Energy xxx (2011) 1e8

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Energy
journal homepage: www.elsevier.com/locate/energy

Analysis of electrical motors load factors and energy savings in an Indian cement industry
M. Thirugnanasambandam a,1, M. Hasanuzzaman b, c, R. Saidur b, c, *, M.B. Ali b, S. Rajakarunakaran a, D. Devaraj d, N.A. Rahim c
a

Department of Mechanical Engineering, Kalasalingam University, Anand Nagar, Krishnankoil 626 190, Tamil Nadu, India Department of Mechanical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia Centre of Research UMPEDAC, Level 4, Engineering Tower, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia d Department of Electrical Engineering, Kalasalingam University, Anand Nagar, Krishnankoil 626 190, Tamil Nadu, India
b c

a r t i c l e i n f o
Article history: Received 7 December 2010 Received in revised form 5 April 2011 Accepted 6 April 2011 Available online xxx Keywords: Cement industry Energy audit Energy savings Motors VSD

a b s t r a c t
Electric motors consume in between 30% and 80% of the total industrial energy use for few selected countries around the world. It was identied that many motors are operated under loaded conditions. In some cases, motors are operated even at 3e16% of their full loads. These low loads can be optimized with the application of variable speed drives (VSD) to match the load requirements. Based on the estimation, it has been found that annually about 1,865,925 MWh of energy can be saved for 60% speed reduction when VSDs are used. It was also found that about 2,122,675 tons CO2emission could be avoided annually by using VSDs for Low Tension (LT) motors for 60% speed reduction. It was also estimated that annually about 4,600,386 MWh of energy can be saved for High Tension (HT) motors for 60% speed reduction using VSDs. The average payback period (PBP) for implementing VSDs for LT and HT motors found to be very low (i.e. about 2 days). In this particular study it is observed that installing both LT and HT capacitors to improve power factor found to be not economically viable owing to low level of energy savings. 2011 Elsevier Ltd. All rights reserved.

1. Introduction The growth of an economy is closely related with the growth in its energy consumption [1]. It is widely recognized that the nonavailability of energy is a serious obstacle to an economic growth, and industrial energy demand is growing at 5% per year [2]. The Indian industrial sector consumes a large proportion of primary energy, accounting for 4.5% of industrial energy use worldwide [3,4]. During the past decade, electricity demand in India has increased many folds at an average rate of 6.13% per year [5]. Industrial sector of India consumed about 44.8% of the total energy use in the year of 2006/07 [6]. According to the International Energy Agency, energy consumption in the Indian industry is projected to be more than double by 2030 [3]. The Indian cement industry is the second largest producer in the world comprising of 130 large cement plants and 206 mini cement plants consisting of

* Corresponding author. Department of Mechanical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia. Tel.: 603 79674462; fax: 603 79675317. E-mail addresses: mtsambandam@gmail.com (M. Thirugnanasambandam), saidur912@yahoo.com, saidur@um.edu.my (R. Saidur). 1 Tel.: 91 4563 289042; fax: 91 4563 289322. 0360-5442/$ e see front matter 2011 Elsevier Ltd. All rights reserved. doi:10.1016/j.energy.2011.04.011

13 rotary kiln plants and 193 vertical shaft kiln plants [7]. The cement sector is the second largest consumers of energy compared to other industrial sectors and consumed about 13.5% of the total industrial energy in the year of 2006/07 in India [6]. The cement sub-sector consumed approximately 12e15% of total industrial energy consumption in Malaysia [8], 15% in Iran [9]. Electric motors have broad applications in industries, businesses, public services, household electrical appliances, powering a variety of equipment, including air blowers, water pumps, compressors and machine tools as can be seen in Fig. 1. In industrially developed and large developing nations, electric motors account for a considerable proportion of total national energy consumption [11]. Energy use, savings, energy efciencies of machines used in industrial sectors were studied by many authors in different parts of the world [12e15]. Share of electric motor energy use for few selected countries is shown in Table 1. As electric motors and motor driven systems use major share of energy in an industry, the cost of energy to operate motors and motor driven systems has become a real concern for industries [31].In India, coal is available in large quantities and prices of various grades of coal are relatively much less compared to the prices of oil and gas in most of the industrial countries. As a result, more carbon is burnt for the generation of each unit of electricity in

