The document calls for an updated assessment of the electric motor system market in Europe, as the existing data is over 20 years old. It notes several changes in the market since then, including new efficient motor technologies, lower costs for power electronics, and increased digitization. The document highlights findings from a recent 2021 US motor study, which found motors to be older than previously estimated and significant improvements in load factors and variable speed drive penetration compared to past studies. It concludes that a new comprehensive assessment is needed to identify large potential electricity savings and inform policies to accelerate market transformation.

1. The Need for an Updated European Motor Study
- Key Lessons from the 2021 US Motor Study
Anibal T. de Almeida
João Fong
16 September 2021

2. ISR – University of Coimbra EU Studies
• 2000
Improving the Penetration of Energy Efficient Motors and Drives. SAVEII
• 2009
Ecodesign Lot 11 : Preparatory study for implementing measures of the
Ecodesign Directive to electric motors.
• 2014
Ecodesign Lot 30 : Preparatory study for implementing measures of the
Ecodesign Directive to electric motors and drives.
2

3. Contents
• Need for updating the existing data on European electric motor
systems stock and operating conditions.
• Relevant findings from the US DOE 2021 study
3

4. Existing Data is outdated
• The last comprehensive European
motor system market assessment was
published over 20 years ago.
• Field characterisation
• Identified savings potential
• Barriers
• Measures to overcome barriers to
improved energy efficiency
• Demand side management actions
4
SAVE II Programme 2000

5. Existing Data is outdated
• Most studies since then have based their assumptions on the data
collected in the SAVE II study:
• Installed motor capacity (per sector, power range and efficiency class)
• Average operating hours
• Average load factor
• Share by end-use application
• Load characteristics (e.g. Torque-speed requirements)
5

6. Major motor market transformation changes
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Source: CEMEP

7. Motor efficiency
7
IE1
IE2
IE5
IE4
IE3
Induction
SynRel
PM
Efficiency

8. MEPS Timeline
8

9. Motors in the EU Market (Dec- 2020)
9

10. Motor market changes
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Commercial
availability of
new technologies
Cost
reductions
in power
electronics
Offshoring of
manufacture
Implementation
of motor
efficiency
standards
Other?
Digitization and
improved controls

11. US example for Motor System Assessment
The US Department of Energy initiated an update of the existing US
Motor System Market Assessment led by Lawrence Berkeley
National Laboratory (LBNL), the (first volume published in January
2021) which provides:
-an updated assessment of the installed stock of motor systems in
both the industrial and commercial (services) sectors
-review of the supply chains supporting motor and drives in the
U.S.,
-performance improvement opportunity available from using best
available technologies and maintenance and operation practices.
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12. End-uses – Major changes (Fans, Refrigeration, Air Comp.)
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Source: US-MSMA 2002
US-MSMA 2021
Share of motor system electricity consumption
2021 2002

13. End-uses
13
Source: SAVE II 2000
Electricity Consumption in the European Union Industrial Sector

14. Motor lifetime (Europe)
The average lifetime of motors (including repairs) in previous EU studies have been
estimated based on expert input (without field assessment) to be:
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1.0 – 7.5 kW: 12 years
7.5 – 75 kW: 15 years
75 – 250 kW: 20 years

15. Motor lifetime based on field assessment
• In 2013 the Swiss Energy Agency S.A.F.E.
assessed 4124 separate motor systems in
18 factories.
• The analysis shows that 56% of all motors
and their respective systems were older
than their expected operating life time
(some were twice the expected age).
15
Source: Impact Energy, Switzerland, 2014

16. Motor Lifetime
16
• The new US Market Assessment
found that the majority of motors is
over 10 years old.
• Even for small motors under 20hp,
over 50% were over 10 years old.
• 63% of the nameplates were illegible.
"For older motors with illegible nameplates, the
likelihood that the facility staff will know the
installation date of a motor preceding their
employment at the facility reasons to be low.
Therefore, it can be inferred that a large
percentage of the motors listed as UTC are
older motors (i.e., greater than 10 years old)."
Source: US-MSMA 2021
Age of industrial motor systems broken down by size.
The distribution of power with each age range follows the overall distribution of motor sizes in the industrial sector. This indicates
that the previously assumed lifetime difference for different power sizes may not be correct.

17. Recycling of old electric motors
• Motors are made of large amounts of recyclable valuable
metals.
• Recycling of aluminium, copper and iron provides an
energy-saving of between 75 and 95 per cent compared
to new production of these metals.
• In Sweden, ABB and Stena Recycling recently signed a
long-term agreement on the recycling of old electric
motors, replacing them with modern high efficiency
motors (estimated 4 TWh of savings).
17
Circular
Economy

18. Annual running hours
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Distribution of annual run hours for industrial motor systems by size category.
The run hours do not vary significantly
across size categories.
Source: US-MSMA 2021

19. Annual running hours (Europe)
19
Source: SAVE II 2000

20. Load Factor and Load Variation
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The results show significant
improvements in load factor.
Source: US-MSMA 2021

21. Load Factor
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The 2002 report found that 44
percent of all industrial motor
systems operated below 40 percent
motor load. The current study finds
that this has improved drastically,
and only 8 percent of all industrial
motor systems now operate below
40 percent motor load.
Source: US-MSMA 2021

22. Load Factor (Europe)
22
Source: SAVE II 2000

23. VSD Penetration
23
Penetration rates of VFDs and other control technologies by equipment (industry)
Source: US-MSMA 2021

24. VSD Penetration (Europe)
24
Source: CEMEP

25. Power Electronics Major Development
More Efficient VSDs (Silicon Carbide Vs Silicon)
25

26. 2019-2025 Power Si Market by Application
26

27. Silicon Carbide – Higher efficiency mainly in regenerative drives
Lower losses and reduced harmonics
27
Tesla 3 first car with a SiC inverter – longer range

28. Digitization
28

29. Digitization
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Source: VHK and Viegand Maagoe, 2021
The preparatory study for the Ecodesign and Energy Labelling Working Plan 2020-2024 identified a
potential of 65-130 TWh/year electricity saving from sensorisation (5-10% reduction).

30. Existing Data is outdated
The lack of sufficient and reliable data is a major barrier to effective
decision making and to the implementation of supported policy
options that enable to reach the full potential energy savings in
motor systems.
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31. Motor System Assessment Benefits
• Energy efficiency programs are able to identify the current market needs
or potential impact when designing rebate and energy efficiency programs.
• Electric grid planners can identify motor system usage characteristics
(flexible loads) when developing plans to support the resilience of the
electric grid.
• Manufacturers of motors, motor driven equipment, and drives can
develop technologies to meet the needs of their market.
• Best practices are identified - Motor system end users are able to identify
energy saving opportunities within their own facilities by having reliable
benchmark information.
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32. Conclusions
• There is a very large electricity savings potential which is available by
using the most recent efficient technologies (motors, drives, end-
uses, digitisation, systems optimization, etc.) both for new
installations and in retrofitting existing plants.
• The EU is the World leader having some of the most innovative
manufacturers and has the most advanced regulation on motors and
drives.
• A comprehensive motor system characterization will contribute to
accelerate the motor systems market transformation and to tap a
huge cost-effective savings potential.
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