Energy 36 (2011) 233e240

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

Energy savings and emissions reductions for rewinding and replacement of industrial motor
M. Hasanuzzaman a, c, *, N.A. Rahim b, c, R. Saidur a, c, S.N. Kazi a
a

Department of Mechanical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia Department of Electrical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia c Centre of Research UMPEDAC, Level 4, Engineering Tower, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia
b

a r t i c l e i n f o
Article history: Received 25 January 2010 Received in revised form 21 September 2010 Accepted 25 October 2010 Available online 24 November 2010 Keywords: Energy savings Industrial motor Emission

a b s t r a c t
Electric motors consume 30e80% of total industrial energy around the world. This study estimates the economic viability of replacing rewound and standard motors with high efciency motors (HEMs) in the industrial sector. The efciency of a motor is degraded when it is rewound and it is better to rewind a larger motor compared with a smaller motor. It was found that a HEM can save on average 5.5% of energy compared with a standard motor. In addition, the payback period was found to be reasonable when a motor is operated at a 50% load. HEMs will also save a sizeable amount of energy and reduce emissions. It was estimated that 67,868 MWh/year energy and US$ 4,343,531 per year could be saved by introducing HEMs. By contrast, 44,582 tons of CO2, 333 tons of SO2 and 122 tons of NOx emissions could be reduced through the aforementioned energy savings. This study found that rewound motors of a larger size and HEMs are economically viable. 2010 Elsevier Ltd. All rights reserved.

1. Introduction The industrial sector is the largest energy user around the world. The electrical energy consumption in Malaysia has increased sharply in the past few years, and modern energy efcient technologies are desperately needed for the national energy policy [1]. Industrial motors use a major fraction of total industrial energy. Electric motors have broad applications in industry, business, public service and household electrical appliances, powering a variety of equipment including wind blowers, water pumps, compressors and machine tools. In industrially developed and large developing countries, electric motors account for a considerable proportion of total national power consumption [2]. The induction motor is the main driven system in modern industrial society [3]. Electric motors consume 30e80% of total industrial energy around the world (Table 1). In Malaysia, electric motors consume about 48% of the industrial energy consumption. Electric motors are also responsible for consuming about 40% of electricity worldwide. In Malaysia, the bulk of electricity in the industrial and commercial sectors is consumed by electric motors. Activities and processes in

* Corresponding author. Centre of Research UMPEDAC, Level 4, Engineering Tower, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia. Tel.: 603 79677611; fax: 603 79675317. E-mail addresses: hasan@um.edu.my, hasan.buet99@gmail.com (M. Hasanuzzaman). 0360-5442/$ e see front matter 2010 Elsevier Ltd. All rights reserved. doi:10.1016/j.energy.2010.10.046

industries are heavily dependent on electric motors for compacting, cutting, grinding, mixing, fans, pumps, materials conveying, air compressors and refrigeration. Motors are also used widely in the commercial sector for air conditioning, ventilation, refrigeration, water pumping, lifts and escalators. Energy losses in a large number of industries prevail, and potential energy efciency improvements are imminent [4]. Among the various sectors contributing to greenhouse gas (GHG) emissions, the contribution of the industrial sector is signicant. Thus, lowering GHG emissions from the industrial sector would reduce overall GHG emissions. Energy conservation means less reliance on energy imports and, thus, less GHG emissions. Previous studies have reported that the implementation of selected options at little or no cost in the industrial sector could reduce GHG emissions by 10e30% [5,6]. The instantaneous emissions associated with electricity generation vary with the demand for electricity. Indeed, the fuel mix needed for electricity generation changes with the kinds of power plants needed to supply the amount of electricity required as well as the uctuating rate of the corresponding emissions [7]. Any reduction in carbon dioxide emissions afforded by a demand-side intervention in the electricity system is typically assessed by means of an assumed grid emissions rate, which measures the CO2 intensity of electricity not used as a result of the intervention. This emissions rate is called the marginal emissions factor (MEF). The accurate estimation of MEF is crucial for performance assessment because its application leads to decisions regarding the relative merits of CO2 reduction strategies