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M. Thirugnanasambandam et al. / Energy xxx (2011) 1e8 Table 1 Share of electric motor energy use for few selected countries. Country Motor energy usage (%) 75 50 65 31 48 65 52 80 70 60 40 49 30 60 References [16,17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30]

Nomenclature ABS AES AER AEU C CRR hr IC L n P kWa kWr SSR annual bill savings (US$) annual energy savings (kWh) annual emission reduction (kg) annual energy used (kWh) cost of unit energy (USD/kWh) capacitor rating required in kVAr annual/daily operating hours incremental cost (US$) load factor (percentage of full load) (%) number of motors motor rated power (kW) actual capacity of an electric motor rated capacity of an electric motor percentage of energy savings for motor speed reduction PBP payback period (year) SSR percentage energy savings associated certain percentage of speed reduction (%) VSD variable speed drive 41cos-(pF1) where pF1 is the existing power factor 42cos-(pF2) where pF1 is the target power factor

US UK EU Jordan Malaysia Turkey Slovenia Canada India China Korea Brazil Australia South Africa

works on electric motor energy efciency standards. Saidur [38], Saidur et al. [14] estimated energy savings for industrial motors based on a walk through energy audit data. However, there are limited works on the electric motors load analysis. Therefore, this paper analyzed energy audit data to estimate load factors for an Indian cement industry. However, energy savings, bill savings and emission reductions for electric motors by using the VSD to match the load requirements were also presented. 2. Methodology This section explains the process of a detailed energy audit, instruments used for data collection, approaches used to estimate energy consumption and energy saving potential when using a VSD. Payback periods (PBPs) for the energy saving strategy are also estimated for the different percentage of speed reductions using VSDs. These are elaborated below: 2.1. A detailed energy audit Before conducting a detailed energy audit for this industry, following preparations have been made. A meeting was held with the appropriate plant personnel who are familiar with the physical conditions and day-to-day operation of the industry. The purpose of the meeting was to identify areas where auditors attention should be focused during the detailed energy audit. Since the audit was carried out second time in the facility, the focused area was limited to electric motors. No specic questionnaires were prepared as the audit team was familiar with the facility. An audit team consisting of qualied and experienced electrical and mechanical engineers were formed. However, it may be mentioned

Indian thermal power plants [5]. The concern for the emission of greenhouse gases and other pollutants has prompted the regulators of utility companies to enforce alternative measures to meet the load growth [31]. Worldwide concern with global climate change has highlighted the challenges faced by industrialized and developing countries in maintaining a sustained process of development [32,33]. A cement production requires massive utilization of energy, resulting in the generation of a considerable amount of carbon dioxide emission as an undesirable by-product [34]. Indias aspiration for economic growth has consequences for energy growth and CO2 emissions [35]. The industrial energy efciency has emerged as one of the key issues in India [36].A comprehensive study on electric motors energy savings, policy, and technology is presented by Nadel et al. [37]. A comprehensive review on the electric motor energy use and savings was presented by Saidur [38]. It may be mentioned that energy can be saved using variable speed drives (VSDs), capacitor banks to improve the power factor, by regular maintenance of electric motors and implementing energy efciency regulations. Electric motor energy can also be saved by avoiding over sizing as mentioned by Nadel et al. [37]. Almeida et al. [10], Garcia et al. [39], and many other researchers carried out some

Table 2 List of equipment and their specications for conducting energy audit. Name of equipment and accessories Specications Measuring parameters Range Accuracy

Enercon make power network analyzer with HT probe (3 No.), with CT 2000 Amps (3 No.), 600 V Matrix make clip on power meter with CT 200 Amps and 1000 Amps Fig. 1. Share of motor energy use by type of end-use, in the industrial sector in EU [10].

