Efficient pumps for all industries

With more records being set for temperature, fires, flooding and other extreme weather events, operating sustainably is a crucial focus for pump operators. KSB is working to help its customers become more environmentally efficient.

Multiple departments across all governments have been tracking the impact and effects of global climate change. According to the Bureau of Meteorology (BOM), Australia’s climate has warmed by an average of 1.47 ± 0.24°C since national records began in 1910. Sea surface temperatures have increased by an average of 1.05°C since 1900. There has been a decline of around 15 per cent in April to October rainfall in southwest Australia since 1970. In southeast Australia, rainfall has decreased by around 10 per cent from April to October since the late 1990s.

As a result, it’s important that all responsible companies and individuals make significant efforts to minimise the effects of climate change by reducing greenhouse gas emissions. Part of that solution is highly efficient pump systems.

The impact of pumping systems

Of the world’s total energy generated, pumping systems, especially centrifugal pumps, consume about 20 per cent. This corresponds to 2284 terawatt hours, which amounts to around 1370 million tonnes of carbon dioxide equivalent (CO₂-e), according to the International Energy Agency (IEA). That volume is about the same as the emissions of 443 coal-fired power plants in one year. Importantly, it is not only the pumps that consume this energy but the entire systems in which they are operated.

Sarel Erasmus, General Manager of Water and Wastewater at KSB Australia, has worked in the industry for many years, which has given him insights into what can be done.

“If you think about pumping systems as a whole, the system is essentially a pipeline with valves connected to a pump and a motor,” said Erasmus. “Motors tend to operate at 85 to 96 per cent efficiency, as opposed to the hydraulic efficiencies of pumps that vary based on the system parameters and pump design. That’s why we need to focus on operational efficiency. We want to improve the efficiency of the entire system unit.”

This holistic approach to optimising the entire system offers the most energy savings, the greatest improvements in system reliability, and reduced maintenance. It also reduces life cycle costs for end-users, with energy alone accounting for an average of 45 per cent of these costs, according to the US Department of Energy.

“We run CFD and hydraulic modelling to ensure our pumps operate at optimum efficiency,” Erasmus said. “Although the initial cost of assets is important, system efficiencies are more important. The total cost of ownership must be considered over the lifetime of the asset. Ultimately, it has a profound impact on our environment, our future and everything in between.”

KSB has set itself the goal of saving 850,000 tonnes of CO₂ per year by 2025 through such optimisation measures. It offers its customers solutions to reduce their energy consumption as far as possible. It provides highly energy-efficient products and options for monitoring and control. KSB advises its customers to ensure their pumps are correctly sized for their application.

What options are available?

There is still plenty that end-users can do to save energy, even once a system is installed.

“Our SES System Efficiency Service carefully examine and analyse the on-site systems,” said Erasmus. “It determines the actual load profile of the pumps and compares it with the design conditions. After identifying impermissible pump operating conditions and critical system conditions, we can make specific recommendations to reduce energy consumption and carbon footprint.”

KSB has also been at the forefront of developing more efficient pump models while manufacturing them in a more environmentally friendly manner. A recent example is our new AmaRex Pro submersible motor pumps, designed to guarantee the best possible performance.

“The AmaRex Pro features IE5-equivalent motors and are coupled to an optimised hydraulic design,” said Erasmus. “That means your assets are highly efficient and further reduce energy consumption.”

The motors were designed with five per cent less copper than conventional motors. Pump casings are being cast out of recycled metals, improving the pump economy’s circularity while reducing greenhouse gas emissions.

“We are making our production facilities around the world more climate-friendly,” Erasmus said. “For example, our plant in Lille, France, where our AmaRex Pro is manufactured, is set to reduce its greenhouse gas emissions by 98 per cent in 2027 compared with 2021. This is achieved through effective system insulation, efficient heating systems, LED lighting, and photovoltaic systems.”

Improving operational efficiency

The KSB team have found that pump operations and pump systems offer many more opportunities to save energy than pump manufacturing alone.

“The reality is that a pump’s carbon footprint is caused by the electricity consumed during its use, representing about 90 to 95 per cent of the footprint over the pump’s lifetime,” said Erasmus. “That provides enormous potential to optimise pumps and their systems. Our global team has been able to reduce the energy consumption of pump systems by working closely with our customers, resulting in significant savings. If an individual or isolated approach is taken by examining individual components, it is only possible to leverage between 5 and 10 per cent of the potential savings.

“Therefore, the greatest potential for optimisation comes from reviewing and improving the pump system. For example, systems often have oversized pumps. Once we identify the inefficiencies and determine the appropriate system requirements, the pump set can be adjusted to offer improved performance.

KSB is committed to playing its part in healing our planet, and through our ongoing investment in research and development, we strongly believe our efforts are making a difference.

For more information, visit www.ksb.com/en-au