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Nomenclature AES c COEF E EF F GEN hp hr L NCV OXID Expected annual bill savings (US$) Average energy cost (US$/kWh) Emission coefcient of fuel (kg/kg or litter) Motor efciency rating (%) Emission factor (kg/kWh) Amount of fuel (kg or litter) Electricity delivered to the grid (kWh) Motor rated horsepower Annual operating hours Load factor (percentage of full load) Net caloric value of fuel Oxidation factor of the fuel

0.746

Conversion factor from horsepower to kW

Subscripts BM Build margin ee Energy-efcient motor i Fuel type j Power plant MEF Marginal emission factor OM Operational margin re Rewind motor std Standard motor w Emission weighted factor y Year

[8]. Electricity generation has recently focused on the problems of urban air pollution, acid deposition, contamination from nuclear accidents and nuclear wastes and the increased concentration of carbon dioxide and other GHGs in the atmosphere [9]. The electricity generation sector in Korea is under pressure to mitigate GHGs as directed by the Kyoto Protocol [10]. Energy savings and emissions reductions can be achieved either by reducing total energy use or by increasing the production rate per unit of energy used. By contrast, improving energy efciency is the key to reducing GHG emissions. Therefore, energy research organisations and governments are actively engaged in developing methods for assessing energy efciency. This assessment can provide a basis for establishing energy policy and help reduce GHG emissions [11]. Fig. 1 presents the distribution of energy consumption by motor for various applications in a typical plant. Saidur identied the following losses occurring in induction motors [2]. The efciency of a motor is determined by intrinsic losses that can be reduced only by changing the motors design. There are two types of intrinsic losses: xed losses, and variable losses. Fig. 2 shows the various losses in the motor. Fixed losses are independent of motor load and consist of magnetic core losses and friction and windage losses. Magnetic core losses consist of eddy current and hysteresis losses in the stator. Variable losses are dependent on load and consist of resistance losses in the stator and rotor and miscellaneous stray losses. Resistances to current ow in the stator and rotor result in heat generation that is proportional to the resistance of the material and the square of the current. Stray losses arise from a variety of sources and are difcult to either measure directly or calculate, but are generally proportional to the square of the rotor current [2]. A motors function is to convert electrical energy to mechanical energy for performing useful work.

Even though standard motors operate efciently in the typical range of 83e92%, energy efcient motors perform signicantly better. An efciency gain to only 92e94% results in a 25% reduction in losses. Motor energy losses can be segregated into ve major areas, each of which is inuenced by design and construction [29e33]. A common cause of motor failure is a problem with the motor windings, and the solution often is to rewind the old motor. Because it is economical in terms of initial cost, rewinding motors is common, particularly for motors with a higher horsepower. However, the motor rewinding process often results in a loss of motor efciency. It is generally cost effective to replace motors under 20 horsepower with new high efciency motors (HEMs) rather than rewind them. When deciding whether to buy a new motor or rewind the old one, it is wise to consider the cost difference between the rewound and a new HEM as well as the relevant energy costs to operate them. A paperboard plant with 485 motors, where an average of three motors were repaired per month, of which about 70% required rewind or replacement [35]. The facility operated 8000 h/year. Collected motor information is shown in Table 2. A robust and efcient induction motor usually converts 90e95% of input electrical power into mechanical work. However, because of the huge amount of energy such motors use, a minor change in efciency will have a major impact on operating cost. A HEM uses specic materials to reduce core and copper losses. Therefore, it generates less heat and requires smaller and more energy efcient cooling fans [36]. Future energy challenges and the environmental crises such as fossil fuel emissions and global warming are urging the world to focus on energy saving programs more than ever. An effective way to face these challenges is to improve the efciency of

Table 1 Electric motor energy use by country. Country US UK EU Jordan Malaysia Turkey Slovenia Canada India China Korea Brazil Australia South Africa Motor energy usage (%) 75 50 65e72 31 48 65 52 80 70 60 40 49 30 60 Reference [13, 14] [15] [16, 17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] Fig. 1. Energy consumption by motor for various applications in a typical plant [12].

