A comprehensive analysis of the energy, economic, and environmental impacts of industrial variable frequency drives

Abstract

Motor systems are ubiquitous throughout the industrial sector, particularly in fluids applications. It is well known that the efficiency of these operations can be greatly enhanced using variable frequency drive (VFD) controls, but adoption of the technology is far from universal. The goal of this paper is to introduce engineering, economic, and environmental analyses to demonstrate benefits to both individual facilities and the state at large. Individual case studies are presented to describe the variety of opportunities for VFD-enhanced motor control; however, this project seeks to describe the combined impact of VFD implementation at a new scale. Data sourced from a U.S. Department of Energy program is used to perform economic and environmental input output analysis to calculate broad impacts of individual audits and recommendations. Results indicate that widespread implementation of VFD controls on motor systems in the industrial sector will introduce significant economic and environmental benefits. One of the scenarios showed a potential reduction of over 4.7 million tonnes of carbon dioxide from regional manufacturing sector as well as a cascading contribution to the regional economy totaling nearly $1 billion. The results are presented as a demonstration of the magnitude of impact that improving control of industrial motor systems can have, as a guide to industry leaders and policymakers about the value of such investments.