Up to 5 A, V and I e 0.5% Volts, amps, kW and kWh e 1% 200 A, kW, pf, kWh, Hz, harmonics etc., 1000 A and 2000 A

Volts, amps, kW, pF, kWh, Hz

Up to 5 A, V and I e 1% 200 A, and 1000 A

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M. Thirugnanasambandam et al. / Energy xxx (2011) 1e8 Table 4 Rated and actual capacities and usage hours of HT motors. Serial no Annual operating hours 5400 5400 5400 8640 8640 7920 7920 8640 8640 8640 8640 7920 8640 7920 8640 8640 8640 7920 8640 8640 8640 8640 8640 8640 8640 8640 7920 8640 8760 7920 8640 8640 8640 7920 8640 8640 8640 7920 5400 8640 8640 8640 8640 8640 8640 8640 8640 8640 8640 7920 8640 8640 7920 8640 8640 8640 8640 8640 8640 7920 8640 8640 7920 8640 8640 8640 8640 8640 8640 7920 8640 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rated capacity (kW) 200 200 275 275 400 400 400 425 560 560 1550 1560 2200 2500 Actual capacity (kW) 127 129 35 69 215 265 277 257 252 328 313 880 1422 1604 Annual operation hours 7920 7920 8640 8640 8640 8640 7920 8640 8640 8640 7920 8640 7920 8640

Table 3 Rated and actual capacities and usage hours of LT motors. Serial no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 Rate capacity (kW) 7.5 9.3 9.3 11 11 11 11 11 11 11 11 11 15 18.5 18.5 18.5 18.5 20 22 22 22 30 30 30 30 30 30 30 30 30.5 31 31 37 37 37 37 45 55 55 75 75 75 75 75 75 75 75 75 90 90 110 110 110 110 132 132 132 132 132 155 160 160 160 175 250 250 250 275 275 275 275 Actual capacity (kW) 3.6 3.6 4.8 1.15 1.5 1.5 1.5 4.5 4.5 4.52 6 7.08 3.34 7.26 9.09 10.38 12.87 11.61 5.7 11.94 15.06 1 1.8 3.63 4.41 9.6 13.2 16.2 18.9 19.8 4.2 9.6 6 13.5 13.53 15.36 23.1 6.3 32.1 6 39.6 41.7 42.2 45.68 46.78 47.6 49.6 51.3 47.2 49.5 16.32 17.4 46.2 57.13 26.6 48.6 65 66 91.5 79.4 18.9 88.8 106.2 118 12.54 109 121.5 85.2 158 166.8 177

that each team was accompanied by an expert (lead auditor who is a certied energy auditor and senior technical personnel with sufcient exposure in conducting a detailed energy audit) to guide and supervise the audit progress. This has been done to ensure that the data collection was carried out reliably. The audit work was started with a kick-off meeting as detailed below: (a) An energy audit kicked off meeting was held with the facility manager/maintenance engineer to introduce an energy audit target and the members of the audit group. The facility manager then explained his manufacturing process and energy-consuming machineries, and provided operation and maintenance records for review by the auditors. (b) Following the meeting, the maintenance engineer took the audit team to the manufacturing plant for the visual observation of the various facilities, locations and the accessibility of measuring points. The audit team was accompanied by the representatives of respective equipment operators. (c) Auditors have reviewed the operating manual vice-versa operating parameters and equipment specications for energy-consuming equipment. (d) In addition to the facility inspection, the auditors discussed with the facility staff to review the implementation of suggestions made in the previous energy audit reports. (e) The instruments were veried for the calibration status by the facility manager and were counter checked with the online instruments installed in the facility to ensure the measurement accuracy in collecting data. The list of instruments used and their specications are shown in the Table 2.

