Energy 36 (2011) 233e240

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Energy
journal homepage: www.elsevier.com/locate/energy

Energy savings and emissions reductions for rewinding and replacement

of industrial motor
M. Hasanuzzaman a, c, *, N.A. Rahim b, c, R. Saidur a, c, S.N. Kazi a
a
Department of Mechanical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia
b
Department of Electrical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia
c
Centre of Research UMPEDAC, Level 4, Engineering Tower, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia

a r t i c l e i n f o a b s t r a c t

Article history: Electric motors consume 30e80% of total industrial energy around the world. This study estimates the
Received 25 January 2010 economic viability of replacing rewound and standard motors with high efficiency motors (HEMs) in the
Received in revised form industrial sector. The efficiency of a motor is degraded when it is rewound and it is better to rewind
21 September 2010
a larger motor compared with a smaller motor. It was found that a HEM can save on average 5.5% of
Accepted 25 October 2010
Available online 24 November 2010
energy compared with a standard motor. In addition, the payback period was found to be reasonable
when a motor is operated at a 50% load. HEMs will also save a sizeable amount of energy and reduce
emissions. It was estimated that 67,868 MWh/year energy and US$ 4,343,531 per year could be saved by
Keywords:
Energy savings
introducing HEMs. By contrast, 44,582 tons of CO2, 333 tons of SO2 and 122 tons of NOx emissions could
Industrial motor be reduced through the aforementioned energy savings. This study found that rewound motors of
Emission a larger size and HEMs are economically viable.
Ó 2010 Elsevier Ltd. All rights reserved.

1. Introduction industries are heavily dependent on electric motors for compacting,

The industrial sector is the largest energy user around the world.
The electrical energy consumption in Malaysia has increased
sharply in the past few years, and modern energy efficient tech-
nologies are desperately needed for the national energy policy [1].
Industrial motors use a major fraction of total industrial energy.
Electric motors have broad applications in industry, business,
public service and household electrical appliances, powering
a variety of equipment including wind blowers, water pumps,
compressors and machine tools. In industrially developed and large
developing countries, electric motors account for a considerable
proportion of total national power consumption [2]. The induction
motor is the main driven system in modern industrial society [3].
Electric motors consume 30e80% of total industrial energy around
the world (Table 1). In Malaysia, electric motors consume about 48%
of the industrial energy consumption. Electric motors are also
responsible for consuming about 40% of electricity worldwide. In
Malaysia, the bulk of electricity in the industrial and commercial
sectors is consumed by electric motors. Activities and processes in
* Corresponding author. Centre of Research UMPEDAC, Level 4, Engineering
Tower, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia.
Tel.: þ603 79677611; fax: þ603 79675317.
E-mail addresses: hasan@um.edu.my, hasan.buet99@gmail.com (M. Hasanuzzaman).
cutting, grinding, mixing, fans, pumps, materials conveying, air
compressors and refrigeration. Motors are also used widely in the
commercial sector for air conditioning, ventilation, refrigeration,
water pumping, lifts and escalators. Energy losses in a large number
of industries prevail, and potential energy efficiency improvements
are imminent [4]. Among the various sectors contributing to
greenhouse gas (GHG) emissions, the contribution of the industrial
sector is significant. Thus, lowering GHG emissions from the
industrial sector would reduce overall GHG emissions. Energy
conservation means less reliance on energy imports and, thus, less
GHG emissions. Previous studies have reported that the imple-
mentation of selected options at little or no cost in the industrial
sector could reduce GHG emissions by 10e30% [5,6]. The instan-
taneous emissions associated with electricity generation vary with
the demand for electricity. Indeed, the fuel mix needed for elec-
tricity generation changes with the kinds of power plants needed to
supply the amount of electricity required as well as the fluctuating
rate of the corresponding emissions [7]. Any reduction in carbon
dioxide emissions afforded by a demand-side intervention in the
electricity system is typically assessed by means of an assumed grid
emissions rate, which measures the CO2 intensity of electricity not
used as a result of the intervention. This emissions rate is called the
marginal emissions factor (MEF). The accurate estimation of MEF is
crucial for performance assessment because its application leads to
decisions regarding the relative merits of CO2 reduction strategies

