robert wilkins, danfoss: lean and clean: equipping modern manufacturers

Exploiting Energy Saving OpportunitiesMarch 19, 2010

Existing technologies offer substantial opportunities to save energy TODAY!

Energy Secretary Chu has referred to energy efficiency, “not as low-hanging fruit, but as fruit already on the ground ready to be picked up.”

DevelopRenewable

Sources

ImproveEnergy

Efficiency

DevelopNew

Technologies

DeployExisting

Technologies

Target: Cut 83%GHG emissions

by 2050

Avenues to Reduce GHG Emissions

Electric motor-driven systems used in industrial processes consumed 679 billion kWh – 23% of all electricity sold in the United States.

These machines make up by far the largest single category of electricity end use in the American economy.

On average, the manufacturing sector could reduce industrial motor energy use by 11% to 18% using mature, proven efficiency technologies and practices.

Energy Savings Opportunities in Industrial Application

EXAMPLE: Variable Frequency Drives (VFDs)*

Are connected between the grid and the motor to vary the motor’s speed.

FixedFrequency

VariableFrequency

VariableSpeed

* Also called variable speed drives (VSDs) or frequency converters

FLOW RPM HEAD RPM2

POWER RPM3

Affinity Laws for Pumps and Fans

RPM FLOW HEAD POWER

100% 100% 100% 100%

90% 90% 81% 73%

80% 80% 64% 51%

70% 70% 49% 34%

60% 60% 36% 22%

50% 50% 25% 13%

40% 40% 16% 6%

Conclusion:Reducing motor speed by 10% to 20% saves 27% to 49% of the power used!

Common Applications

Air Conditioning

Process cooling

Water / wastewater systems

Industrial pumps

Compressors

Blowers

Irrigation

Food and beverage processing

• Systems must be sized for peak load conditions

• But, normally operate much lower than peak

• With fixed speed motors, output has to be controlled by

• Cycling systems on and off, or • Installing throttling mechanisms

• This wastes 20% to 30% of the energy (or more)

VFD Shipments as % of Induction Motor Shipments (2008)

0%

10%

20%

30%

40%

EMEA Japan USA

• Europe and Japan far exceed the US in deploying VFDs

• Of course, electric utility rates are much higher in many of these countries.

Data source: IMS Research, Austin, TX.

Summary and Policy Implications

• Known technologies can save massive amounts of energy.

• Deployment rates are low in USA where energy is cheap.

• Steps are needed to induce deployment

• Price signals

• Rebates or credits to retrofit existing facilities

• Standards, promotion and education, to encourage that new facilities are designed with modern equipment

• Accelerating deployment of existing technologies would create systems to encourage rapid deployment of future technology developments.

MasterPumpDrive

PressureSensor

FollowerPumpDrive

FollowerPumpDrive

In 2025:

CO2 emissions from factories and product transport must be reduced by 25% compared to the 2007 level

The share of renewable energy must be increased by 25% compared to the 2007 level

25% less CO2 and 25% more sustainable energy in 2025

Danfoss’ Own Energy and Environment Goals

Results within Danfoss

7.8% Energy reduction 2009 v 2008

Thank you!