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Copper (I2R) loss 58%

Stator loss Rotor loss

Table 3 End use electricity consumption by electric motor in the industrial sector in 2006 [39]. Industry No of industry Electricity consumption (MWh/year) 22,293 5835 32 96,648 100,097 47,710 633,541 27,531 56,640 29,791 28,405 99,131 55,738 3635 26,929 1,233,957 Average (MWh/year) 4458 2917 16 19,329 25,024 6815 158,385 13,765 28,320 2708 9468 24,782 27,869 1211 8976

Core (Iron) loss 12%

Eddy current loss Hysteresis loss External fan windage Internal fan windage Bearing, grease, loading spring Surface loss due to current
Food and beverages Textile Fabricated metal Paper industry Glass Wood Basic iron steel Automobile Chemical Rubber Plastic Cement Petrochemical Consumer appliances Electronics Total 5 2 2 5 4 7 4 2 2 11 3 4 2 3 3 59

Friction and windage loss 14%

Stray losses 15%

Harmonics Leakage flux

Fig. 2. Losses in a typical motor [30,34].

electric motors, one of the greatest energy consumption apparatuses in the world [37]. Energy efciency is one of the most important and cost effective ways of meeting the demands of sustainable development [38]. In the literature, a number of works have been reported about the use of HEMs to reduce the energy consumption of motors. However, there is no detailed work on the cost effectiveness of rewound motors. The aim of this study is to analyse the energy consumption, energy savings, emissions reductions, bill savings and payback period of rewound, standard and high efciency motors with different capacities and loading operations. 2. Methodology 2.1. Data collection Tenaga Nasional Berhad (TNB) conducted a detailed survey on consumer behaviour towards electricity consumption and the end usage of electricity in the industrial sector in Malaysia in 2006. The survey investigated total energy consumption, types of energy supply, types of equipment and energy consumption and usage behaviour. The energy consumption of electric motors in the industrial sector in Malaysia was collected from the TNB nal report and is presented in Table 3. 2.2. Formulation of energy savings, bill savings and payback period The primary goal of a motor manufacturer is reducing production costs while preserving available power. A motor can be made

to be more efcient by improvements in design: magnetic cores with plates made of ferrosilicon alloys, better lled slots using more copper, larger rotor conductors, improvements in air-gaps, core heads, fans and bearings, and better dimensional design. HEMs typically cost 10e25% more than standard motors [40]. The annual energy savings (AES) attained by replacing standard efcient motors with high energy efcient motors can be estimated by using the following equation [40e42]:

 AES hp L 0:746 hr

 1 1 100 Estd Eee

(1)

The AES attained by replacing rewound motors with high energy efcient motors can be estimated by using the following equation:

 AES hp L 0:746 hr

 1 1 100 Erd Eee

(2)

The annual bill savings associated with the above energy savings can be calculated as [42]:

Savings AES c

(3)

A simple payback period for different energy saving strategies can be calculated by using Equation (4).

Simple payback period years

Incremental cost Annual dollar savings

(4)

The input data needed to estimate the energy savings and payback period for different strategies are shown in Tables 5e7.

Table 2 Breakdown of motor horsepower and motor repair [35]. Motor size <20 horsepower 20 25 30 40 50 75 100 125 400 750 Number of motors 347 (Replacement, not repaired) 15 10 2 3 27 18 21 32 6 4

2.3. Motor efciency and rewind cost Motors operate at their maximum efciency when they are fully loaded. Efciency drops dramatically below 70% loading.
Table 4 Motor rewind practices [44]. Motor hp 1e5 6e20 21e50 51e100 100e200 >200 Failed motor rewound (%) 20 61 81 90 91 95

236 Table 5 Typical motor efciency and cost [46].

M. Hasanuzzaman et al. / Energy 36 (2011) 233e240 Table 7 Input data for motor energy consumption, energy and bill savings [19]. Parameters Average usage hours Average electricity cost (US$/kWh) Value 6000 0.064

Motor hp Rewind High efciency Standard motor Rewind High efcient cost motor cost efciency efciency motor (US$) (US$) efciency 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 330 380 500 550 600 660 760 880 980 1100 1320 1650 2200 2400 2650 2860 3080 3500 375 525 638 825 975 1238 1500 1950 2325 3750 4500 5325 7385 8650 10,620 13,650 15,100 20,000 82.5 83.5 86.0 86.6 87.3 88.7 89.4 89.7 90.4 90.8 90.5 91.1 90.6 91.8 92.3 93.1 93.2 92.6 80.5 81.7 84.2 85.0 85.8 87.7 88.5 88.9 89.7 90.2 90.0 90.6 90.1 91.3 91.8 92.6 92.8 92.2 90.8 91.3 92.3 92.6 93.2 93.9 94.3 94.5 95.0 95.2 95.3 95.5 95.2 95.5 95.7 95.7 95.9 96.0

motor is better to rewind than a smaller motor is (Table 4). Green Motor Practices Group members investigated the efciency of rewound motors (Fig. 3). Based on the investigation, the best tted equation is used to calculate this efciency (Table 5). The efciency of standard, rewound and high efciency motors under different loading operations are calculated using Fig. 4 and shown in Table 6. The increment price of a HEM is calculated based on Table 8 and shown in Table 14.

2.4. Reduction of emissions from the electricity consumption of the motor Energy savings by using a HEM have been calculated based on the survey of 59 industries in Malaysia. This showed that HEMs can save an average 5.5% energy (Table 10). 2.4.1. Emissions calculation The Kyoto Protocol species a exible mechanism called the clean development mechanism as a cost effective instrument for mitigating global GHG emissions. The clean development mechanism facilitates the participation of developing countries since emissions baselines are necessary to determine emissions reductions and the baseline emissions factors of power plants can be calculated by using the combined margin [49]. The combined margin is a combination of the operating margin and build margin factors [49,50]. The analysis of the baselines is then carried out by using a simple operating margin and simple adjusted operating margin because the low cost/must run resources in Peninsular, Sarawak and Sabah constitute less than 50%. This result was found to be similar to those for the simple operating margin because low cost/must run resources constitute less than 50% of the total grid generation. Therefore, the rest of this study and the baseline calculations will only focus on the simple operating margin [49]. 2.4.2. Operating margin The operating margin refers to adjustments in the existing grid mix because of project activity. The planning horizon is rather short-term. Therefore, the short-term marginal costs (the operating costs for the last unit produced by a plant to meet the demand) are relevant. The emissions produced by the plants, which are on the margin, are taken to calculate the operating margin [49]. The operating margin has been calculated by using Equation (5):

Over-sizing is often a means to ensure greater reliability [43]. A motor needs to be rewound for two reasons: (i) when excess heat has damaged the insulation so that electricity passes from winding to winding without going through all of them or (ii) when the winding has been detached at a place away from the end of the coil. The efciency of a motor is degraded when it is rewound. Most studies of the effects of rewinding have found that some degradation of efciency occurs each time a motor is rewound. The available studies are characterised by small samples and varied methods; however, the ndings specify that the degradation of efciency associated with rewinding falls in the range of 1e2% [44]. According to a recent study by the Green Motor Practices Group, properly planned and performed rewinds cause no efciency loss in electric motors. Performance improvements, increased power density, reliability and efciency come from advances in materials and craftsmanship. For example, better resins and insulating tapes improve thermal dissipation. Automated coil forming technology and the precise application of insulating tapes ensure consistent coil duplication for improved installation and operation. A qualied service provider can ensure that a rewound motor meets the original efciency [43]. A larger

Table 6 Efciency of standard, rewound and high efciency motors at different loads [47]. Motor hp Load (50%) Estd 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 70.1 71.0 73.1 73.6 74.2 75.4 76.0 76.2 76.8 77.2 76.9 77.4 77.0 78.0 78.5 79.1 79.2 78.7 Erd 68.4 69.4 71.6 72.3 72.9 74.5 75.2 75.6 76.2 76.7 76.5 77.0 76.6 77.6 78.0 78.7 78.9 78.4 Eee 77.2 77.6 78.5 78.7 79.2 79.8 80.2 80.3 80.8 80.9 81.0 81.2 80.9 81.2 81.3 81.3 81.5 81.6 Load (75%) Estd 73.8 74.7 77.0 77.5 78.1 79.4 80.0 80.3 80.9 81.3 81.0 81.5 81.1 82.2 82.6 83.3 83.4 82.9 Erd 72.0 73.1 75.4 76.1 76.8 78.5 79.2 79.6 80.3 80.7 80.6 81.1 80.6 81.7 82.2 82.9 83.1 82.5 Eee 81.3 81.7 82.6 82.9 83.4 84.0 84.4 84.6 85.0 85.2 85.3 85.5 85.2 85.5 85.7 85.7 85.8 85.9 Load (100%) Estd 82.5 83.5 86.0 86.6 87.3 88.7 89.4 89.7 90.4 90.8 90.5 91.1 90.6 91.8 92.3 93.1 93.2 92.6 Erd 80.5 81.7 84.2 85.0 85.8 87.7 88.5 88.9 89.7 90.2 90.0 90.6 90.1 91.3 91.8 92.6 92.8 92.2 Eee 90.8 91.3 92.3 92.6 93.2 93.9 94.3 94.5 95.0 95.2 95.3 95.5 95.2 95.5 95.7 95.7 95.9 96.0

1.2 Efficiency Reduction (%) 1 0.8 0.6 0.4 0.2

y = 8E-05x 2 - 0.018x + 1.3844 R2 = 0.9964

0
20 30 40 50 Motor Capatity (hp) 60 70 80

Fig. 3. Efciency reduction of a rewound motor [45].

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237

100 80

Table 9 Average electric motor life [48]. Motor hp Less than 1 1e5 5.1e20 21e50 51e125 Greater than 125 Average life (year) 12.9 17.1 19.4 21.8 28.5 29.3 Life range (year) 10e15 13e19 16e20 18e26 24e33 25e38

Efficiency (%)

60 40 20 0 0 20 40 60 80 100 Percentage of full load (%)

Fig. 4. Relationship between motor loading and efciency [2].

Table 10 Motor horsepower and percentage of energy savings. Motor hp 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 Average Energy savings (%) 10.1 9.3 7.3 6.9 6.8 5.9 5.5 5.4 5.1 4.8 5.3 4.8 5.1 4.0 3.7 2.8 2.9 3.7 5.5

P EFOM;y
i;j

Fi;j;y COEFi;j P
j

GENj;y

(5)

The emissions coefcient COEFi,j is obtained from Equation (6):

COEFi;j NCVi EF OXID

(6)

2.4.3. Build margin The build margin stands for the investment alternatives in other sources of electricity. The planning horizon is rather long-term. Planned projects can be entirely displaced or only delayed by the project, and it also represents the trend or types of technology and fuels used for newly installed capacity power generation. The build margin emissions factor is calculated as the generation-weighted average emissions factor by using the following formula [49]:

EFMEF;y wOM EFOM;y wBM EFBM;y

(8)

P EFBM;y
i;j

Fi;j;y COEFi;j P
j

GENj;y

(7)

2.4.4. Combined margin The nal step in applying the consolidated methodology for determining the baseline is to calculate the baseline emissions factor. This is calculated as the weighted average of the emissions factor of the operating margin and build margin. The formula used to calculate this weighted average combined marginal emissions factor is as follows [49]:
Table 8 Increment price of a HEM over a standard motor [19]. Motor hp 1 2 3 4 5.5 7.5 15 20 25 30 40 50 60 75 Increment price (US$) 24 25 27 60 65 91 147 197 246 257 231 281 574 518