0360-5442/$ e see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2010.10.046
234 M. Hasanuzzaman et al. / Energy 36 (2011) 233e240

Nomenclature 0.746 Conversion factor from horsepower to kW

AES Expected annual bill savings (US$) Subscripts

c Average energy cost (US$/kWh) BM Build margin
COEF Emission coefficient of fuel (kg/kg or litter) ee Energy-efficient motor
E Motor efficiency rating (%) i Fuel type
EF Emission factor (kg/kWh) j Power plant
F Amount of fuel (kg or litter) MEF Marginal emission factor
GEN Electricity delivered to the grid (kWh) OM Operational margin
hp Motor rated horsepower re Rewind motor
hr Annual operating hours std Standard motor
L Load factor (percentage of full load) w Emission weighted factor
NCV Net calorific value of fuel y Year
OXID Oxidation factor of the fuel

[8]. Electricity generation has recently focused on the problems of
urban air pollution, acid deposition, contamination from nuclear
accidents and nuclear wastes and the increased concentration of
carbon dioxide and other GHGs in the atmosphere [9]. The elec-
tricity generation sector in Korea is under pressure to mitigate
GHGs as directed by the Kyoto Protocol [10]. Energy savings and
emissions reductions can be achieved either by reducing total
energy use or by increasing the production rate per unit of energy
used. By contrast, improving energy efficiency is the key to
reducing GHG emissions. Therefore, energy research organisations
and governments are actively engaged in developing methods for
assessing energy efficiency. This assessment can provide a basis for
establishing energy policy and help reduce GHG emissions [11].
Fig. 1 presents the distribution of energy consumption by motor for
various applications in a typical plant.
Saidur identified the following losses occurring in induction
motors [2]. The efficiency of a motor is determined by intrinsic
losses that can be reduced only by changing the motor’s design.
There are two types of intrinsic losses: fixed losses, and variable
losses. Fig. 2 shows the various losses in the motor. Fixed losses are
independent of motor load and consist of magnetic core losses and
friction and windage losses. Magnetic core losses consist of eddy
current and hysteresis losses in the stator. Variable losses are
dependent on load and consist of resistance losses in the stator and
rotor and miscellaneous stray losses. Resistances to current flow in
the stator and rotor result in heat generation that is proportional to
the resistance of the material and the square of the current. Stray
losses arise from a variety of sources and are difficult to either
measure directly or calculate, but are generally proportional to the
square of the rotor current [2]. A motor’s function is to convert
electrical energy to mechanical energy for performing useful work.
Even though standard motors operate efficiently in the typical
range of 83e92%, energy efficient motors perform significantly
better. An efficiency gain to only 92e94% results in a 25% reduction
in losses. Motor energy losses can be segregated into five major
areas, each of which is influenced by design and construction
[29e33].
A common cause of motor failure is a problem with the motor
windings, and the solution often is to rewind the old motor.
Because it is economical in terms of initial cost, rewinding motors is
common, particularly for motors with a higher horsepower.
However, the motor rewinding process often results in a loss of
motor efficiency. It is generally cost effective to replace motors
under 20 horsepower with new high efficiency motors (HEMs)
rather than rewind them. When deciding whether to buy a new
motor or rewind the old one, it is wise to consider the cost differ-
ence between the rewound and a new HEM as well as the relevant
energy costs to operate them. A paperboard plant with 485 motors,
where an average of three motors were repaired per month, of
which about 70% required rewind or replacement [35]. The facility
operated 8000 h/year. Collected motor information is shown in
Table 2.
A robust and efficient induction motor usually converts 90e95%
of input electrical power into mechanical work. However, because
of the huge amount of energy such motors use, a minor change in
efficiency will have a major impact on operating cost. A HEM uses
specific materials to reduce core and copper losses. Therefore, it
generates less heat and requires smaller and more energy efficient
cooling fans [36]. Future energy challenges and the environmental
crises such as fossil fuel emissions and global warming are urging
the world to focus on energy saving programs more than ever. An
effective way to face these challenges is to improve the efficiency of

Table 1
Electric motor energy use by country.