Table 5 Specication of (HT) motors power factors. Serial no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Rate capacity (kW) 950 850 4100 4100 1060 400 560 1425 525 1425 1425 400 400 200 Current pf 0.89 0.80 0.92 0.92 0.85 0.95 0.78 0.93 0.96 0.95 0.96 0.80 0.85 0.89 kVAr installed (Power Capacitors) 300 1000 1000 1000 300 125 200 500 100 500 500 100 200 400

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Table 6 Energy savings and bill savings of LT motors. Serial no Load (%) Energy use (MWh) Energy savings (MWh/year) 20% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 48.00 38.71 51.61 10.45 13.64 13.64 13.64 40.91 40.91 41.09 54.55 64.36 22.27 39.24 49.14 56.11 69.57 58.05 25.91 54.27 68.45 3.33 6.00 12.10 14.7 32.00 44.00 54.00 63.00 64.92 13.55 30.97 16.22 36.49 36.57 41.51 51.33 11.45 58.40 8.00 52.80 55.60 56.27 60.91 62.37 63.47 66.13 68.40 52.44 55.00 14.84 15.82 42.00 51.94 20.15 36.82 49.24 50.00 69.32 51.23 11.81 55.50 66.38 67.43 5.02 43.60 48.60 30.98 57.45 60.65 64.36 1944 1944 2592 3888 1296 5184 3888 3905 993 1188 1188 5607 2886 11,120 11,232 7855 8969 9195 10,316 13,011 4925 863 1555 3136 3810 8294 10,454 13,997 16,556 15,682 8295 3629 5185 13,270 11,691 10,693 19,957 4988 17,345 5184 34,214 36,029 36,463 39,470 40,416 41,129 42,852 44,323 40,777 39,204 49,364 14,104 15,035 36,590 41,992 22,981 56,157 57,024 79,058 62,890 16,326 76,723 84,117 101,954 10,843 94,176 104,976 136,501 73,608 152,919 132,096 855 855 1140 437 570 523 523 1711 1711 1718 2281 2467 1270 2530 3456 3946 4893 4046 2167 4539 5725 380 684 1380 1677 3650 4600 6159 7285 6900 1597 3650 2281 4705 5144 5839 8781 2195 7632 2281 15,054 15,853 16,044 17,367 17,783 18,097 18,855 19,502 17,942 17,250 6206 6616 16,100 21,720 10,111 18,477 24,709 25,091 34,786 27,672 7184 33,758 37,011 44,860 4771 41,437 46,189 32,388 60,061 58,122 67,285 40% 1419 1419 1892 725 946 867 867 2838 2838 2851 3785 4093 2107 4197 5734 6547 8118 6712 3595 7530 9498 630 1135 2290 2781 6055 7632 10,218 12,086 11,448 2649 6055 3785 7806 8534 9687 14,569 3641 12,662 3784 24,977 26,301 26,618 28,813 29,504 30,024 31,282 32,356 29,767 28,619 10,296 10,976 26,711 36,036 16,776 30,655 40,995 41,628 57,712 45,910 11,918 56,008 61,405 74,427 7916 68,748 76,632 53,734 99,646 96,430 111,631 60% 1730 1730 2307 884 1154 1058 1058 3460 3460 3476 4614 4990 2569 5117 6991 7982 9897 8184 4383 9181 11,580 768 1384 2791 3391 7382 9304 12,457 14,735 13,957 3230 7383 4615 9517 10,405 11,810 17,762 4439 15,437 4614 30,451 32,066 32,452 35,128 35,970 36,604 38,138 39,448 36,292 34,892 12,553 13,381 32,565 43,934 20,453 37,373 49,980 50,751 70,362 55,972 14,530 68,284 74,864 90,739 9650 83,817 93,429 65,512 121,486 117,565 136,098 Bill Savings (US$/year) 20% 79,240 79,241 105,647 158,484 52,841 211,324 158,484 159,181 40,483 48,437 48,437 228,551 117,645 453,269 457,830 320,161 365,573 374,805 420,479 530,345 200,748 570,528 929,750 35,183 155,310 127,841 63,392 338,091 674,861 639,222 338,115 147,932 211,356 540,900 476,528 435,862 813,478 203,302 706,997 1,746,715 1,647,400 1,676,455 1,608,837 211,307 1,394,625 1,468,582 1,806,673 1,486,279 1,662,139 1,598,007 2,012,133 574,895 612,860 1,491,474 1,711,669 936,723 2,289,044 2,324,374 3,222,513 2,563,478 665,475 3,127,340 3,428,711 4,155,788 441,983 3,838,740 4,278,962 5,563,971 3,000,380 6,233,197 5,384,397 40% 131,466 131,468 175,279 262,939 87,668 350,606 262,939 264,096 67,165 80,362 80,362 379,186 195,184 752,014 759,581 531,177 606,519 621,836 697,613 879,890 333,060 946,558 1,542,539 58,371 257,674 212,099 105,173 560,923 1,119,656 1,060,528 560,964 245,433 350,659 897,402 790,604 723,135 1,349,634 337,297 1,172,973 2,897,958 2,733,187 2,781,391 2,669,207 350,577 2,313,809 2,436,511 2,997,434 2,465,872 2,757,640 2,651,240 3,338,312 953,804 1,016,791 2,474,490 2,839,815 1,554,108 3,797,732 3,856,348 5,346,442 4,253,044 1,104,084 5,188,542 5,688,542 6,894,830 733,291 6,368,818 7,099,187 9,231,134 4,977,903 10,341,441 8,933,204 60% 160,281 160,282 213,696 320,569 106,882 427,452 320,569 321,980 81,886 97,976 97,976 462,295 237,964 916,839 926,064 647,599 739,455 758,129 850,515 1,072,743 406,059 1,154,023 1,880,630 71,165 314,151 258,587 128,225 683,866 1,365,060 1,292,972 683,915 299,227 427,516 1,094,092 963,887 881,630 1,645,445 411,225 1,430,063 3,533,127 3,332,242 3,391,011 3,254,238 427,416 2,820,945 2,970,541 3,654,406 3,006,337 3,362,054 3,232,333 4,069,997 1,162,856 1,239,649 3,016,844 3,462,240 1,894,735 4,630,112 4,701,576 6,518,264 5,185,217 1,346,075 6,325,756 6,935,346 8,406,025 894,012 7,764,723 8,655,173 11,254,396 6,068,950 12,608,058 10,891,167