The emissions factors of the operating margin and build margin are weighted equally, each 50%, by default, although different weights can be used with appropriate justication. The MEF of the electricity system in Great Britain from 1st January 2002 to 31st December 2009 was estimated as 0.69 kg CO2/kWh. An attempt was then made to project the MEF into the future to enable the assessment of long-term demand-side interventions scheduled to be built over the coming seven years and estimated of the MEF of 0.60 kg CO2/kWh in 2016 [8]. Table 11 shows the combined MEFs in 2006 in Malaysia. 3. Results and discussion 3.1. Rewinding a failed motor or replacing with a HEM Energy savings, bill savings and the payback period associated with energy savings as a result of using a HEM are presented in Table 12 for different motor sizes and loads. Replacing a failed motor rather than rewinding saves energy in a number of ways. The market assessment found that industrial end users rewind 40% of the motors that fail each year and the percentage of motors repaired increases with the horsepower capacity of the motor [44]. According to the energy savings analysis, using HEMs can save

Table 11 Combined MEFs in 2006 in Malaysia. Combined marginal emissions factors (kg/kWh) CO2 0.6595 SO2 0.0049 NOx 0.0018

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M. Hasanuzzaman et al. / Energy 36 (2011) 233e240

Table 12 Energy and bill savings and payback period for a HEM over a failed rewound standard motor at different loads. Motor hp Increment price (US$) Energy savings (kWh/year) Load (50%) 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 45 145 138 275 375 578 740 1070 1345 2650 3180 3675 5185 6250 7970 10,790 12,020 16,500 1855 2541 2744 3813 4873 4956 5490 7020 8188 9199 12,202 14,911 19,569 19,024 23,377 23,026 27,514 45,215 Load (75%) 2643 3620 3909 5433 6942 7060 7820 10,001 11,664 13,104 17,383 21,242 27,877 27,102 33,302 32,803 39,196 64,412 Load (100%) 3154 4320 4665 6483 8284 8425 9332 11,935 13,919 15,638 20,744 25,349 33,267 32,341 39,740 39,144 46,774 76,866 Bill savings (US$/year) Load (50%) 85 117 126 175 224 228 253 323 377 423 561 686 900 875 1075 1059 1266 2080 Load (75%) 122 167 180 250 319 325 360 460 537 603 800 977 1282 1247 1532 1509 1803 2963 Load (100%) 145 199 215 298 381 388 429 549 640 719 954 1166 1530 1488 1828 1801 2152 3536 Payback period (year) Load (50%) 0.5 1.2 1.1 1.6 1.7 2.5 2.9 3.3 3.6 6.3 5.7 5.4 5.8 7.1 7.4 10.2 9.5 7.9 Load (75%) 0.4 0.9 0.8 1.1 1.2 1.8 2.1 2.3 2.5 4.4 4.0 3.8 4.0 5.0 5.2 7.2 6.7 5.6 Load (100%) 0.3 0.7 0.6 0.9 1.0 1.5 1.7 1.9 2.1 3.7 3.3 3.2 3.4 4.2 4.4 6.0 5.6 4.7

energy but increases the initial purchase cost of the new motor (Table 12). The amount of saved energy is increased by increasing the motor load. Payback period analysis shows that payback period increases with the horsepower of the motor. It has also been found that payback period decreases by increasing the percentage of the load. Therefore, it is better to rewind a larger horsepower motor. Table 4 shows that 81% of motors with more than 20 horsepower are rewound and that this percentage is increased by increasing the horsepower.

decreases by increasing the percentage of the load. Table 9 shows that the average motor life is more than 12 years.

3.3. Energy and bill savings and emissions reductions Energy is an indispensable factor for continuous development and economic growth. The demand for energy is increasing rapidly in developing countries because of automation, industrialisation and urbanisation. The energy demand in Malaysia increased by 20% between 1999 and 2002 [51]. As a result, the installation capacity of energy increased from 14,291 MW in 2000 to 19,227 MW in 2005. It is predicted that it will be 25,258 MW by the end of 2010 [52,53]. Electric motors consume about 48% of the energy in the industrial sector in Malaysia. By using HEMs, about 5.5% energy could be saved. The amounts of energy savings, bill savings and emissions reductions are shown in Table 14. A survey result of 59 industries in Malaysia showed that the total amount energy savings would be is 67,868 MWh/year and the corresponding bill savings US$ 4,343,531 per year. In Malaysia, there are about 3000 industries in different sectors [39]. If HEMs could be used in all these industries, about

