Higher energy efficiency thanks to turbine with optimized compressed-air consumption
Bietigheim-Bissingen, December 2015 – In the EcoBell3 Dürr has a highly efficient atomizer generation to use for the electrostatic application of all paints. Now the turbine which drives the flexible bell disc/shaping air ring system has been further optimized. Depending on the application, the new turbine variants allow up to 40 percent compressed-air savings. The particular feature here is that upgrade kits are also available for its predecessor, the EcoBell2.
“High Efficiency” and “Highest Efficiency” are the names of the two modern turbines which make the new generation of the EcoBell even more economical for the same output. Optimized vanes and nozzles ensure less compressed air and therefore less energy is required while spraying.
Which variant is recommended depends on the specific requirements in the customer’s plant. The High-Efficiency turbine, for instance, delivers really outstanding performance at up to 70,000 rpm. The EcoBell3 requires approx. 15 percent less compressed air for this than the previous models, and the EcoBell2 as much as approx. 20 percent less. Experience tells us, however, that the EcoBell2 atomizers operate in the rotary speed range up to 50,000 rpm in 90 percent of applications – with maximum paint flow rates of 600 milliliters. Under these conditions, e.g. for interior painting, the Highest-Efficiency turbine achieves compressed-air savings of approximately 40 percent.
Consequently, the High-Efficiency solution can save around 1,500 euros per year in the costs of compressed air and spare parts, and the Highest-Efficiency solution even as much as about 2,000 euros – for each robot. An upgrade will therefore pay for itself completely after just one year. With up to 100 atomizers per paint shop, this yields correspondingly high overall savings. Apart from the turbine function, the connection between the bell disc and the turbine has also been improved by means of a special thread geometry. That enhances system safety against the risk of the bell disc becoming detached and thus extends the bell disc’s service life.
Save energy and reduce CO2
“We are therefore promoting the sustainable use of existing systems – on the one hand, financially as a result of significant energy savings and, on the other hand, thanks to corresponding CO2 reductions,” declares Dr. Hans Schumacher, who heads up Dürr’s Application Technology division.
That is because, as a consequence of the substantially reduced compressed-air consumption, the EcoBell3 requires up to 3,500 kWh or 5,670 kWh less compressor power per robot thanks to the new High-Efficiency and Highest-Efficiency turbines, respectively, and therefore generates up to 3.3 tons less carbon dioxide per year. But the turbines’ consumption is not their only winning feature. Dürr reliably protects the turbines against electrical corrosion with a nickel-based protective surface coating, thereby ensuring an extended service life.
The customers benefit from these Dürr innovations not just when it comes to new investments, but also for atomizers which are already in use. “Several thousand EcoBell2 and EcoBell3 systems are in operation around the world. These atomizers can be upgraded with immediate effect in order to make production even more efficient and sustainable,” states Dr. Schumacher.