How to save cost and energy with the Zytec TORQ couplings?

The Zytec contact-free magnetic coupling is a Game Changer in rotating equipment, which unlocks hidden energy/CO2 reduction potential and costs. Installations become contact-free and yet connected, which provides the new highest level of Reliability, Safety, Sustainability & lowest TCO. This innovative technology makes it possible to save up to 50% of energy consumption and reduce up to 50% of operating costs. Applications include pumps, fans, generators, compressors and conveyors which are used in sectors such as industry (general), Water and Waste Water, Heating Ventilation Air-Conditioning (HVAC), Chemical Industry, Oil and Gas Industry, Maritime Sector, Pulp and Paper Industry and Mining.
 

The breakthrough technology provides a solution to many different problems regarding rotating equipment. Simplicity is the strength of this solution. A mechanical solution that is easily and quickly applicable in both existing (retrofit) and new installations. The Zytec magnetic coupling connects your equipment contact-free and can control the speed of your installation. The result is that fewer parts are required, making the overall installation more robust and reliable.

The results are often spectacular. 

• Four Zytec couplings were installed on four pumps within two days, resulting in energy savings of 340 households (= 600 tons of CO2). This with a payback time of 1.1 years.
• In a business critical fan, the maintenance interval has been extended from 6 months to 6 years with a Zytec coupling, vibrations have been reduced by 80%. This with a payback time of 0.8 years.
• In the case of a fan in an explosive atmosphere (ATEX), the fluid coupling (contains maintenance and wear parts such as bearings, seals and oil) is replaced by a low-maintenance Zytec coupling (does not contain maintenance or wear parts such as bearings, seals and oil). The maintenance interval has been extended from 2 years to 20+ years. Furthermore, the safety has increased because when the fluid coupling fails the temperature melt plug melts and the oil is thrown out of the fluid coupling. This can no longer occur with a contact-free magnetic coupling.

Fan with a Zytec contact-free magnetic coupling in a cooling tower.
With this cooling tower, the fluid coupling by the fan is replaced by a Zytec contact-free magnetic coupling. Previously every 2 years they had to repair the fluid coupling to replace bearing, seals and oil. The Zytec contact-free magnetic coupling has no consumable parts and is therefore completely maintenance-free for 20+ years. The Mean Time Between Repair (MBTR) has gone from 2 years to 20+ years. A tenfold increase in the MTBR. In the video below it had just rained that day, therefore a pool of water is visible under the coupling. You can see the start process of the fan with a motor that halfway switched to a higher speed. This is used to cool at 2 different levels.

Watch the documentary about "The pardise on earth starts in the Netherland" for more insights of the impact of the technology.

The Zytec coupling provides a solution to:

• Increase reliability
• Reduce downtime
• Improve safety
• Reduce Total Cost of Ownership
• Save energy and reduce CO2
• Reduce maintenance 
• Misalignment
• Clean speed control (no harmonic distortion)
• Improve power quality (prevention inexplicable errors) 
• Reduce vibration and noise
• Shock loads
• Subsidence and earthquake damage control
• Mounting deformation
• ATEX compliance

Because of a significant energy saving and (often hidden) cost reduction, Zytec solutions will result, most of the time, in a payback period of less than two years and a yield of over 30%.

Leading customers using Zytec TORQ Couplings: