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Energy efficient operation of induction motor drives: Economic and environmental analysis in cement manufacturing

Energy consumption is increasing day by day and so greenhouse gas emissions. Heavy industries, which consume almost 50% of total energy produced, there is a strong need to implement energy efficiency measures. The electric motor driven systems (EMDS) such as fans, blowers, ventilators, pumps, and compressors are widely used in industries and consume 80% of total industrial electricity. A huge electrical energy saving potential exists with these applications since they frequently come under partial load condition. The optimal flux operation of motors provides significant savings in such conditions, especially in the steady‐state. There are two methods, namely, loss model control (LMC) and search control (SC) used for finding an optimal flux value. In this paper, a case study has been performed to analyze the efficiency improvement of motors of an industrial unit by utilizing superior features of LMC and SC techniques together in a novel way. A total of 65 EMDS are being considered as energy‐efficiency load points for the detailed investigation of a typical integrated cement‐manufacturing unit, located at Durg district, C.G., India. The efficiency improvement validation has been carried out on the MATLAB platform. Significant savings of $2.19 million per annum in energy expenditures, 48,899 tons less per annum of combusted coal and nearly 50,366 tons less greenhouse emissions are estimated at 1 yr. The projected energy use will be in line with “good practice” benchmarks for the sector as well help in “carbon emission reduction target” of state and country. © 2018 American Institute of Chemical Engineers Environ Prog, 38: 672–679, 2019