Lot 30 ELECTRIC MOTORS & Drives

Transcription

1 Lot 30 ELECTRIC MOTORS & Drives Anibal De Almeida ISR University of Coimbra ISR University of Coimbra 1

2 Motor System Energy Use Global Electricity demand by end-use Source: A+B International 2008 * * Industrial Motors 40%

3 Industrial Motor System Energy Use Electricity Consumption in the European Union Industrial Sector Source: ISR University of Coimbra

4 Efficiency Classes and Market Transformation

5 Beyond IE3 - Super-Premium Motors -NEMA Premium IE3) have 15-20% lower losses than IE2 motors A Super-Premium (new IE4 Class) must have at least a 15% loss difference in relation to IE3 / Premium What is the feasibility and the ambition? Are IE5 Ultra-Premium (20% lower losses than IE2) motors possible?

6 Average loss fraction in SCIMs as a function of the rated power

7 IE4-Super Premium Motor Promising Technologies A- Fixed Speed -Induction motors -Line-Start Permanent Magnet with Auxiliary Rotor Cage for fixed speed applications. B-Variable Speed applications Using a electronic Variable Speed Drive (VSD) -Permanent Magnet Motor -Rare Earth -Ferrite with Amorphous Metals -Synchronous Reluctance Motors -Speed and torque control is possible -Large energy savings possible (e.g. variable flow pump and fan applications)

8 IEC-NEMA Commercial Motor Technology Classes

9 Potential loss reduction in a radial-flux 30-kW, 4-pole, 50-Hz electric motor (Cases 1 & 2: design improvement and eventual use copper in the rotor cage; Case 3: use of amorphous metal in the core; Case 4: variable-reluctance synchronous technology with or without auxiliary squirrel-cage for starting; Case 5: use of a larger/superior frame size).

10 Radial-flux Motor Commercial Models

11 IE4 Super Premium Induction Motors Rated Output: 3 to 355 kw Frame sizes: EN Standard 132S to 355A/B Number of poles: 2, 4 and 6 Voltage: 400V, 50 Hz

12 Hybrid Rotor Motor Commercial Models

13 Radial-flux Motor Commercial Models

14 Best Available Technologies (BAT) Synchronous Reluctance Motors ISR University of Coimbra 14

15 Same stator size, different rotor type: loss reduction (note: stator copper losses slightly increase and rotor losses are reduced to zero).

16 Rated speed in some commercial motor commercial models of different classes

17 IEC Efficiency Classification Standard

18 Reference prices ( /kw, absolute and p.u.) of commercial fixed-speed 4-pole, 50-Hz SCIM and LSPM models with standard frame sizes

19 Ferrite Magnets As alternative to Rare-Earth

20 Amorphous Metal Ribbon Casting

21 Magnetic Properties-AM Vs Si Steel

22 Axial-flux PMSM, using amorphous metal in the core and ferrite PMs (Source: Hitachi Ltd.)

23 Efficiency of 11-kW axial-flux PMSM, using amorphous metal in the core and ferrite PMs (Source: Hitachi Ltd.)

24 Axial/oblique-flux PMSM, using ferrite PMs (Source: NovaTorque)

25 System efficiency of 3-kW axial/oblique-flux PMSM, using ferrite PMs (Source: NovaTorque)

26 Best Available Technologies (BAT) Permanent Magnet Synchronous Motors (PMSM) ISR University of Coimbra 26

27 Full-load efficiency as defined by the proposed 2nd edition of IEC and theoretical limits for commercial models.

28 Comparison of Different 11-kW, 4-pole, 50-Hz Motors

29 Motor Drive Efficiency Dependency on the Load and Speed EFFICIENCY MAPS PMSM & SCIM

30 Motor Efficiency Trends Synchronous motors - PMSM/LSPMs and VRSMs - prove to be significantly more efficient than SCIMs, in the low power range. In general, synchronous technology has a flatter efficiency curve, being less dependent on the motor load, which is an important advantage since most motors operate at partial load and/or with variable load. IE4 Super Premium SCIM are already a reality, and they cost only 15% more than IE3-Class SCIMs, - an excellent option for small-medium power ranges. The proposed IE5 Ultra-premium Efficiency Levels are feasible. This fact is particularly important in the low power range, in which there is the largest efficiency gain potential

31 Methodology Outline 1. Product Definition, Standards & Legislation 2. Economics & Market 3. Consumer Analysis & Local Infrastructure 4. Technical Analysis of Existing Products 5. Definition of Base Case EuP EcoReport 7. Improvement Potential 6. Technical Analysis of Best Available Technology (BAT) 8. Policy, Impact and Scenario Analysis ISR University of Coimbra 31

32 LOT 11 Product Definition In Regulation 640/2009 electric motor is defined as a single speed, three-phase 50 Hz or 50/60 Hz, squirrel cage induction motor that: has 2 to 6 poles, has a rated voltage of U N up to V, has a rated output P N between 0,75 kw and 375 kw, is rated on the basis of continuous duty operation. ISR University of Coimbra 32

33 Product Definition Lot 30: Products outside the scope of Regulation 640/2009 on electric motors, such as: special-purpose inverter duty motors (asynchronous servo motors), permanent magnet motors, motors cooled by their load (fans), including motors and products under Article 1, points 2(b), (c) and (d) drives, such as soft starters, torque or variable speed drives (VSD) from 120W 1 000kW. Motors in the scope of the Regulation 640/2009 from 375kW 1 000kW. ISR University of Coimbra 33

34 LOT 30 Included in the study are: motors that are capable of continuous duty operation motors that are integrated into other equipment but that can be tested separately have a rated power P N from 0,12 kw to 1000 kw ISR University of Coimbra 34

35 Categorisation For the purpose of this study, motors shall be divided into three major categories according to output power: 1. Small Motors 120 W to 750 W 2. Medium Motors 0,75 kw to 375 kw (motors NOT covered by Reg. 640/2009) 3. Large Motors 375 kw to 1000 kw Large Motors include LV an MV motors ISR University of Coimbra 35

36 Drives The high potential savings of Variable Speed control, especially in centrifugal load applications, is also widely recognized and is to be the subject of further analysis including hardware, software and interaction with the motor, to evaluate its combined efficiency. Other motor controllers, which can be applied in loads with small variability, such as Soft- Starters. ISR University of Coimbra 36

37 Focus on System approach ISR University of Coimbra 37

38 EN Particularly important is the work being carried out by CENELEC TC22X Technical Committee: EN50598 Parts 1-2-3: International Standard: Energy efficiency for Power drive systems, motor starters, power electronics and their driven applications. ISR University of Coimbra 38

39 EN ISR University of Coimbra 39

40 EN EN : Procedure for determining the energy efficiency indicators of motor driven applications by using the extended product approach and semi analytical models EN : Energy efficiency indicators for Power drive systems and Motor starters EN : Environmental aspects and product declaration for Power drive systems and Motor starters ISR University of Coimbra 40

41 EN This Standard specifies the energy and eco-design requirements for power driven systems, motor starters, power electronics used in motor driven applications. It enables the system energy efficiency to be determined based on defined criteria such as load profiles, service conditions or drive topologies. It describes the boundary conditions arising from pulse frequency, power supply topology and cabling, filtering, control strategy that influence the energy efficiency of the system. ISR University of Coimbra 41

42 Harmonization of efficiency classification standards in the World IEC Four efficiency classes: IE3: Premium efficiency (16-20% lower losses than IE2) IE2: High efficiency (existing Eff1, EPAct) IE1: Standard efficiency (existing Eff2) IE4: Super-Premium Efficiency only presented in the form of an informative annex (Annex A of IEC ) ISR University of Coimbra 42

43 IEC IEC is currently under revision. In its next edition it will be divided into two parts: Part 1 - Efficiency classes of line operated AC motors Part 2 - Efficiency classes of variable speed AC motors Publication of Part 1 is forecast to the beginning of 2014 while Part 2 is still in the early stages of development. ISR University of Coimbra 43