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2.2. Energy audit data An audit team has followed a random and convenient sampling method and chosen an industry in the cement sector. The recorded data is analyzed using basic engineering skill as well as ones own experience to arrive practically acceptable results. The data recorded are primary and actual without any ambiguity. It may be noted that a statistical tool is not required in this case as data were actual within practically acceptable error. During the audit in the facility, an audit team counted all the equipment on a production oor, took notes on rated power from technical specications on the equipment and operating hours per working day. An audit team has also estimated total working days in a year in consultation with a responsible person of a production process. The most important data that have been collected during the audit are power rating and operation time of energy-consuming machineries; and power factor. Then actual operating data on the power consumption and power factors were measured using portable power meters. Using this data, an analysis has been carried out to estimate energy consumption, load factors for electric motors used in this industry. Based on load factors, VSDs are applied for electrical motors used in this industry to match load requirements so that energy can be saved. It may be mentioned that data collection by a meter (such as power meter, electric pliers) or experimental investigation would be the best one. Data was taken as Business As Usual without making any changes in the operating situation. This may help the auditors to make practically implementable and economically viable recommendations to reduce energy consumption. 2.3. Mathematical formulations The necessary formulations to estimate load factors, energy consumption, energy savings, emission reduction, PBPs, and capacitors ratings are presented in this section. 2.3.1. Load factor An electric motor load factor can be estimated using Eq. (1):
Table 7 Emission reduction and payback periods (PBPs) of LT motors. Serial no Emission reduction CO2 (ton) 20% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 973 973 1297 497 649 595 595 1946 1946 1955 2595 2807 1445 2878 3932 4489 5566 4603 2465 5163 6513 432 778 1570 1907 4152 5233 7006 8287 7850 1817 4152 2595 5352 5852 6642 9989 2497 8682 2595 17,126 18,034 18,251 19,756 20,230 20,587 21,449 22,186 20,411 19,623 7060 7526 18,315 24,709 11,503 21,019 28,109 28,543 39,572 31,479 8172 38,403 42,104 51,033 5427 47,139 52,545 36,844 68,325 66,120 76,543 40% 1614 1614 2152 825 1077 987 987 3229 3229 3243 4305 4656 2397 4775 6523 7448 9235 7636 4090 8567 10,805 717 1292 2605 3164 6888 8682 11,624 13,749 13,023 3014 6889 4306 8880 9709 11,020 16,573 4142 14,404 4305 28,413 29,920 30,281 32,778 33,563 34,155 35,587 36,808 33,863 32,557 11,713 12,486 30,386 40,994 19,084 34,873 46,636 47,355 65,654 52,227 13,558 63,715 69,855 84,668 9005 78,208 87,177 61,128 113,357 109,699 126,992 60% 1968 1968 2624 1006 1313 1203 1203 3937 3937 3954 5249 5677 2922 5821 7952 9080 11,259 9310 4986 10,444 13,173 874 1575 3175 3858 8398 10,585 14,171 16,763 15,878 3674 8398 5250 10,826 11,836 13,435 20206 5050 17,561 5249 34,641 36,478 36,917 39,962 40,920 41,641 43,386 44,876 41,286 39,693 14,280 15,223 37,046 49,979 23,267 42,516 56,857 57,735 80,043 63,674 16,530 77,679 85,165 103,225 10,978 95,350 106,284 74,526 138,203 133,742 154,825 PBP (day) 20% 4 5 4 11 9 9 9 3 3 3 2 2 5 3 2 2 2 2 5 2 2 36 20 10 8 4 3 2 2 2 9 4 7 4 3 3 2 11 3 15 2 2 2 2 2 2 2 2 2 2 8 7 3 2 6 3 2 2 2 3 10 2 2 2 24 3 2 4 2 2 2 40% 2 3 2 7 5 6 6 2 2 2 1 1 3 1 1 1 1 1 3 1 1 21 12 6 5 2 2 1 1 1 5 2 4 2 2 2 1 7 2 9 1 1 1 1 1 1 1 1 1 1 5 5 2 1 4 2 1 1 1 2 6 1 1 1 14 2 1 2 1 1 1 60% 2 2 2 6 4 5 5 1 1 1 1 1 3 1 1 1 1 1 2 1 1 18 10 5 4 2 1 1 1 1 4 2 4 2 2 1 1 6 2 7 1 1 1 1 1 1 1 1 1 1 4 4 2 1 3 2 1 1 1 1 5 1 1 1 12 1 1 2 1 1 1

