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MALTA

Investigating ways to increase the efficient use of Electrical Energy in the Manufacturing Industry. MALTA. Energy Efficient Electric Motor Systems. Key Experts: Prof. Ing. C. Spiteri- Staines Co-Supervisors: Dr. Cedric Caruana Researcher: Mr. Peter Spiteri.

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MALTA

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  1. Investigating ways to increase the efficient use of Electrical Energy in the Manufacturing Industry MALTA

  2. Energy Efficient Electric Motor Systems Key Experts: Prof. Ing. C. Spiteri- StainesCo-Supervisors: Dr. Cedric Caruana Researcher: Mr. Peter Spiteri Industrial Partners : PlaymobilToly Products Andrews Feeds

  3. Introduction It is estimated that motor driven systems account for around 65% of the electricity consumed by the European industry. 1.5% improvement in the motors’ efficiency implies a reduction of around1% energy consumption in the European industry. The more efficient use of energy in the manufacturing industry has become a key factor for the industrial organisations to maintain a competitive edge.

  4. Aims of Project The objective is to facilitate the adoption of energy saving measures on electric motors by the Maltese industry. Carry out an extensive Data gathering exercise on Energy Usage and Patterns of Electrical Motor Systems in various local industries Develop a user-friendly software tool to help organisations take intelligent decisions on the options available for reducing electric motors’ energy consumption. Other benefits derived from project: Knowledge on : electrical motors used in selected manufacturing industries energy savings mechanisms for manufacturing industry Additional benefits: possibility for reduced heat dissipation and lower maintenance costs.

  5. Increasing Efficiency in Motor Systems

  6. Results • Experimental Tests were carried out : • In a laboratory set-up and • On-site in selected industries • Studies were carried out to quantify the energy savings that can be achieved by a Motor Energy Controller (MEC) or a High Efficient Motor (HEM). • On-site Case Studies: • Andrews Feeds (Malta) Ltd • Motor Energy Controller • High Efficient Motor • Toly Products (Malta) Ltd • Motor Energy Controller • FS Eng. & Plastics Ltd (Malta) • Motor Energy Controller • Lab rig tests: • Profile of an Elevator load • Two different Injection Mould Machine profiles 6

  7. Laboratory Test Rig schematic

  8. Laboratory Test Rig

  9. Lab test rig results Motor (5.5kW) at no load 35% Energy Savings 471W 305W Motor Energy Controller switched ON

  10. Lab test rig results Comparison of efficiency with the MEC ‘on’ and ‘off’ for different operating points High Load Low Savings Low Load High Savings

  11. Elevator Profile (Lab Results) 5.3% overall energy savings 1% 9.7%

  12. Injection Mould Machine (Lab Results) Profile 1 12

  13. Injection Mould Machine (Lab Results) Profile 2 MEC OFF 3.3% energy savings MEC ON

  14. Case Study 1 Motor Energy Controller (MEC) installed on elevator motor at Andrews Feeds Ltd More than 20% energy savings were achieved at low load

  15. Case Study 2 Motor Energy Controller (MEC) installed IMM motor at Toly Products Ltd • Motor Energy Controller (MEC) was installed on an Injection Mould Machine at Toly Products (Malta) Ltd • Motor rating = 22kW • Average power with the MEC OFF = 7.12kW • Average power with the MEC ON = 6.89kW • Energy savings = 3.2%

  16. Case Study 3 Motor Energy Controller (MEC) installed on IMM at FS Engineering & Plastics Ltd 2.2% energy savings

  17. High Efficient Motor (HEM) replaced ‘older’ elevator motor at Andrews Feeds Ltd. Case Study 4 Around 25% overall energy savings More than 35% energy savings at low load

  18. Motor Energy Saving Tool (MEST) Screenshot of software tool developed to guide technical persons in industry to take right decisions in order to increase the efficiency in motor applications

  19. Increasing Energy Efficiency during Testing of Equipment by novel Grid‐connected Load Units Industrial Partners : Abertax Delta (Malta) Key Experts: Dr. Maurice Apap Co-Supervisors: Prof. C. Spiteri Staines & Prof. J. Cilia Researchers: Mr. Francarl Galea

  20. Introduction Manufacturing Cycle Testing of each product must take place before reaching the market and the customer. Testing of certain products leads to high energy consumption. power supply full load burn-in test usually last for a minimum of 24 hours. (can exceed 400,000kWhr yearly.) batteries testing is carried out by cycling.

  21. Aims This project is targeted at increasing the efficiency during testing of manufactured electrical equipment: namely, DC Power Supplies and Battery Banks. • Currently Electrical Energy consumed during testing is ‘wasted’ (as heat) in Active Loads. • The aim of this project is to REDIRECT the Electrical Energy used during testing back to the Electrical Supply. • 70% energy saving is predicted.

  22. Case Study • Testing of a 70V 800W Power Supply with the Regenerative Load • The energy savings obtained in this test were 83% (excluding losses in the Power Supply).

  23. Case Study • List of savings obtained when testing various models of Power Supplies

  24. Thank you for your attention- next talk shall consider in detail one case study concerned with regenerative load testing MALTA

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