Electricity price hike to drive focus on energy 13 May 2011

UK plants are being forced to address their energy spend by improving efficiency, but massive savings available from variable-speed drives and high efficiency motors are not being recognised.

That is key among the findings from a survey sponsored by ABB, which reveals that UK manufacturers prefer changing energy supplier and turning out lights, ahead of more lucrative and sustainable ways to save costs and cut energy consumption.

Steve Ruddell, energy spokesperson for ABB in the UK, observes that, while there is far greater awareness of the cost of energy, with 52% having experienced price hikes in the past year, plant engineers will have to look beyond the 'low hanging fruit'.

"It is encouraging that manufacturers are looking at ways to reduce their energy bills, [but] many are still only scratching the surface in terms of the savings that are achievable." He comments.

"Reducing lighting costs is highly commendable, but the reality is that the real savings exist by reducing energy use within manufacturing processes," he explains.

When it comes to saving electricity costs, 30% of manufacturers thought the most effective way would be to change electricity supplier. Clamping down on non-efficient lighting and compressed air leakage was also favoured. Investing in equipment that makes industrial processes more efficient came further down the list.

"This list is upside down," insists Ruddell. "Most companies can save thousands of pounds worth of electricity and some can even save hundreds of thousands of pounds by upgrading existing industrial processes, often at comparatively low cost."

Ruddell is concerned that the people tasked with allocating the resources in industry "are not more aware of how electricity is used". His point is that, if equipment is bought on the basis of purchase price alone – at the expense of high running costs – nothing is gained.

"Additionally, process efficiency in industry needs to be addressed in order to get CO2 emissions down. 65% of electricity in industry is used by electric motors, but approximately only 10% of motors have efficient speed control," Ruddell says.

ABB's own analysis shows that most processes in industry are designed for a worst-case scenario that only occurs infrequently, if at all. Yet, motors tend to be left running at a fixed speed which is much higher than what the production requires. Most motors can be reduced to 80% speed without any negative effects on the process, according to Ruddell – with a 20% reduction in speed saving nearly half the energy.

"The potential energy savings in industry are staggering. Realising these savings could help to substantially reduce CO2 emissions. However, our survey suggests people are looking for savings in the wrong places," states Ruddell.

Brian Tinham

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