A global motor replacement success story: Insights from a steel wire company [MA17]

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Date & Time

March 4, 2025 ; 15h00 - 16h00 CET

Speaker

Kurt Stockman, Ghent University, Department of Electromechanical Systems and Metal Engineering

Description

This webinar outlines the process of implementing a successful worldwide motor replacement programme at a large steel wire company. To meet its sustainability goals, the company decided to evaluate the potential benefits of upgrading to high-efficiency motors (IE4 or IE5) in its wire drawing machinery. The installed base consists of over 1,000 machines, which originally used frequency-controlled IE2 and IE3 induction motors.

Prof. Kurt Stockman of Ghent University will discuss the various phases of the project, starting with the collection of energy efficiency data from manufacturers. He will also cover the validation testing of this data based on motor performance assessments and an analysis of the compatibility of the selected high-efficiency motors with the original power electronic converters. The motor analysis includes induction motors, synchronous reluctance motors, and permanent magnet motors.

Following the technical evaluation of potential energy savings, the economic factors, including payback periods, were analysed. Additionally, the presentation will address the complexities of different energy costs across various regions worldwide and their impact on the payback period.

Finally, the speaker will discuss the actual rollout of the motor replacement initiative and share the initial field results of the energy measurements.

Following the presentation, you will have plenty of time to engage with the speaker during the Q&A session.

Recordings

Key takeaways

• Company Overview: Bekaert, a global leader in steel wire transformations, aims for a 46.2% reduction in scope 1 and scope 2 greenhouse gas emissions, focusing on energy efficiency due to the electricity-intensive nature of the industry (1,650 kWh/t).
• Project Scope: The company initiated a project to replace older IE1, IE2, and IE3 induction motors (IM) with high-efficiency motors (IE4 or IE5) in their wire drawing machinery, which processes 1 million tonnes of tire cord annually with a fleet of 25,000 machines.
• Load Profile Analysis: Emphasis was placed on the widely used 22kW - 1000 rpm machines (3,500 units, 85% average uptime). Most machines operated in the field weakening region, necessitating a detailed energy efficiency analysis.
• Benchmarking: Collected data on existing motor technologies (IE1, IE2, IE3) frequently integrated with or without Variable Speed Drives (VSD) to establish performance benchmarks.
• Technology Assessment: Conducted thorough evaluations of state-of-the-art motor technologies, including Induction Motors (IM-IE4), Synchronous Reluctance Motors (SynRM), Permanent Magnet Motors (PM), and Permanent Magnet Assisted Synchronous Reluctance Motors (PMSM).
• Performance Validation: Customized motors tailored to the specific load profiles were developed, leading to an 8.95% efficiency increase for replaced IE1 motors and a 5.75% increase for IE3 motors, reducing power loss by 1 to 1.5 kW per hour.
• Economic Analysis: Evaluated payback periods and internal rate of return (IRR), accounting for variables such as original motor type, potential VFD replacements, and regional electricity costs. Average payback was 2 years for IE1 and 4 years for IE3 motors, supporting management's decision for a comprehensive replacement programme.
• Implementation Success: Replacement of all 3,500 motors was completed within 3 years, with new installations featuring the customized PMSM motors as standard.
• Lessons Learned:
  • Custom motor solutions can significantly enhance business cases for large-scale replacements.
  • Drive compatibility issues can arise, potentially adding costs if VSDs must also be replaced.
  • Efficiency measurements are crucial in the field weakening regions, as IE standards do not currently address this aspect.
  • Positive results from this programme encourage the company to explore replacements for additional motor systems, specifically the 15kW and 45kW categories.

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