kWa kWr

(1)

2.3.2. Estimation of energy use Electrical energy used by electric motors can be estimated using Eq. (2) [40]:

AEU n P L hr

(2)

2.3.3. Estimation of energy saving by using VSDs The energy savings of motors when VSDs are installed can be calculated as [41]:

AESVSD n P L hr SSR

(3)

2.3.4. Economic analysis The annual bill savings (ABS) of motors when VSDs are installed, can be calculated as

ABSVSD AESVSD C

(4)

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2.3.5. PBP A PBP can be expressed mathematically using Eq. (5). The incremental cost (IC) of electric motors when using VSDs has been considered as US$80/kW based on industrial practice in India.

3.2. Results and discussions Using data from Table 3 and Eqs. (1)e(3), load factors, energy use, energy savings and bill savings for all LT electric motors for using VSDs were estimated and presented in Table 6 for 20%, 40% and 60% speed reductions, respectively. From Table 6, it has been observed that motors with serial no. 4, 5, 6, 7, 22, 23, 24, 25, 31, 33, 38, 40, 51, 52, 61 and 65 are operated at very low load factors (i.e. 3e16%). Therefore, it can be stated that sizeable amount of energy is wasted as these motors are operated at very low loads. In this study, authors analyzed load factor for less than 70% for various motors to identify motors with lower load factors so that energy saving measures can be applied to reduce their energy consumption. It was observed that many motors are operated less than 70% of their loads for this industry. Bortoni [45] reported that about 44% of motors in industrial facilities operate at 40% or less of their full load capacities in the US. Only few motors run at anywhere near the full load as mentioned by Capehart et al. [46], based on their energy audit experiences. Authors also mentioned that 75% of the motors have loaded factors less than 60%. One of the authors of Capehart et al. [46] performed over 100 audits of medium-sized manufacturing companies, and reported that the average motor load factors have ranged from about 30e40%. Normally, load factors for most motors in buildings and industrial facilities range from 50% to 70% as reported by Jayamaha [47]. Therefore, installation of VSDs in electric motors to match load requirements could be considered as a potential solution to reduce electric motors energy use along with the emission reduction with a reasonable investment. The estimated annual energy savings (AES) found to be 1,865,925 MWh for 60% speed reduction for LT motors. The corresponding ABS found to be 174,328,711 US$. Saidur et al. [14] studied energy consumption, savings and emission reductions for industrial motors in Malaysia by using different energy savings strategies including VSDs. Authors estimated about 56,329 MWh/year, 93,453 MWh/year, 104,975 MWh/ year of energy can be saved for 20%, 40% and 60% speed reduction, respectively. Authors also estimated about 3,604,995 US$/year, 5,981,015 US$/year and 9,718,400 US$/year can be saved as electric bills for 20%, 40% and 60% speed reductions, respectively. In another study conducted by Saidur and Makhilef [48] found that VSDs are very useful in saving substantial amount of energy for motors used in rubber industriesin Malaysia. They found that annually about 27,039 MWh; 44,858 MWh and 54,689 MWh of energy can be saved for 20%, 40% and 60% speed reduction,