44 IEC (Ed.1) The standard will cover single-speed electric motors that are rated according to IEC or IEC (explosive atmospheres), are rated for operation on a sinusoidal voltage supply and: have a rated power P N from 0,12 kw to 1000 kw have a rated voltage U N above 50 V up to 1 kv have 2, 4, 6 or 8 poles ISR University of Coimbra 44

45 IEC (Ed.1) ISR University of Coimbra 45

46 IEC (Ed.1) The efficiency levels in the power range 0,75 to 375 kw, already covered by the current edition of the standard suffered no changes. Between 0,12 and 0,75 kw the limit values of efficiency were extrapolated, and between 375 and 1000 kw the fixed values were expanded. An IE5 level is envisaged for a future revision, with the goal of reducing the losses of IE5 by some 20% relative to IE4. ISR University of Coimbra 46

47 MEPS Worlwide 3-phase IM (Medium Motors) Efficiency Levels Efficiency Classes Testing Standard Performance Standard IEC IEC MEPS Premium Efficiency IE3 USA Europe 2015* (>7,5kW), 2017 Canada Low Uncertainty Mexico Korea 2015 High Efficiency IE2 Australia New Zealand Brazil Korea China Europe Switzerland Standard Efficiency IE1 Costa Rica Israel Medium Uncertainty Taiwan ISR University of Coimbra 47

48 MEPS WorldWide (Small Motors) USA Energy Conservation Standards for Small Electric Motors, ranging from 1/4 to 3 horsepower (0,18 to 2,2 kw), alone or as a component of another piece of non-covered equipment. The standards apply to three types of induction motors: Polyphase Small Electric Motor Single-phase Capacitor-Start Induction-Run Single-phase Capacitor-Start Capacitor-Run Effective March, 2015 ISR University of Coimbra 48

49 MEPS WorldWide (Small Motors) China GB Minimum allowable values of energy efficiency and efficiency grade for small-power motors Applies to: small three phase asynchronous motors (10W - 2.2kW), capacitor run asynchronous motors (10W - 2.2kW), capacitor start induction motors (120W - 3.7kW), double value capacitor induction motors (250W - 3kW) for general purpose with the voltage 690V, 50Hz AC power, and also to fan motors for room air conditioner (6W - 550W). ISR University of Coimbra 49

50 MEPS WorldWide (Large Motors) China A labelling and financial incentive scheme for Medium Voltage (6000V) and High Voltage (10000) three-phase asynchronous motors is also being introduced. It covers motors in the 355 kw to kw power range. ISR University of Coimbra 50

51 Prodcom data for electric motors sold (EU-27, 2010) 0,01% ISR University of Coimbra 51

52 Prodcom data for electric motors sold (EU-27, 2010) Total number of motor sold: ISR University of Coimbra 52

53 Small motor market Note: Others include toys, video recorders, hi-fi stereo systems, photographic equipment, agriculture, defense and aerospace, clocks, garage doors and a growing range of other automated household functions and security systems. ISR University of Coimbra 53

54 Prodcom data for electric motors sold (EU-27, 2010) Total number of motor sold: ISR University of Coimbra 54

55 Prodcom data for electric motors sold (EU-27, 2010) Total number of motor sold: ISR University of Coimbra 55

56 Large Motor Market (CEMEP) Power range > 375 kw but 1000 kw (excluding traction motors) Thousands of Market Share(%) units sold Low Voltage 1,6 14,2% Medium Voltage 3,4 30,1% > 1000 kw (excluding traction motors) Low Voltage 0,6 5,3% Medium Voltage 5,7 50,4% Total 11,3 100% ISR University of Coimbra 56

57 Global stock and electricity consumption share for electric motors ISR University of Coimbra 57

58 Estimated EU-27 polyphase induction motor market in 2010 (Data Source: CEMEP) ISR University of Coimbra 58

59 Market trends Small motors The market of single-phase motors has been slowly declining as they are being replaced by other technologies in HVAC, domestic appliances and some industrial applications. The falling price of PM Synchronous motors /DC brushless motors is encouraging the gradual replacement of existing DC products and of induction motors. ISR University of Coimbra 59

