In the midst of international summits and governmental policies, companies from across the industrial spectrum are beginning to understand the importance of saving energy, reducing carbon footprint and developing more eco-friendly products and processes.
The obvious benefits of energy efficient manufacturing include reduced operational and production costs, increased competitiveness, environmental gains and improved consumer welfare. This special report from, Industrial automation components supplier European Automation, analyses how industrial automation can help manufacturers become more energy efficient. It also analyses the industry impact of the European Union’s Ecodesign Directive, the Energy Savings Opportunity Scheme (ESOS) and relevant ISO standards.
In 2009, the European Union revised its Ecodesign Directive. The framework ensures designers of energy-using (EUPs) and energy-related products (ERPs) reduce the energy consumption and environmental impact of these products. Estimates show that over 80 per cent of a product’s environmental impact can be determined during the design phase. Ecodesign ensures products have a reduced environmental impact and lower energy consumption throughout their lifecycle, while maintaining the same levels of functionality.
Induction motors
When it comes to industry, the potential for energy saving is staggering. It is well-known that induction motors use about 30 per cent of all the electricity generated in the world, which means they have great potential for energy savings. In fact, simply by estimating the right size and capacity of a motor, you can save up to 10 per cent on electricity consumption.
Controlling the motor speed in a variable speed application using a variable speed drive (VSD) can further increase the energy savings to as much as 60 per cent. These numbers make it clear that, simply by correctly estimating and controlling electrical motors, manufacturers can reduce their energy consumption.
As motors have evolved, manufacturers have managed to achieve better efficiency. The International Electrotechnical Commission constantly updates its international standard
defining the energy efficiency classes of single speed, three-phase motors. The standard has also been adopted in the European Union and UK and is known as the BS EN 60034-30:2009.
Minimizing the costs
According to the 640/2009 regulations of the Ecodesign directive, starting June 2011, motors manufactured in and operating in the EU have to meet at least the efficiency level
IE2 (High efficiency). From January 1, 2015, IE3 (Premium Efficiency) became mandatory for motors from 7.5 to 375 kW. The next phase starts on January 1, 2017, when IE3 requirements extend to all motors between 0.75 and 375 kW; with one exception: IE2 motors can still be bought, but only if installed with a VSD. This exception should be enough to demonstrate just how important VSDs are for industry. Not only would fitting a VSD allow manufacturers to minimize the costs of complying to new Ecodesign regulations and future proof operations, it also brings enormous energy savings, reduces motor wear by using soft start and stop technology and opens up new technological opportunities.