PBPyr

ICVSD ABSVSD

(5)

2.3.6. Estimation of emission reduction The emission released by burning fossil fuels to generate electricity has a negative impact to the environment. Thus the reduction of emission is an important aspect for the protection of environment. The CO2 emission factor to generate electricity is considered to be 316 ton of CO2/TJ based on Reddy and Ray [42]. Thus the amount of emission that can be reduced associated with the energy savings are estimated using Eq. (6) [43,44]:

AERCO2 AES EFCO2

(6)

2.3.7. Estimation of a capacitor rating A capacitor rating for the power factor improvement can be estimated using Eq. (7):

CRR P tan f1 tan f2

(7)

3. Data, results and discussions This section presents data necessary for the analysis of load factors, energy use, energy savings and estimation of emission reductions. These are briey explained in the following sections.

3.1. Data on electrical motors Low Tension (LT) and High Tension (HT) motors were installed for various process operations in this industry. Their rated and actual capacities and usage hours are listed in Tables 3 and 4. These are the necessary data to estimate load factors and energy used by electric motors. Table 5 shows the rated power, power factors and installed capacity of the capacitors for HT motors.

Table 8 Energy savings and bill savings of HT motors. Serial no Load (%) Energy use (MWh) Energy savings (MWh/year) 20% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 63.4 64.5 12.8 25.1 53.8 66.3 69.3 60.5 45.0 58.6 20.2 56.4 64.6 64.1 100,426 102,168 30,413 59,638 185,933 229,133 219,542 222,156 283,530 217,728 247,975 760,182 1,125,590 1,384,560 44,187 44,954 13,382 26,241 81,810 100,818 96,599 97,749 95,800 124,753 109,109 334,480 495,260 609,206 40% 73,311 74,583 22,201 43,535 135,731 167,267 160,266 162,174 158,941 206,977 181,022 554,933 821,681 1,010,729 60% 89,379 90,930 27,067 53,077 165,480 203,928 195,393 197,719 193,778 252,342 220,698 676,562 1,001,775 1,232,258 Bill Savings (US$/year) 20% 4,128,391 4,200,052 1,250,280 2,451,697 7,643,508 9,419,426 9,025,245 9,132,689 8,950,594 11,655,673 10,194,054 31,250,466 46,272,142 56,918,117 40% 6,849,447 6,968,290 2,074,239 4,067,475 12,681,347 15,627,756 14,973,652 15,151,917 14,849,858 19,337,861 16,912,885 51,847,390 76,769,656 94,432,410 60% 8,350,680 8,495,590 2,528,870 4,958,984 15,460,796 19,052,993 18,255,568 18,472,886 18,104,679 23,576,313 20,619,814 63,211,188 93,595,838 115,129,865