Country Motor energy usage (%) Reference

US 75 [13, 14]
UK 50 [15]
EU 65e72 [16, 17]
Jordan 31 [18]
Malaysia 48 [19]
Turkey 65 [20]
Slovenia 52 [21]
Canada 80 [22]
India 70 [23]
China 60 [24]
Korea 40 [25]
Brazil 49 [26]
Australia 30 [27]
South Africa 60 [28]
Fig. 1. Energy consumption by motor for various applications in a typical plant [12].
 M. Hasanuzzaman et al. / Energy 36 (2011) 233e240 235

Table 3
Copper (I2R) Stator loss End use electricity consumption by electric motor in the industrial sector in 2006
loss 58% [39].
Rotor loss
Industry No of industry Electricity Average
consumption (MWh/year)
Core (Iron) Eddy current loss (MWh/year)

loss 12% Food and beverages 5 22,293 4458

Hysteresis loss Textile 2 5835 2917
Fabricated metal 2 32 16
External fan windage Paper industry 5 96,648 19,329
Friction and Glass 4 100,097 25,024
windage loss Internal fan windage Wood 7 47,710 6815
14% Basic iron steel 4 633,541 158,385
Bearing, grease, loading spring Automobile 2 27,531 13,765
Chemical 2 56,640 28,320
Surface loss due to current Rubber 11 29,791 2708
Stray losses Plastic 3 28,405 9468
Harmonics Cement 4 99,131 24,782
15%
Petrochemical 2 55,738 27,869
Leakage flux Consumer appliances 3 3635 1211
Electronics 3 26,929 8976
Fig. 2. Losses in a typical motor [30,34]. Total 59 1,233,957

to be more efficient by improvements in design: magnetic cores

electric motors, one of the greatest energy consumption appara-
with plates made of ferrosilicon alloys, better filled slots using more
tuses in the world [37]. Energy efficiency is one of the most
copper, larger rotor conductors, improvements in air-gaps, core
important and cost effective ways of meeting the demands of
heads, fans and bearings, and better dimensional design. HEMs
sustainable development [38].
typically cost 10e25% more than standard motors [40].
In the literature, a number of works have been reported about
The annual energy savings (AES) attained by replacing standard
the use of HEMs to reduce the energy consumption of motors.
efficient motors with high energy efficient motors can be estimated
However, there is no detailed work on the cost effectiveness of
by using the following equation [40e42]:
rewound motors. The aim of this study is to analyse the energy


consumption, energy savings, emissions reductions, bill savings 1 1
and payback period of rewound, standard and high efficiency AES ¼ hp  L  0:746  hr    100 (1)
Estd Eee
motors with different capacities and loading operations.
The AES attained by replacing rewound motors with high
energy efficient motors can be estimated by using the following
2. Methodology
equation:
2.1. Data collection

1 1
AES ¼ hp  L  0:746  hr    100 (2)
Erd Eee
Tenaga Nasional Berhad (TNB) conducted a detailed survey on
consumer behaviour towards electricity consumption and the end The annual bill savings associated with the above energy savings
usage of electricity in the industrial sector in Malaysia in 2006. The can be calculated as [42]:
survey investigated total energy consumption, types of energy
supply, types of equipment and energy consumption and usage Savings ¼ AES  c (3)
behaviour. The energy consumption of electric motors in the A simple payback period for different energy saving strategies
industrial sector in Malaysia was collected from the TNB final report can be calculated by using Equation (4).
and is presented in Table 3.
Incremental cost
Simple payback period ðyearsÞ ¼ (4)
2.2. Formulation of energy savings, bill savings and payback period Annual dollar savings
The input data needed to estimate the energy savings and
The primary goal of a motor manufacturer is reducing produc-
payback period for different strategies are shown in Tables 5e7.
tion costs while preserving available power. A motor can be made

