Otis Singleton
Machinery consumes a lot of power and energy, and the energy consumption depends on the context and the type of machinery. The industrial sector uses electricity to operate machinery and facilities, with manufacturing accounting for the largest share of annual industrial energy consumption. In 2022, the total U.S. electricity consumption was about 4.07 trillion kWh, a 3.2% increase from 2021, and the highest amount recorded. The industrial sector's share of total U.S. electricity retail sales was 26% in 2022, down from 31.1% in 2000. The use of machine drives in manufacturing processes accounts for a significant portion of electricity consumption, with some industries, such as textiles, plastics, and rubber, having higher energy consumption than others. Large industrial facilities can demand more than 100 MW of power, and electricity costs make up a significant portion of the total life-cycle cost of a motor.
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What You'll Learn
Energy consumption in manufacturing
The energy consumption in manufacturing has two main categories: fuel consumption and non-fuel consumption. Fuel consumption involves the use of combustible energy sources like natural gas, coal, and fuel oils, which are used for generating heat and electricity. In 2018, natural gas was the most significant fuel source, accounting for about 38% of total energy consumption in manufacturing. Additionally, fuel oils made up 3% of manufacturing energy use, while biomass was almost exclusively used as fuel by the wood and paper products industries.
Non-fuel consumption, on the other hand, refers to the use of raw materials or feedstocks to create products. In 2018, non-fuel sources accounted for about 32% of total first-use energy by US manufacturers. Hydrocarbon gas liquids (HGLs) were the most significant non-fuel source, making up 46% of manufacturing feedstock use. Natural gas, again, played a significant role as a feedstock, particularly in fertiliser production.
It's worth noting that electricity powers about 89% of motors in manufacturing. The use of machine drives in energy-intensive manufacturing processes accounts for a substantial portion of total manufacturing electric motor energy consumption. However, the specific energy consumption of machinery depends on various factors, including the type of industry, the efficiency of the machines, and the overall energy efficiency of the manufacturing process.
Efforts to improve energy efficiency in manufacturing can have a significant impact on total energy consumption. The US Department of Energy's sourcebook, for instance, highlights the importance of energy efficiency measures in reducing the total ownership costs related to machine drives. Furthermore, the US Energy Information Administration's (EIA) long-term energy projections consider the effects of increases in energy efficiency, projecting a decline in electricity use for motors in certain industries, such as chemicals, despite increases in production.
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Fossil fuels vs electricity
Machinery can consume a lot of power and energy, depending on the context. Power is the instantaneous rate of energy consumption, while energy is power across time. For example, 1kW of power for 1 millionth of a second is very little energy, whereas 0.0000001 kW of power over a million years is a lot of energy.
The use of machinery in manufacturing processes accounts for about 70% of total manufacturing electric motor energy consumption. In some industries, such as textiles, plastics, and rubber, machine drives can account for up to 25% of delivered energy use. On the other hand, in energy-intensive industries, such as petroleum, coal, food products, and chemicals, machine drives tend to account for a smaller share of energy use due to the significant amounts of energy required for other parts of the manufacturing process.
Fossil fuels, such as coal, oil, and natural gas, have been a major source of energy for electricity generation, powering the Industrial Revolution and improving the quality of life worldwide. However, burning fossil fuels releases carbon dioxide and other greenhouse gases, contributing to climate change and global warming. In 2016, 67.8% of Canada's electricity generation greenhouse gas emissions came from coal, despite coal only accounting for 9.3% of Canada's electricity generation.
Fossil fuel power stations have machinery to convert the heat energy of combustion into mechanical energy, which then operates an electrical generator. The typical thermal efficiency for coal and oil-fired plants is around 37%, while combined-cycle gas-fired plants can achieve 56-60% efficiency. However, as of 2015, carbon capture and storage of emissions are not economically viable for fossil fuel power stations.
Electricity is also used to power machinery in manufacturing processes, with electricity powering about 89% of motors in manufacturing. Electric motors are used for pumps, fans, air compressors, and rotating machinery. In some cases, electricity may be a cheaper and greener alternative to fossil fuels. For example, it may be cheaper to install a 4 5 MW steam recompressor for 4 evaporators than a triple effect train.
In summary, both fossil fuels and electricity are used to power machinery, with electricity becoming an increasingly important source of energy as the world moves towards decarbonization. While fossil fuels have played a significant role in the past, their environmental impact has led to a shift towards renewable and more sustainable energy sources.
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Power vs energy
Machinery and other manufacturing processes consume a lot of electricity. In fact, electricity powers about 89% of motors in manufacturing. The level of electricity use in manufacturing has broader implications for total energy use.
Now, what is the difference between power and energy? Power and energy are two related but distinct physical quantities. Power is the rate at which energy is transferred or converted, and it is typically measured in watts (W), kilowatts (kW), megawatts (MW), etc. On the other hand, energy is the total quantity of work done, and it can be stored and measured in many forms, such as joules, BTUs, newton-meters, and even calories. When we talk about electrical energy, it is commonly measured in watt-hours (Wh), kilowatt-hours (kWh), or megawatt-hours (MWh).
