inefficient . Collectively , industrial electric motors use approximately 45 percent of all energy produced , being primarily used in fans and pumps . By replacing older electric motors with more efficient modern systems , we could reduce total global energy consumption by up to 10 percent .
Improving efficiency with motors and drives One effective way to improve a fan or pump motor ’ s efficiency is to pair motors with a variable speed drive ( VSD ). A VSD adjusts a motor ’ s speed to exactly match the requirements of the task . Any time it is not operating at full speed , it is saving power . Slowing a motor can produce significant savings – reducing a motor ’ s speed by just 20 percent reduces energy use by 50 percent .
Despite this , experts currently estimate that only a quarter of all industrial motors are paired with a drive , so industrial businesses are missing out on a significant opportunity to save electricity .
In addition to adding drives , facilities can upgrade to more efficient electric motors . The EU Ecodesign Regulation requires new installations and upgrades taking place after July 2023 to use motors of IE4 level efficiency or greater . The most efficient motors today are synchronous reluctance motors ( SynRM ), which achieve IE5 efficiency by using a VSD . Upgrading from an existing IE2 motor to an IE5 SynRM motor-drive package cuts energy losses by approximately 50 percent . Modern motors are designed to work as drop-in replacements for older models , making it easy to upgrade . In addition to hardware improvements , digitalisation can take energy efficiency to the next level . Digitally connected drives transmit valuable data from the motor and driven machine to show exactly how much energy is being used . Operators can then analyse this data , identify potential inefficiencies , then take action to address them – thus , increasing their energy efficiency while maintaining process quality and reliability .
The financial benefits of energy efficiency By using less energy , more efficient equipment produces significant savings . These savings mean that it pays for itself . Typical payback periods for equipment such as a VSD , for example , may be around one to three years , but while energy prices are high they can be as low several months . To quickly and easily estimate the potential energy and cost savings for your facility , try ABB ’ s EnergySave Calculator .
For example , a sewage treatment plant in Bocholt , Germany , upgraded the motors in its pumps to IE5 SynRM motor-drive packages and redesigned the pump geometry . It now processes the same volume of water using 40 percent less electricity , resulting in a significant reduction in OpEx . Now that the motors and drives have paid for themselves , they will continue to produce savings throughout their useful lifetime .
Energy efficiency : better for planet and profit The news that businesses are having to cut important investments and delay sustainability efforts is concerning .
Fortunately , the technology is available today to enact meaningful change . Energy efficiency is the key to overcoming both the financial challenges of high energy prices and doing the right thing by achieving sustainability targets .
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