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

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 discusses the various phases of the project, starting with the collection of energy efficiency data from manufacturers. He also covers 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 addresses the complexities of different energy costs across various regions worldwide and their impact on the payback period.

Finally, the speaker discusses the actual rollout of the motor replacement initiative and shares the initial field results of the energy measurements.

Speaker: Prof. Kurt Stockman, Ghent University

0:00:00 Welcome
0:01:08 Introductions
0:06:50 Research Goal & Approach
0:09:15 Step 1 - Bekaert Load Profile Analysis
0:11:23 Step 2 - Benchmark Data: Measurements
0:13:25 Step 3 - IE4 and IE5 Motor Assessment
0:19:45 Step 4 - Payback Time (IRR)
0:23:19 Step 5 - Roll-Out on 22kW - 1000 rpm machines
0:24:48 Conclusions