2.3. Motor efficiency and rewind cost

Table 2
Breakdown of motor horsepower and motor repair [35].
Motors operate at their maximum efficiency when they are
Motor size Number of motors
fully loaded. Efficiency drops dramatically below 70% loading.
<20 horsepower 347 (Replacement, not repaired)
20 15 Table 4
25 10 Motor rewind practices [44].
30 2
40 3 Motor hp Failed motor rewound (%)
50 27 1e5 20
75 18 6e20 61
100 21 21e50 81
125 32 51e100 90
400 6 100e200 91
750 4 >200 95
236 M. Hasanuzzaman et al. / Energy 36 (2011) 233e240

Table 5 Table 7
Typical motor efficiency and cost [46]. Input data for motor energy consumption, energy and bill savings [19].

Motor hp Rewind High efficiency Standard motor Rewind High efficient Parameters Value
cost motor cost efficiency efficiency motor Average usage hours 6000
(US$) (US$) efficiency Average electricity cost (US$/kWh) 0.064
5 330 375 82.5 80.5 90.8
7.5 380 525 83.5 81.7 91.3
10 500 638 86.0 84.2 92.3
15 550 825 86.6 85.0 92.6 motor is better to rewind than a smaller motor is (Table 4). Green
20 600 975 87.3 85.8 93.2 Motor Practices Group members investigated the efficiency of
25 660 1238 88.7 87.7 93.9
30 760 1500 89.4 88.5 94.3
rewound motors (Fig. 3). Based on the investigation, the best fitted
40 880 1950 89.7 88.9 94.5 equation is used to calculate this efficiency (Table 5). The efficiency
50 980 2325 90.4 89.7 95.0 of standard, rewound and high efficiency motors under different
60 1100 3750 90.8 90.2 95.2 loading operations are calculated using Fig. 4 and shown in Table 6.
75 1320 4500 90.5 90.0 95.3
The increment price of a HEM is calculated based on Table 8 and
100 1650 5325 91.1 90.6 95.5
125 2200 7385 90.6 90.1 95.2 shown in Table 14.
150 2400 8650 91.8 91.3 95.5
200 2650 10,620 92.3 91.8 95.7
250 2860 13,650 93.1 92.6 95.7
2.4. Reduction of emissions from the electricity consumption of the
300 3080 15,100 93.2 92.8 95.9
400 3500 20,000 92.6 92.2 96.0 motor

Energy savings by using a HEM have been calculated based on

the survey of 59 industries in Malaysia. This showed that HEMs can
Over-sizing is often a means to ensure greater reliability [43]. A save an average 5.5% energy (Table 10).
motor needs to be rewound for two reasons: (i) when excess heat
has damaged the insulation so that electricity passes from winding 2.4.1. Emissions calculation
to winding without going through all of them or (ii) when the The Kyoto Protocol specifies a flexible mechanism called the
winding has been detached at a place away from the end of the clean development mechanism as a cost effective instrument for
coil. The efficiency of a motor is degraded when it is rewound. mitigating global GHG emissions. The clean development mech-
Most studies of the effects of rewinding have found that some anism facilitates the participation of developing countries since
degradation of efficiency occurs each time a motor is rewound. The emissions baselines are necessary to determine emissions
available studies are characterised by small samples and varied reductions and the baseline emissions factors of power plants can
methods; however, the findings specify that the degradation of be calculated by using the combined margin [49]. The combined
efficiency associated with rewinding falls in the range of 1e2% margin is a combination of the operating margin and build
[44]. According to a recent study by the Green Motor Practices margin factors [49,50]. The analysis of the baselines is then
Group, properly planned and performed rewinds cause no effi- carried out by using a simple operating margin and simple
ciency loss in electric motors. Performance improvements, adjusted operating margin because the low cost/must run
increased power density, reliability and efficiency come from resources in Peninsular, Sarawak and Sabah constitute less than
advances in materials and craftsmanship. For example, better 50%. This result was found to be similar to those for the simple
resins and insulating tapes improve thermal dissipation. Auto- operating margin because low cost/must run resources constitute
mated coil forming technology and the precise application of less than 50% of the total grid generation. Therefore, the rest of
insulating tapes ensure consistent coil duplication for improved this study and the baseline calculations will only focus on the
installation and operation. A qualified service provider can ensure simple operating margin [49].
that a rewound motor meets the original efficiency [43]. A larger
2.4.2. Operating margin
The operating margin refers to adjustments in the existing grid
Table 6
Efficiency of standard, rewound and high efficiency motors at different loads [47].
mix because of project activity. The planning horizon is rather
short-term. Therefore, the short-term marginal costs (the oper-
Motor hp Load (50%) Load (75%) Load (100%)
ating costs for the last unit produced by a plant to meet the
Estd Erd Eee Estd Erd Eee Estd Erd Eee demand) are relevant. The emissions produced by the plants,
5 70.1 68.4 77.2 73.8 72.0 81.3 82.5 80.5 90.8 which are on the margin, are taken to calculate the operating
7.5 71.0 69.4 77.6 74.7 73.1 81.7 83.5 81.7 91.3 margin [49]. The operating margin has been calculated by using
10 73.1 71.6 78.5 77.0 75.4 82.6 86.0 84.2 92.3
Equation (5):
15 73.6 72.3 78.7 77.5 76.1 82.9 86.6 85.0 92.6
20 74.2 72.9 79.2 78.1 76.8 83.4 87.3 85.8 93.2
25 75.4 74.5 79.8 79.4 78.5 84.0 88.7 87.7 93.9
1.2
30 76.0 75.2 80.2 80.0 79.2 84.4 89.4 88.5 94.3
y = 8E-05x 2 - 0.018x + 1.3844
Efficiency Reduction (%)

