Inefficient energy use was a brake on animal feed producer Nijsen's sustainable ambitions. Through technical optimisation, we eliminated reactive power penalties and immediately created space on the transformers for future growth.
Nijsen in Veulen has been processing residual streams from the food industry into high-quality animal feed for over 30 years. With two production facilities and its own solar farm, energy management is complex. However, the electrical installations consumed a disproportionate amount of 'reactive power'(reactive power). This is energy that loads the grid and transformer without being converted into useful work.
For technical managers and executives, this brought uncertainty. The inefficiency not only led to monthly fines on energy bills, but also snatched precious capacity from in-house transformers. This created the risk that future expansions would become impossible without heavy investment in infrastructure. HyTEPS was brought in to turn this invisible loss item into usable power.
"To reduce the risk of fines, Nijsen wanted to reduce the reactive power," he said.
To identify the exact cause of the capacity loss, our engineers carried out an in-depth Power Quality analysis in collaboration with Fudura. We mapped the energy flows of the main power supply and the solar farm in detail. The measurements showed that the Power Factor (the measure of efficiency) on the main distributors remained stuck at 0.76 and 0.79 respectively. A score far below the ideal value of 1.
This low Power Factor confirmed the presence of excessive inductive power. Our analysis showed that this reactive power unnecessarily loaded the transformers, resulting in high RMS currents. Based on this data and simulations, we designed a solution that not only combats the symptoms (penalties), but makes the installation fundamentally more efficient.
The advised proposals were implemented immediately: the new breaker 'trip' times have been reduced to 0.12s and 0.08s, where previously they were 0.48s and 0.27s. These reductions of 75% and 70% ensure shorter trip times, reducing energy levels during an arc while maintaining coordination between protective devices. This makes the cabinets safer and, in the event of an incident, the right device is always switched off correctly.
The results were immediately visible after commissioning. On the first main distributor, the Power Factor improved from 0.76 to 0.96 and the current draw dropped from 1150 A to 900 A. On the second distributor, we saw an improvement from 0.79 to 0.96, with a current reduction from 1350 A to 950 A. In total, this achieved over 550 Amps of 'free' space on the transformers. The plant is now stable, efficient and ready for expansion.
An efficient installation means lower costs and greater operational reliability. Are you running up against your contract power limits or paying penalties for blind current? Our engineers offer the solution.
HyTEPS
Beemdstraat 3
5653 MA Eindhoven
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