . The expected energy savings compared to the replaced variable-speed gear coupling have been exceeded by far, so that the power plant unit can be operated even more efficiently in the future. This modernization project is a great success for everyone involved and guarantees efficient and reliable operation in the Mittelbüren power plant in the future.

In summary, the following project highlights result:

  • Energy savings of 12 815 MWh per year compared to the variable speed gear coupling
  • CO2 reduction of approx. 12 400 tons per year (corresponds to a CO2 consumption of 1 550 German residents)
  • Mechanical and electrical implementation and commissioning in 15 days
  • The foundations were not changed and the existing anchor points of the variable-speed gear coupling were adopted, thanks to the matching footprint
  • The existing lubricating oil cooler could continue to be used, the working oil cooler has been shut down due to lower the lower losses and reduced oil flow
  • Neither the pump nor the Main drive had to be repositioned on the existing foundation
  • Simple and safe integration into the existing control system (through SET’s control system simulation and customer acceptance in advance)

Retrofit order from swb Erzeugung AG

Located next to a steel works, the power plant unit converts blast furnace gas and converter gas into electricity.

SET has been awarded from swb Erzeugung AG & Co. KG to replace an existing hydraulic speed control coupling at the Mittelsbüren power plant in Bremen, Germany, with an energy-efficient SETCON® drive system. The aim of the project is to significantly modernise and improve the efficiency of the overall system, which will increase the total plant unit efficiency by 1%. 

Using the variable speed SETCON® system to drive a boiler feed pump with a power of 6.5 MW allows swb Erzeugung AG & Co. KG to considerably reduce its electrical energy consumption and greenhouse gas emissions. In concrete terms, the SETCON® drive system will result in a saving of around 10,770 MWh and 12,400 tonnes of CO2[1] a year.

The old system is scheduled to be replaced in the third quarter of 2020 during the power plant’s periodic overhaul. As the SETCON® drive system has exactly the same footprint (series concept) as the existing hydraulic speed control coupling, the power plant will only have to be shut down for a short time to enable cost-efficient installation, no structural changes to the machine bed will be required. All other units such as the main motor, boiler feed pump and booster pump can continue to operate without modification following the overhaul.

SETCON® is an electro-mechanical variable speed drive system developed by SET that is perfect for replacing hydraulic couplings thanks to its high energy efficiency and outstanding retrofit capabilities. This innovative new drive concept is particularly well-suited for variable-speed operation of pumps, compressors and blowers with a drive power of > 4 MW and rated speeds of > 3,500 rpm, and the use of standard industrial components guarantees high system reliability and availability.

The Mittelsbüren power plant in Bremen is fired with blast furnace and converter gas taken from the neighbouring steel works, which reduces the latter’s CO2 emissions. The plant unit, which has an electrical output of 238 MW, is operated by swb Erzeugung AG & Co. KG, the division of the swb group responsible for conventional electricity and heat generation. The swb group has 2,145 employees and achieved a turnover of 1,361.1 million euros in 2018. The gas is taken from the furnaces in the steel works next door operated by ArcelorMittal Bremen, part of the world’s largest steel group ArcelorMittal, headquartered in Luxembourg.

                                [1] Blast furnace gas emission factor standard value = 0.965 tonnes CO2/MWh (LUGV)

further information:

Performance tests at Sulzer (Deutschland) Pumpen GmbH in Bruchsal, Germany

November 18-20, 2015 saw further performance tests being conducted on the 4.1 MW SETCON® at Sulzer (Deutschland) Pumpen GmbH in Bruchsal/Germany. Similar to the tests at Elin Motoren GmbH in Weiz/Austria, the complete powertrain including boiler feed water pump was put through its paces here.

And once again the electro-mechanical differential system proved its excellent capabilities, efficiency, and reliability. All the customer’s requirements were met to PCK Raffinerie GmbH’s complete satisfaction and the professional cooperation between the companies involved was also demonstrated.

Local and international customers from the energy, industry, and oil and gas sectors also had the opportunity to gain an impression of the SETCON® benefits over these few days. All those who attended the event were impressed with its performance and agreed that the SETCON® is an ideal solution for efficient and reliable control.

Sulzer Technical Review – “Wind Generators as Role Models”

In the latest issue of Sulzer Technical Review with the titel ” Wind Generators as Role Models” Sulzer Pumpen (Deutschland) GmbH presents SET GmbH and its electro-mechanical Differential System.
“Wind Generators as Role Models”

Dirk Küllmey, Klaus Löffler 04.11.2015…SET has been active in the field of wind power for more than 20 years, and it has developed wind generator gearboxes, which maintain the generated power at 50 Hz despite changing wind loads. Together with Sulzer, SET has now made use of this innovative gearbox concept on pumps… read the whole article: [Sulzer Technical Review]

DSgear-set® for a 4.1MW boiler-feed pump at PCK site in Schwedt (Germany)

SET’s electro-mechanical differential gear points the way ahead for the entire wind sector. In the interim this technology is also meeting with great interest in industry.

In the 4th quarter of 2014 Sulzer Pumps GmbH awarded SET GmbH a contract to install its electro-mechanical differential gear system (DSgear-set®) at the PCK refinery in Schwedt (Germany). By the 2nd quarter of 2015 the DSgear-set® will replace the existing direct drive system in order to meet future challenges in terms of sustainability and life cycle costs (LCC). SET’s electro-mechanical differential gear emerged as the best technology ahead of the competition in view of its speed variability range, efficiency, and robustness.

The DSgear-set® has to provide a rated power of 4,080 kW for a boiler feed-water pump, which is essential for the refinery processes at the site. In this flagship project the operating companies expect the DSgear-set® to ensure high cost savings, maximum reliability and Efficiency.Due to the excellent cooperation between the companies involved, follow-up projects are planned.