60 Market Trends (PRODCOM data) Medium motors ISR University of Coimbra 60

61 Market trends Medium motors Conventional Brushed DC motor market is expected to continue to decline The decrease in demand of single-phase integral motors is expected to persist due to the increased use of electronic speed controls Permanent Magnet Synchronous Motors are mostly customized products, but they are expected to become widely available commercially, in standard mechanical dimensions Line-start permanent magnet motors, recently introduced in the market, are expected to become more widely available ISR University of Coimbra 61

62 Market trends Medium motors The market in this power range is expected to continue to be largely dominated by threephase induction motors, in the next years. The growing penetration of more efficient motors (IE2 and IE3) will continue, mainly driven by imposed regulation. ISR University of Coimbra 62

63 Market trends Large motors The large motor market is a very specialized market, with custom motors designed for specific applications. Since more time and money are spent in the specification of this high cost products, there is a tendency to address high efficiency performance during the process. Therefore, the market structure is not expected to experience major changes. ISR University of Coimbra 63

64 Estimated EU-27 VSD market in 2012 (Data Source: CEMEP) ISR University of Coimbra 64

65 Contactors market in 2012 (Data Source: CAPIEL) ISR University of Coimbra 65

66 Estimated EU-27 Soft-Starter market in 2012 (Data Source: CAPIEL) ISR University of Coimbra 66

67 Electricity prices EU average (27 countries) 0,0935 /kwh Industrial Sector 500 MWh < Consumption < MWh ISR University of Coimbra 67

68 Repair and Maintenance Costs Small motors are normally not repaired and are replaced upon failure. Medium power induction motors above 11 kw are normally repaired at least 2 times during its lifetime but this can occur up to 4 times. ISR University of Coimbra 68

69 Repair and Maintenance Costs Comparison between repair prices and new motor prices ISR University of Coimbra 69

70 BaseCases Small Motors For Small motors in the power range of 120 W up to 750 W, two BaseCases will be considered: BaseCase 1 1-Phase Induction Motor (IM), 375 W, IE1 BaseCase 2 3-Phase Induction Motor (IM), 375 W, IE1 ISR University of Coimbra 70

71 BaseCases Medium Motors Medium motors in the power range from 0.75 kw up to 375 kw: BaseCase 3 3-Phase IM, 1,1 kw IE2 BaseCase 4 3-Phase IM, 11 kw IE2 BaseCase 5 3-Phase IM, 110 kw IE2 ISR University of Coimbra 71

72 BaseCases Large Motors Large motors in the power range above 375 kw, up to 1000 kw: BaseCase 6 3-Phase IM, 750 kw LV, IE2 BaseCase 7 3-Phase IM 750 kw MV (6600V), IE2 ISR University of Coimbra 72

73 BoM Small Motor (375 W IE1) Materials Number of Phases 1-Phase 3-Phases Electrical steel (kg/kw) 12,5 10,5 Other steel (kg/kw) 3,0 2,1 Cast iron (kg/kw) 0-3,5 0-3,0 Aluminium (kg/kw) 4,0 3,6 Copper (kg/kw) 2,3 1,9 Insulation material (kg/kw) 0,06 0,06 Packing material (kg/kw) 2,0 2,0 Impregnation resin (kg/kw) 0,4 0,4 Paint (kg/kw) 0,12 0,12 Source: CEMEP ISR University of Coimbra 73

74 BoM Medium Motors (IE2) Materials Electrical steel (kg/kw) Other steel (kg/kw) Motor Rated Power 1,1 kw 11 kw 110 kw 8 4,8 3,6 1,6 1 0,7 Cast iron (kg/kw) 2,5 (0,0-5,0) 1 (0,0-2,0) 3 Aluminium (kg/kw) 0,5-4,0 0,25-1,8 0,2 Copper (kg/kw) Insulation material (kg/kw) Packing material (kg/kw) Impregnation resin (kg/kw) Paint (kg/kw) 1,9 0,9 0,6 0,05 0,02 0,01 1 0,9 0,5 0,3 0,1 0,05 0,1 0,05 0,01 Source: CEMEP ISR University of Coimbra 74