40 76.2 75.6 80.3 80.3 79.6 84.6 89.7 88.9 94.5 1

R2 = 0.9964
50 76.8 76.2 80.8 80.9 80.3 85.0 90.4 89.7 95.0 0.8
60 77.2 76.7 80.9 81.3 80.7 85.2 90.8 90.2 95.2
0.6
75 76.9 76.5 81.0 81.0 80.6 85.3 90.5 90.0 95.3
100 77.4 77.0 81.2 81.5 81.1 85.5 91.1 90.6 95.5 0.4
125 77.0 76.6 80.9 81.1 80.6 85.2 90.6 90.1 95.2
0.2
150 78.0 77.6 81.2 82.2 81.7 85.5 91.8 91.3 95.5
200 78.5 78.0 81.3 82.6 82.2 85.7 92.3 91.8 95.7 0
250 79.1 78.7 81.3 83.3 82.9 85.7 93.1 92.6 95.7 20 30 40 50 60 70 80

300 79.2 78.9 81.5 83.4 83.1 85.8 93.2 92.8 95.9 Motor Capatity (hp)
400 78.7 78.4 81.6 82.9 82.5 85.9 92.6 92.2 96.0
Fig. 3. Efficiency reduction of a rewound motor [45].
 M. Hasanuzzaman et al. / Energy 36 (2011) 233e240 237

100 Table 9
Average electric motor life [48].

80 Motor hp Average life (year) Life range (year)

Efficiency (%)

Less than 1 12.9 10e15

60 1e5 17.1 13e19
5.1e20 19.4 16e20
21e50 21.8 18e26
40 51e125 28.5 24e33
Greater than 125 29.3 25e38
20

0 Table 10
0 20 40 60 80 100 Motor horsepower and percentage of energy savings.
Percentage of full load (%) Motor hp Energy savings (%)