To illustrate the difference, consider the following example: if you use a 60W light bulb for 5 hours, it will consume 300Wh of energy. In this case, the 60W rating is the power rating of the lightbulb, indicating the rate at which energy is transferred from electricity to light over time.
Another way to understand the difference is through the concept of work. Energy is the capacity to do work, while power is the rate of doing work. For instance, pushing a sofa across a room or lifting a suitcase into an overhead compartment are examples of work. The work done remains the same whether you push the sofa slowly or quickly, but the power required to do it will differ. If you push the sofa faster, you are applying more power, but the energy expended remains constant.
In the context of machinery, both power and energy consumption are important considerations. When discussing a machine that runs continuously, such as a motor, it is relevant to consider its power consumption. On the other hand, energy consumption is more relevant when comparing the efficiency of different machines performing the same task, as it takes into account the time required to complete the task.
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Energy efficiency measures
Machinery and industrial processes are major consumers of electricity. In manufacturing, machine drives account for an average of close to 10% of delivered energy use, with this figure rising to 25% in industries such as textiles, plastics, and rubber.
Given the high energy costs associated with machinery, implementing energy efficiency measures can have a large effect on total ownership costs. Here are some strategies to improve energy efficiency in machinery and industrial processes:
- Set Baselines and Prioritize Actions: Establish energy consumption baselines to measure improvements over time and focus on areas with the highest energy savings potential for immediate impact.
- Real-Time Monitoring: Utilize energy management systems (EMS) to track energy usage across all processes and equipment in real-time. This allows for the identification of trends and anomalies.
- Data Analytics: Analyse consumption patterns to identify areas of improvement and optimize energy performance.
- High-Efficiency Machinery: Invest in high-efficiency equipment with better energy ratings and lower consumption. Upgrade outdated machinery to energy-efficient alternatives.
- Variable Speed Drives (VSDs): Install VSDs on motors to adjust energy use based on demand, reducing energy waste.
- Preventive Maintenance: Regularly maintain equipment to ensure optimal performance and energy efficiency. Proper maintenance can help identify and address issues that cause unnecessary energy usage.
- Process Automation: Implement automation technologies to enhance precision, reduce human error, and minimize energy waste.
- Insulation and Sealing: Improve insulation and seal leaks in building infrastructure to reduce energy loss and maintain efficient temperature control.
- Energy-Efficient Design: Integrate energy efficiency into machine control designs. Measure and monitor energy use, and optimize machines, production lines, and facilities through control systems and other changes.
- Voltage Optimization: Supplying excess voltage to machines can waste energy. Ensure machines are designed to accept the appropriate voltage, and consider using step-down transformers to reduce supply voltage when necessary.
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Electricity in modern life
Electricity is an essential part of modern life. People use it for lighting, heating, cooling, and refrigeration, and to operate appliances, computers, electronics, machinery, and public transportation systems.
The industrial sector uses electricity to operate machinery and facilities. For example, the manufacturing industry uses electricity for process heat, and the food processing industry uses electricity for cooling, freezing, and refrigerating food. The industrial sector accounts for most direct electricity use, with manufacturing accounting for about 78% of total annual industrial sector electricity purchases, followed by construction (8%), mining (8%), and agriculture (4%).
Electricity use varies significantly across manufacturing industries. Machine drives account for an average of close to 10% of delivered energy use in manufacturing, but this share can be as high as 25% in the textiles, plastics, and rubber industries. On the other hand, machine drives used in more energy-intensive industries, such as petroleum and coal products, food products, and chemicals, tend to account for a smaller share of energy use within those industries because of the significant amounts of energy needed for other parts of the manufacturing process.
Electricity costs make up about 96% of the total life-cycle cost of a motor, so energy efficiency measures can have a large effect on the total ownership costs related to machine drives. The U.S. Department of Energy's Next Generation Electric Machines (NGEM) program aims to develop a new generation of energy-efficient, high-power-density, high-speed, integrated medium-voltage (MV) drive systems for a wide variety of critical energy applications. These systems will reduce industry's energy footprint and greenhouse gas emissions while supporting U.S. global competitiveness in clean energy products.
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Frequently asked questions
Machinery uses a significant amount of electricity, especially in the industrial sector. The industrial sector's electricity consumption has increased over the years, with manufacturing accounting for the largest share.
Large industrial facilities can demand varying amounts of electricity, depending on their size and specific operations. Some facilities may require over 100 MW of power.
Energy-intensive industrial processes include refrigeration, pumps, fans, compressors, materials handling, materials processing, and facility HVAC systems.
Machinery drives can account for a significant portion of delivered energy use in manufacturing, sometimes up to 25%. Increased electricity use in manufacturing can disproportionately affect total primary energy consumption due to the energy required to generate electricity.
Yes, there are ongoing initiatives, such as the NGEM program, which aims to develop more energy-efficient, high-power-density, and high-speed electric motors and drive systems. These advancements can reduce energy consumption and greenhouse gas emissions in the industrial sector.