75 BoM Large Motors (750 kw IE2) Materials Voltage Low Voltage Medium Voltage Electrical steel (kg/kw) 3,2 3,2 Other steel (kg/kw) 0,4 0,9 Cast iron (kg/kw) 1,8 2,0 Aluminium (kg/kw) 0,1 0,01 Copper (kg/kw) 0,4 0,6 Insulation material (kg/kw) 0,03 0,2 Packing material (kg/kw) 0,1 0,15 Impregnation resin (kg/kw) 0,03 0,03 Paint (kg/kw) 0,02 0,02 Other (plastic terminals, etc.) 0,02 0,03 Source: CEMEP ISR University of Coimbra 75

76 BoM - VSDs Materials Rated Power 0,37 kw 1.1 kw 11 kw 110 kw 750 kw Steel (kg/kw) - 0,5 0,16 0,05 0,045 Aluminium (kg/kw) 1,3 1 0,22 0,01 0,009 PVC Plastic (kg/kw) 0,4 0,3 0,05 0,03 0,027 PWB (kg/kw) 0,26 0,2 0,03 0,01 0,009 Electronics small (SMD, IC,...) (kg/kw) 0,26 0,2 0,07 0,04 0,036 Electronics big (IGBT, Thyristors,...) (kg/kw) 0,065 0,05 0,02 0,03 0,027 Source: LOT 11 ISR University of Coimbra 76

77 Use Phase - VSDs Basecase Efficiency VSDs Efficiency Size (kw) Torque 100% 75% 50% 25% VSD - Very Small 0, VSD - Small 1, VSD - Medium VSD - Large VSD - Very Large Source: DoE and ISR-UC ISR University of Coimbra 77

78 Environmental Impacts Use phase dominates for each product. The only other significant impact is that of particulates, which relates to the weight and volume of products in distribution. Improved designs using conventional induction motor technology will have a small increase in these factors, but it is thought that any reduction in energy saving would justify the increase in particulates. ISR University of Coimbra 78

79 Breakdown of environmental impact, by type and life cycle phase (1,1 kw 3-Phase IM) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% End of life Use Distribution Production 0% ISR University of Coimbra 79

80 Best Available Technologies (BAT) ISR University of Coimbra 80

81 Single-Phase Motors For single-phase motors, adding a secondary run capacitor This design provides optimum levels of both starting-torque and efficient running characteristics ISR University of Coimbra 81

82 Best Available Technologies (BAT) Permanent Magnet Synchronous Motors (PMSM) ISR University of Coimbra 82

83 Losses in VSDs Switching losses (output stage) Line-rectifier (input stage) Typical percent of losses for Factors affecting these losses passive front-end converters 30 to 50 % Motor-current and switchingfrequency. 20 to 25 % losses Line-current (nearly proportional to motor power). Forward losses (output stage) 15 to 20 % Motor current. Internal control circuit Losses (microcontroller, internal power supply, display,keyboard, buscommunication,digital and analogue ins/outs ) 5 to 20 % Nearly constant. Switching losses (line-side converter / active front-end only) Compound losses (line-side converter / active frontend only) - Line-current and switchingfrequency (nearly proportional to motor power). - Line-current (nearly proportional to motor power). ISR University of Coimbra 83

84 Best Available Technologies (BAT) VSDs ISR University of Coimbra 84

85 Improvement potential Small motors under 750 W BaseCase (IE1) > BAT1 (IE2) > BAT2 (IE3) > BAT3 (IE4) Medium motors (750 W 375 kw) BaseCase (IE2) > BAT1 (IE3) > BAT2 (IE4) > BNAT (IE5) Large motors (375 kw 1000 kw) BaseCase (IE2) > BAT1 (IE3) ISR University of Coimbra 85

86 Improvement potential The following assumptions have been made: Production phase. A nominal 20% increase of materials has been assumed for an increase of one IE level. Distribution. The distance and the packaged volume are assumed to be the same, as often the design will comprise a longer stack of active materials within the same casing. Maintenance. More efficient motors run cooler and so may have a longer time between maintenance, but this is a modest effect and so is not taken account of. Disposal. This is assumed to be the same. ISR University of Coimbra 86