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M. Thirugnanasambandam et al. / Energy xxx (2011) 1e8 Table 9 Emission reductions and PBPs of HT motors. Serial no Emission reduction CO2 (ton) 20% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 50,267 51,140 15,223 29,851 93,068 114,691 109,891 111,199 108,982 141,919 124,122 380,504 563,408 693,033 40% 83,398 84,845 25,256 49,526 154,408 190,283 182,319 184,489 180,812 235,457 205,931 631,291 934,744 1,149,805 60% 101,677 103,441 30,792 60,381 188,250 231,989 222,279 224,925 220,442 287,064 251,066 769,657 1,139,620 1,401,817 PBP (days) 20% 2 2 9 5 2 2 2 2 3 2 6 2 2 2 40% 1 1 6 3 1 1 1 1 2 1 4 1 1 1 60% 1 1 5 2 1 1 1 1 1 1 3 1 1 1

factor improvement capacitors will not be economically viable since cost saving is very low. 4. Conclusions It was found that many motors are operated at very low load (i.e. 3e16%). Therefore, application of VSDs can be considered as a potential solution to optimize motor loads to avoid energy wastage by these motors. It may be recommended that industries can use MotorMaster software to estimate load requirements of the plants before installing electric motors for various industrial applications. The potential of annual energy and bill savings for LT motors were found to be about 1,865,925 MWh and 174,328,711 US$, respectively, for 60% speed reduction. It was estimated that annually about 2,122,675 tons CO2 can be reduced for 60% speed reduction. It is also estimated that annually about4,600,386 MWh of energy and 429,768,060 US$ bills can be saved for 60% speed reduction for all HT motors. This will reduce annually about 5,233,400 tons of CO2. It was also found that the average of the PBP is about 2 days for 60% speed reduction using VSDs for both LT and HT motors. In this particular study it is observed that installing both LT and HT capacitor to improve power factor found to be not economically viable owing to low level of energy savings Acknowledgement Authors sincerely thank the National Small Industries Corporation, Government of India and the Management of Gujarat Cement Works, Kuvava,Gujarat, India for providing the data. References
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respectively. Authors also estimated about 1,730,397US$, 2,870,890US$ and 3,500,103US$ annual cost savings for 20%, 40% and 60% speed reductions, respectively. By using data from Table 3 and Eqs. (5) and (6), emission reduction and PBPs for all LT electric motors have been estimated and presented in Table 7 for 20%, 40% and 60% speed reductions. It was estimated that about 2,122,675 tons CO2 emission can be reduced by LT motors annually for 60% speed reduction. Using data taken from Table 4 and Eqs. (2)e(5), energy savings and bill savings for all HT motors were estimated and presented in Table 8. The estimated energy savings by HT motors found to be 4,600,386 MWh/year for 60% speed reductions. This amount will save about 429,768,060 US$/year as electricity bill for 60% speed reduction. By using data from Table 4 and Eqs. (5) and (6), emission reduction and PBPs for all HT motors have been estimated and presented in Table 9. The estimated CO2 emission reduction by HT motors is found to be about 5,233,400 tons annually for 60% speed reduction. The average PBP for using VSDs to reduce energy consumption found to be about 2 days. By analyzing data in Table 5, it has been identied that the improvement of power factor by installing capacitors can also be made. Using data from Table 5 and Eq. (7), the size of capacitors to improve a power factor to 0.99 for HT motors were estimated and presented in Table 10. Direct energy savings with the improvement of power factors with the installation of capacitors are impossible. Based on experiences and literatures, it can be stated that the increased power factor will reduce the line current and therefore, cable loss by only 0.25e0.5%. Therefore, it may be stated that installation of power
Table 10 Size required capacitors and installation cost for HT motors. Serial no KVAr required to improve pf 0.99 (power capacitors) 350 350 900 900 400 50 200 250 90 230 230 130 150 45 Cost of kVAr (INR) at INR 1500/kVAr 185,500 185,500 477,000 477,000 212,000 26,500 106,000 132,500 47,700 121,900 121,900 530,000 68,900 79,500

1 2 3 4 5 6 7 8 9 10 11 12 13 14

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Please cite this article in press as: Thirugnanasambandam M, et al., Analysis of electrical motors load factors and energy savings in an Indian cement industry, Energy (2011), doi:10.1016/j.energy.2011.04.011