Fig. 4. Relationship between motor loading and efficiency [2]. 5 10.1

7.5 9.3
10 7.3
P 15 6.9
Fi;j;y  COEFi;j 20 6.8
i;j
EFOM;y ¼ P (5) 25 5.9
GENj;y 30 5.5
j 40 5.4
50 5.1
The emissions coefficient COEFi,j is obtained from Equation (6): 60 4.8
75 5.3
COEFi;j ¼ NCVi  EF  OXID (6) 100 4.8
125 5.1
150 4.0
200 3.7
250 2.8
2.4.3. Build margin 300 2.9
The build margin stands for the investment alternatives in other 400 3.7
sources of electricity. The planning horizon is rather long-term. Average 5.5
Planned projects can be entirely displaced or only delayed by the
project, and it also represents the trend or types of technology and
fuels used for newly installed capacity power generation. The build
margin emissions factor is calculated as the generation-weighted EFMEF;y ¼ wOM  EFOM;y þ wBM  EFBM;y (8)
average emissions factor by using the following formula [49]:
The emissions factors of the operating margin and build margin
P
Fi;j;y  COEFi;j are weighted equally, each 50%, by default, although different
i;j
P weights can be used with appropriate justification. The MEF of the
EFBM;y ¼ (7)
GENj;y electricity system in Great Britain from 1st January 2002 to 31st
j December 2009 was estimated as 0.69 kg CO2/kWh. An attempt
was then made to project the MEF into the future to enable the
assessment of long-term demand-side interventions scheduled to
2.4.4. Combined margin be built over the coming seven years and estimated of the MEF of
The final step in applying the consolidated methodology for 0.60 kg CO2/kWh in 2016 [8]. Table 11 shows the combined MEFs in
determining the baseline is to calculate the baseline emissions 2006 in Malaysia.
factor. This is calculated as the weighted average of the emissions
factor of the operating margin and build margin. The formula used 3. Results and discussion
to calculate this weighted average combined marginal emissions
factor is as follows [49]: 3.1. Rewinding a failed motor or replacing with a HEM

Table 8 Energy savings, bill savings and the payback period associated
Increment price of a HEM over a standard motor [19].
with energy savings as a result of using a HEM are presented in
Motor hp Increment price (US$) Table 12 for different motor sizes and loads. Replacing a failed
1 24 motor rather than rewinding saves energy in a number of ways. The
2 25 market assessment found that industrial end users rewind 40% of
3 27
the motors that fail each year and the percentage of motors
4 60
5.5 65
repaired increases with the horsepower capacity of the motor [44].
7.5 91 According to the energy savings analysis, using HEMs can save
15 147
20 197
25 246 Table 11
30 257 Combined MEFs in 2006 in Malaysia.
40 231
50 281 Combined marginal emissions factors (kg/kWh)
60 574 CO2 SO2 NOx
75 518 0.6595 0.0049 0.0018
238 M. Hasanuzzaman et al. / Energy 36 (2011) 233e240

Table 12
Energy and bill savings and payback period for a HEM over a failed rewound standard motor at different loads.

Motor hp Increment price (US$) Energy savings (kWh/year) Bill savings (US$/year) Payback period (year)

Load (50%) Load (75%) Load (100%) Load (50%) Load (75%) Load (100%) Load (50%) Load (75%) Load (100%)
5 45 1855 2643 3154 85 122 145 0.5 0.4 0.3
7.5 145 2541 3620 4320 117 167 199 1.2 0.9 0.7
10 138 2744 3909 4665 126 180 215 1.1 0.8 0.6
15 275 3813 5433 6483 175 250 298 1.6 1.1 0.9
20 375 4873 6942 8284 224 319 381 1.7 1.2 1.0
25 578 4956 7060 8425 228 325 388 2.5 1.8 1.5
30 740 5490 7820 9332 253 360 429 2.9 2.1 1.7
40 1070 7020 10,001 11,935 323 460 549 3.3 2.3 1.9
50 1345 8188 11,664 13,919 377 537 640 3.6 2.5 2.1
60 2650 9199 13,104 15,638 423 603 719 6.3 4.4 3.7
75 3180 12,202 17,383 20,744 561 800 954 5.7 4.0 3.3
100 3675 14,911 21,242 25,349 686 977 1166 5.4 3.8 3.2
125 5185 19,569 27,877 33,267 900 1282 1530 5.8 4.0 3.4
150 6250 19,024 27,102 32,341 875 1247 1488 7.1 5.0 4.2
200 7970 23,377 33,302 39,740 1075 1532 1828 7.4 5.2 4.4
250 10,790 23,026 32,803 39,144 1059 1509 1801 10.2 7.2 6.0
300 12,020 27,514 39,196 46,774 1266 1803 2152 9.5 6.7 5.6
400 16,500 45,215 64,412 76,866 2080 2963 3536 7.9 5.6 4.7