3.2. New standard efcient motor or HEM Energy savings, bill savings and the payback period associated with energy savings as a result of using a HEM are presented in Table 13 for different motor sizes and loads. According to the energy savings analysis, using HEMs can save energy (Table 12). The amount of saved energy is increased by increasing the motor horsepower and operating load. Payback period analysis shows that the payback period is less than two years even though the motor is operated at a 50% load. It has also been found that payback period

Table 13 Energy and bill savings and payback period for a HEM over a standard motor at different loads. Motor hp Increment price (US$) Energy savings (kWh/year) Load (50%) 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 63 80 97 132 167 202 237 306 376 446 550 725 899 1073 1422 1770 2119 2816 1459 2020 2090 2955 3819 4110 4591 5964 7051 8041 10,990 13,316 17,553 16,668 20,269 19,208 23,861 40,281 Load (75%) 2078 2878 2977 4210 5440 5854 6540 8496 10,045 11,455 15,656 18,970 25,005 23,745 28,875 27,364 33,992 57,383 Load (100%) 2480 3435 3552 5023 6491 6986 7805 10,138 11,987 13,670 18,683 22,637 29,840 28,336 34,458 32,654 40,564 68,477 Bill savings (US$/year) Load (50%) 67 93 96 136 176 189 211 274 324 370 506 613 807 767 932 884 1098 1853 Load (75%) 96 132 137 194 250 269 301 391 462 527 720 873 1150 1092 1328 1259 1564 2640 Load (100%) 114 158 163 231 299 321 359 466 551 629 859 1041 1373 1303 1585 1502 1866 3150 Payback period (year) Load (50%) 0.9 0.9 1.0 1.0 1.0 1.1 1.1 1.1 1.2 1.2 1.1 1.2 1.1 1.4 1.5 2.0 1.9 1.5 Load (75%) 0.7 0.6 0.7 0.7 0.7 0.7 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.0 1.1 1.4 1.4 1.1 Load (100%) 0.5 0.5 0.6 0.6 0.6 0.6 0.7 0.7 0.7 0.7 0.6 0.7 0.7 0.8 0.9 1.2 1.1 0.9

M. Hasanuzzaman et al. / Energy 36 (2011) 233e240 Table 14 Energy and bill savings and the potential emissions reduction of motors in the surveyed industries. Industry Energy savings (MWh/year) Bill savings (US$/year) Emission reduction CO2 (tons) 805 211 1 3492 3616 1724 22,890 995 2046 1077 1026 3581 2014 131 973 44,582 SO2 (tons) 6 2 0 26 27 13 171 7 15 8 8 27 15 1 7 333 NOx (tons) 2 1 0 10 10 5 63 3 6 3 3 10 6 0 3 122

239

Food and beverages Textile Fabricated metal Paper industry Glass Wood Basic iron steel Automobile Chemical Rubber Plastic Cement Petrochemical Consumer appliances Electronics Total

1226 321 2 5316 5505 2624 34,845 1514 3115 1639 1562 5452 3066 200 1481 67,868

78,471 20,540 113 340,200 352,341 167,939 2,230,064 96,909 199,373 104,866 99,986 348,943 196,199 12,795 94,790 4,343,531

345,084 MWh/year of energy could be saved. GHG emissions reduction is one of the most important challenges. By introducing high energy efciency motors, GHG emissions could be reduced by 44,582 tons of CO2, 333 tons of SO2 and 122 tons of NOx in the 59 industries surveyed in Malaysia. 4. Conclusion Industrial motor efciency improvement is one of the most important energy saving options. By introducing HEMs into the industrial sector, 5.5% of energy could be saved. The HEM payback period range is 0.5e2 years, even though the motor is operated at a 50% load. Rewinding a motor degrades its efciency in the range of 1%e2%. By contrast, rewinding large horsepower motors is economically viable. Using HEMs in the industrial sector in Malaysia could save a huge amount of energy and reduce emissions. The proper planning of rewinding and replacing motors (with HEMs) could save about 6% of their total yearly energy consumption. Energy savings and emissions reductions are greater at higher motor operation loads. References
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