87 Impact on moving from IE1 Motors to IE3 (370 W 3-Ph IM) 3. Production 3. Distribution 3. Use 3. End of life IE1 IE3 % IE1 IE3 % IE1 IE3 % IE1 IE3 % Total Energy (GER) % % 22,628 20,795-8% % of which, electridity (MJ) % 0 0 0% 22,625 20,791-8% 0 0 0% Water (process) 9 9 0% 0 0 0% 1,508 1,386-8% 0 0 0% Water (cooling) % 0 0 0% 60,334 55,441-8% 0 0 0% Waste, non-haz./ landfill 23,535 41,110 75% % 26,468 24,516-7% % Waste, hazardous/ incinerated 5 5 0% 1 1 0% % % Greenhouse Gases in GWP % 6 6 0% % % Ozone Depletion, emissions 0 0 0% 0 0 0% 0 0 0% 0 0 0% Acidification, emissions % % 5,829 5,359-8% % Volatile Organic Compounds (VOC) 1 1 0% 0 0 0% % 0 0 0% Persistent Organic Pollutants (POP) % 0 0 0% % % Heavy Metals % 3 3 0% % % PAHs % 3 3 0% % 0 0 0% Particulate Matter (PM, dust) % % % % Emissions (Water) 0 0 0% 0 0 0% 0 0 0% 0 0 0% Heavy Metals % 0 0 0% % % Eutrophication % 0 0 0% 1 1 0% 0 0 0% Persistent Organic Pollutants (POP) 0 0 0% 0 0 0% 0 0 0% 0 0 0% ISR University of Coimbra 87

88 Impact of moving from IE2 to IE3 (750 kw IM) Production Distribution Use End of life IE2 IE3 % IE2 IE3 % IE2 IE3 % IE2 IE3 % Total Energy (GER) 11 97, ,709 % 4,394 4,394 0% 31,014,656 30,757,665-1% 9,832 10,788 10% of which, electricity (in primary MJ) 12,253 13,299 9% 9 9 0% 31,013,320 30,756,230-1% % Water (process) 3,553 3,555 0% - - 0% 2,067,582 2,050,442-1% % Water (cooling) 15,161 15,230 0% - - 0% 82,702,011 82,016,411-1% % Waste, non-haz./ landfill ,26 237,91 6,476,534 7,414,391 % 2,145 2,145 0% 36,022,808 35,734,093-1% 6 8 8% Waste, hazardous/ incinerated % % 714, ,718-1% 18,558 18,558 0% Greenhouse Gases in GWP ,538 7,231 % % 1,353,501 1,342,288-1% % Ozone Depletion, emissions - - 0% - - 0% - - 0% - - 0% Acidification, emissions 15 83,503 96,248 % % 7,986,771 7,920,695-1% 1,647 1,785 8% Volatile Organic Compounds (VOC) % % 11,692 11,595-1% % Persistent Organic Pollutants (POP) 11 34,722 38,487 % % 203, ,978-1% 1,523 1,638 8% Heavy Metals 13 19,890 22,549 % % 532, ,988-1% 3,947 4,219 7% PAHs 22 3,974 4,850 % % 61,240 60,742-1% % Particulate Matter (PM, dust) 10,94 20,434 20,905 2% 1 10,941 0% 172, ,132-1% 17,685 18,894 7% Emissions (Water) - - 0% - - 0% - - 0% - - 0% Heavy Metals 13 6,344 7,137 % 3 3 0% 200, ,378-1% 1,130 1,207 7% Eutrophication ISR 3% University 0 of Coimbra 0 0% % %

89 Life Cycle Cost (euros) Life Cycle Costs of different technological 10,000,000 options 1,000, ,000 10,000 1, Basecase BAT1 BAT2 BAT3 BAT ISR University of Coimbra 89

90 payback to annual operating hours: Small Payback (Years) induction motor - 1 phase IE1 25,00 20,00 15,00 10,00 5,00 BAT1 BAT2 BAT3 BAT Annual Opearting Hours ISR University of Coimbra 90

91 Thank you ISR University of Coimbra 91