energy but increases the initial purchase cost of the new motor
(Table 12). The amount of saved energy is increased by increasing
the motor load. Payback period analysis shows that payback period
increases with the horsepower of the motor. It has also been found
that payback period decreases by increasing the percentage of the
load. Therefore, it is better to rewind a larger horsepower motor.
Table 4 shows that 81% of motors with more than 20 horsepower
are rewound and that this percentage is increased by increasing the
horsepower.
3.2. New standard efficient motor or HEM
Energy savings, bill savings and the payback period associated
with energy savings as a result of using a HEM are presented in
Table 13 for different motor sizes and loads. According to the energy
savings analysis, using HEMs can save energy (Table 12). The
amount of saved energy is increased by increasing the motor
horsepower and operating load. Payback period analysis shows that
the payback period is less than two years even though the motor is
operated at a 50% load. It has also been found that payback period
decreases by increasing the percentage of the load. Table 9 shows
that the average motor life is more than 12 years.
3.3. Energy and bill savings and emissions reductions
Energy is an indispensable factor for continuous development
and economic growth. The demand for energy is increasing rapidly
in developing countries because of automation, industrialisation
and urbanisation. The energy demand in Malaysia increased by 20%
between 1999 and 2002 [51]. As a result, the installation capacity of
energy increased from 14,291 MW in 2000 to 19,227 MW in 2005. It
is predicted that it will be 25,258 MW by the end of 2010 [52,53].
Electric motors consume about 48% of the energy in the industrial
sector in Malaysia. By using HEMs, about 5.5% energy could be
saved. The amounts of energy savings, bill savings and emissions
reductions are shown in Table 14. A survey result of 59 industries in
Malaysia showed that the total amount energy savings would be is
67,868 MWh/year and the corresponding bill savings US$ 4,343,531
per year. In Malaysia, there are about 3000 industries in different
sectors [39]. If HEMs could be used in all these industries, about

Table 13
Energy and bill savings and payback period for a HEM over a standard motor at different loads.

Motor hp Increment price (US$) Energy savings (kWh/year) Bill savings (US$/year) Payback period (year)

Load (50%) Load (75%) Load (100%) Load (50%) Load (75%) Load (100%) Load (50%) Load (75%) Load (100%)
5 63 1459 2078 2480 67 96 114 0.9 0.7 0.5
7.5 80 2020 2878 3435 93 132 158 0.9 0.6 0.5
10 97 2090 2977 3552 96 137 163 1.0 0.7 0.6
15 132 2955 4210 5023 136 194 231 1.0 0.7 0.6
20 167 3819 5440 6491 176 250 299 1.0 0.7 0.6
25 202 4110 5854 6986 189 269 321 1.1 0.7 0.6
30 237 4591 6540 7805 211 301 359 1.1 0.8 0.7
40 306 5964 8496 10,138 274 391 466 1.1 0.8 0.7
50 376 7051 10,045 11,987 324 462 551 1.2 0.8 0.7
60 446 8041 11,455 13,670 370 527 629 1.2 0.8 0.7
75 550 10,990 15,656 18,683 506 720 859 1.1 0.8 0.6
100 725 13,316 18,970 22,637 613 873 1041 1.2 0.8 0.7
125 899 17,553 25,005 29,840 807 1150 1373 1.1 0.8 0.7
150 1073 16,668 23,745 28,336 767 1092 1303 1.4 1.0 0.8
200 1422 20,269 28,875 34,458 932 1328 1585 1.5 1.1 0.9
250 1770 19,208 27,364 32,654 884 1259 1502 2.0 1.4 1.2
300 2119 23,861 33,992 40,564 1098 1564 1866 1.9 1.4 1.1
400 2816 40,281 57,383 68,477 1853 2640 3150 1.5 1.1 0.9
 M. Hasanuzzaman et al. / Energy 36 (2011) 233e240 239

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