Motor Systems - Glass IndustryTechnologies & Measures
|Technology or Measure||Energy Savings Potential||CO2 Emission Reduction Potential Based on Literature||Costs||Development Status|
|Power Factor Correction||Commercial|
The savings associated with an ongoing motor maintenance program could range from 2% to 30% of total motor system energy use (Worrell et al., 2008. p. 40)
|Proper Motor Sizing||Commercial|
|Adjustable Speed Drives|
Typical energy savings with the use of ASDs are shown to vary between 7% and 60% (Worrell et al., 2008. p.41).
An audit in a US based container glass industry identified energy saving potentials by installing ASDs for cooling water pumps, for furnace air and stack draft blowers, and for cooling blowers in the forming and glass handling sections. Savings for the cooling motor pumps and for the furnace air blowers are identified to be 524,600 kWh/year and 808,400 kWh/year, respectively (Worrell et al., 2008. p. 41).
Replacing old cooling water pumps with new ones fitted with ASDs an automative glass company in the US saved 3.2 GWh/year of energy, while also reducing the need for water use and the use chemicals for water treatment (Worrell et al., 2008. p. 41).
In a speciality glass factory in the US, energy saving potentials of 700 MWh/year, 200 MWh/year, and 100 MWh/year are identified by installing ASDs for mold cooling fan motor, for a cooling loop motor, and for a machine cooling loop, respectively.
By installing ASDs on the main suction fan motors in its wool forming process, a glass wool insulation producer in the UK was able to reduce the energy consumption of the fans by 55%, saving 3.8 GWh of electricity annually (Worrell et al., 2008. p. 41).
By installing ASDs on the main suction fan motors in its wool forming process, a glass wool insulation producer in the UK was able to reduce CO2 emissions by 1600 tons/year (Worrell et al., 2008. p. 41).
In a US based container glass indsutry, the estimated payback times for installing ASDs were as following: 1.8 years for the cooling water pumps; 1.7 years for the furnace air and stack draft blowers; 1.8 years for the cooling blowers in the forming and glass handling.
Savings in the automative glass manufacturing plant totalled $ 280 000 (energy savings alone $ 98 000). The investment costs were $350 000, giving a payback period of 15 months (Worrell et al., 2008. p. 41).
In the speciality glass factory, payback times for installing ASDs for mold cooling fan motor, for a cooling loop motor, and for a machine cooling loop had payback times of 1 year, 1.2 years, and 2.8 years, respectively (Worrell et al., 2008. p. 41).
The payback period for installing ASDs on the main suction fan motors for the glass wool insulation material production, the plant in the UK realized a payback time of 2 years (Worrell et al., 2008. p. 41).
|Strategic Motor Selection Using Life Cycle Costing|
In general premium efficiency motors are most economically attractive when replacing motors with annual operation exceeding 2,000 hours/year.
An audit of two Glass Container plants in the US found opportunities to replace large motors with energy-efficient motors with a payback period of 2.5 years or less (Worrell et al., 2008. p.39).
|Minimizing Voltage Unbalances.|
For a 100 hp motor operating 8,000 hours per year, a correction of the voltage unbalance from 2.5% to 1% will result in electricity savings of 9,500 kWh or almost $500 at an electricity rate of $0.05/kWh (Worrell et al., 2008. p.42)
The typical payback period for voltage controller installation on lightly loaded motors in the United States is 2.6 years (Worrell et al., 2008. p.42).
|Motor Management Plans||Commercial|
|Use of High-Efficiency Cog Belts|
As compared to standard V-belts cog belts and high-torque cog belts are 2% and 6% more energy efficiency, respectively. Motor load reductions of 2 to 10% have been shown from replacing vee belts with cog belt (Worrell et al., 2008. p.42). In the US, installation of efficient notched belts on belt-driven applications at in a glass plant was estimated to save 200 MWh/year (Worrell et al., 2008. p.42).
estimates the payback for replacing standard belts with more efficient ones to be 6 months to 3 years. Other case studies taken from each of the glass segments (fiber, flat, container, and specialty) estimate the average payback period over all glass sectors for installing more efficient belts at less than 10 months. The payback time was virtually immediate for installing efficient notched belts on belt-driven applications at in a glass plant in the US (Worrell et al., 2008. p.42).
Motor Systems - Glass Industry Publications
Energy Efficiency Improvement and Cost Saving Opportunities for the Glass Industry - An ENERGY STAR® Guide for Energy and Plant Managers
Prepared primarily with the US Glass Industry, this document provides information about energy efficiency measures applicable to glass manufacturing, including performance and cost benchmarks whenever possible.