In 2020, electric motors and their applications accounted for about 70% of the electricity consumption of industry in the EU-27 and over 40% in the service sector. Today, around 8 billion electric motors are in use in the EU, consuming almost 50% of the electricity produced by the Union. The sector is very heterogeneous, with a wide variety of technologies, applications and sizes, ranging from tiny motors, such as those driving computer cooling fans, to huge motors in heavy industries. Even if there are directives today that say that only high-efficiency motors should be placed on the market, and despite the growing awareness of the energy consumption and emissions associated with electric motors, the penetration of high-efficient technologies is slower than expected. According to data presented by the European project EUropean MOtor REnovation (EU-MORE)[1], an initiative that aims to increase the replacement rate of old, inefficient electric motors through the development of new policies, by 2022 around 70% of electric motors on the EU market were of class IE1 and IE2. More efficient motors mean energy savings. According to the project data, as much as 25 TWh/year could be saved by replacing old motors with IE3 motors and assuming a 4% energy efficiency gain, which is the difference between IE3 and IE1 motors. And again, According to the project’s data, this saving could amount to 75 TWh/year if electric motor replacement policies also included audits to encourage system-level improvements such as proper sizing, digitisation, appropriate sensing, elimination of unnecessary drives and use of variable speed drives.
Given these numbers, why is penetration of new motors so slow? João Fong, ISR University of Coimbra, partner in the EU-MORE European project, explains: «Motors are often essential for production processes and their replacement is seen as complex, so it is not considered a feasible energy saving measure for many companies. Furthermore, motors tend to remain in service much longer than their expected life, often up to 30-40 years, which has significant implications for energy efficiency. Quick replacement of these old engines could lead to significant energy savings». But there are also other barriers to engine replacement as, for example, lack of identification of energy saving potential, economic barriers and lack of awareness of the benefits of efficiency.
Replacement means sustainability
Increasing the degree of replacement of inefficient units with new generation motors is in line with European policies to mitigate climate change – Green Deal first and foremost – and with the Commission’s important ambition to become carbon neutral by 2050. In addition, there is the ambition – but also the need – to move to a more circular economy where end-of-life means recovery and recycling and not waste. In this perspective, the importance of the efficient and sustainable use of materials is imperative. Most electric motors are made of recyclable materials with a high residual value, such as copper, iron, electrical steel and aluminum. Recycling these metals and introducing automated processes for motor recycling and remanufacturing would significantly reduce emissions compared to production with metallurgical primary metals.
Added to this, of course, is the current geopolitical context, with the war in Ukraine and pressure on energy prices, which reminds us of and underlines the importance for the EU to become more independent in terms of energy and raw materials.
EU-MORE: tools to find the most effective policy measure
In this context, the European project EU-MORE, starting in 2022 and financed under the European LIFE project framework, aims to develop tools for policy impact projection, monitoring and evaluation that will help Member States to meet their obligations under the Energy Efficiency Directive (EED) In particular, it aims to:
- propose appropriate policies to improve the uptake of high-efficiency motors, combined with motor system optimisation, that can help Member States meet their energy efficiency targets;
- collect data on the subject and develop a model to assess the impact of various policy scenarios in terms of energy savings and greenhouse gas emissions;
- propose policies to stimulate system efficiency (correct motor sizing, variable speed drives, etc);
- promote the use of high-value recyclable materials and the recovering of source material to ensure that motor innovation programmes will contribute the EU circular economy objectives;
- promote the exchange of knowledge on the subject
To better meet its objectives, EU MORE is conducting a survey among electric motor users to understand the potential challenges of early replacement of old motors, as well as to get opinions on how to overcome the challenges.
Which policies to date?
Among the tasks of the project is a mapping of policies supporting energy efficiency measures that are already in place. The project conducted an analysis of policies that directly and indirectly support the replacement of old, inefficient engines or the upgrading of engine systems. The results? Ivan Sangiorgio, Institute for European Energy and Climate Policy – IEECP and project partner, explains: «The policies analysed are mostly aimed at the industrial sector and the service sector. The results show a strong predominance of financial measures, mostly subsidies and loans, followed by mandatory standards. The analysis revealed very little implementation of measures aimed at the education and training of professionals in the field. Moreover, motor replacement is generally included in the transversal efficiency programmes. At national level, Germany was found to be the country with the largest number of policies involving electric motors, followed by Austria. In Italy, as in France, actions addressing motor innovation are eligible under the umbrella of white certificates, which deal with energy efficiency in general, but do not specifically target electric motors».
(by Maria Luisa Doldi)
