DRIVES, CONTROLS & MOTORS FEATURE
SAVING ENERGY WITH ELECTRIC MOTORS
The price of a motor often tends to influence purchasing decisions rather than its operating costs, but with new motor technology delivering greater energy
efficiency, specifying a direct-drive magnetically geared motor could be the answer, says Magnomatics
T
oday, we are increasingly focusing on the efficiency and sustainability of electric
motors, partly due to new Government innovation grants targeting green advancements. However, those purchasing motors are often not the ones that use them, so the focus tends to be on the cost of acquisition rather than the operating costs. Cheaper does not mean better and more efficient – for high use applications the cost of electric motors can be less than 5% of the total cost of ownership. In 2011 the IEA report, Walking the Torque,
laid out quite clearly the issues present with regards to motors, and even whole drive systems, where efficiency was not optimised. An example of this is where synchronous motors are used to drive constant speed pumps or fans controlled via a throttle or valve.
standards of motor efficiency are set by Governments, but although many motor manufacturers are developing solutions that are more efficient, price rather than operating cost tends to influence purchase decisions, which is illogical when the energy cost will be 95% of the cost of ownership. Widespread recognition of climate change
has influenced positive change and now many Governments are supporting the idea of innovation grants, and linking them to the green agenda. The UK’s Industrial Energy Efficiency
Accelerator (IEEA) program (funded by BEIS and managed by the Carbon Trust) is trying to address the cost versus energy issues through the funding of projects that focus on energy efficiency. One of these projects
inefficient gearboxes and pulley systems, commonly used in this sector, the project will demonstrate the energy savings available from this advanced motor technology, compared with currently used IE3 motors equipped with gearboxes and pulleys. The recovery of fuel is a harsh application
and provides the perfect demonstration platform for Magnomatics’ magnetically geared motor in unforgiving operating conditions where the motor will experience high torque, speed fluctuations and vibration. Additionally, thanks to the technology, the shredder can benefit from reduced maintenance times thanks to the removal of gearbox components, and the ability to deal with high torques caused by abnormal loads owing to the drive pole being able to slip safely should material become lodged in the rotor. It will be installed alongside an existing
processing line, allowing for an exact comparison to be made against a traditional processing route, whilst also allowing an opportunity for the trial to tackle other feed materials and provide valuable data.
MAKING SAVINGS It is expected that the demonstrator project using the new motor technology will deliver energy savings of approximately 16% compared with the current IE3 motors equipped with gearboxes and pulleys. This would result in an efficiency saving of over 61,000 tonnes of CO2
after only five years for
a UK market uptake of 40%. IEEA funding was important to this project.
De Almeda (see diagram above) has made
this common knowledge for some time and has concluded that if all elements of these drive systems could be converted to the optimal efficiency, there would be an overall 10% reduction in electricity consumption. This is a significant saving, especially as electric motors are estimated to use 45% of the electricity generated. Most of these motors are used in industrial applications, with transport currently one of the smallest areas.
MOTOR EFFICIENCY The latest IEA Report recommends minimum
is the Caiman project which involves the development of a Wolong Laurence Scoot motor, using Magnomatics’ technology, for use in a refuse shredder which will be manufactured by Donasonic. The installed shredder will use a new
direct-drive magnetically geared motor at Ellgia’s Scunthorpe waste management site. The site produces over 80,000 tonnes per year of refuse derived fuel and solid recovered fuel, an important fuel source for industry and electricity co-generation. It will be used for the production of solid recovered fuel. By removing the need for
/ DESIGNSOLUTIONS
The funding allows project partners to collaborate and cooperate, diminishing financial risk, and allowing the sharing of expertise. The results of this allow the effectiveness of the technology and its carbon/energy saving to be demonstrated with a consortium including both a vendor and a buyer for the shredders, enabling a far more cost-effective and efficient route to market. The development of yet another key energy
saving magnetic drive solution would further cement Magnomatics’ position as a world leader in this technology, attracting sustainable business from international ‘blue- chip’ OEMs and generating significant UK based non-recurring engineering revenues.
Magnomatics
www.magnomatics.com
DESIGN SOLUTIONS | DECEMBER/JANUARY 2021 29
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