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The economic, social and environmental aspects of sustainable development rely on the complex optimization of many factors, including resource conservation, waste minimization, energy efficiency, climate change mitigation, longer product life cycles, and effective recycling. Copper, the “green” material, plays an important role in all of these solutions. Energy efficiency is of dominant importance nowadays due to increasing electrical energy demand, increasing awareness of Global warming & increase in prices of fossil fuels. Bridging this gap from the supply side is a very difficult and expensive proposition. The only viable way to handle this crisis, apart from capacity addition, is the efficient use of available energy, which is possible by using energy efficient devices. Electric motors are a basic need of industry. Motors and motor driven systems are huge consumers of electricity, they are estimated to account for 43%-46% of all global electricity consumption & Moreover electrical motor driven systems consume approximately 70% of energy consumed by the industry. If the entire world were to adopt a least life cycle approach to motor systems, the energy efficiency savings potential is 3,890 billion kWh p.a. by 2030, nearly 30 percent of the total. However, the penetration of energy efficient motors remains low in India and at the same time, below IE1 motors have a substantial market share. Harmonization of the current Indian Standards with IEC 600034-30 shall enable the promulgation of labelling up to IE3 / IE4 and the phase-out of below IE2 motors. Electrical energy consumption can be greatly reduced by replacing older, worn out motors with energy-efficient equivalents and specifying energy efficient motors in new equipment. Such practices not only lower energy costs but also improve equipment reliability.

Essential to consider Least Lifecycle Cost:

Energy efficiency improvements are usually technically simple, relatively low cost and quick and easy to implement. Often, it is simply a matter of sensible purchasing decisions, buying the unit with the lowest lifetime cost rather than the one with the lowest purchase price.

Copper Die-Cast Rotor Technology for Induction Motors & Pumps

The electrical efficiency of motors can be improved by replacing the standard aluminium electrical conductor in the motor rotor with copper, which has a much higher electrical conductivity. Until recently, die-cast motor rotors were produced only from aluminium while researchers worked on solving technological issues with copper pressure die-casting. Today, copper pressure die-casting is a proven technology and thousands of die-cast copper motor rotors are produced annually for motor applications where energy savings are prime design objectives. The use of copper in place of aluminum for conductor bars and end rings of induction motor rotors results in improvements in motor energy efficiency due to a significant reduction in IR losses. Motor modelling by a number of manufacturers has demonstrated that motors with copper rotors yield overall rotor loss reductions from 15 to 20% compared to aluminum. The advantages of motors with copper motor rotors on an equivalent basis with aluminium include the following;

  • They generate less heat and reduce thermal stresses, including those on insulation, which enable them to operate longer.
  • The increased electrical conductivity of the copper rotor material plus the need for a smaller volume of steel enables the motors to be shorter in length.
  • Motors have 1‐5% higher energy efficiency ratings, so therefore consume less energy.
  • Motors have lower overall manufacturing costs.

Current and potential applications for motors incorporating die cast copper rotors

Application Driver
Agricultural pumps Efficiency, torque
Water circulation pumps Efficiency, torque
Oil well pumps Efficiency, torque
Aeronautic applications Low volume, high speed
Refrigeration compressors High efficiency
Ceiling conveyor belt Low weight

Copper as a choice for rotors in Motors & Pumps:

The attributes of copper for electrical applications is well appreciated due to its better electrical conductivity. The advantages of using copper include:

  • Improved Performance by way of reduced losses and higher Efficiencies and reduced temperature rise
  • Increased power density resulting in reduced size (Less power to space ratio) and reduced active material content resulting in material cost reduction

With the technological breakthrough in copper die casting, now it is economically viable for mass production of copper rotors. In india copper rotors are commercial viable, and are supplied by KITRA industries, who has done continuous R&D for developing good quality rotors with world’s lowest process cost & are supplying commercially in large quantities.

Switch to IE2 / IE3 EE Motors

Benefits of Energy Efficient Motors:
Many efficient motors run cooler and are more likely to withstand voltage variations and harmonics than standard motors

Many efficient motors have a slightly higher power factor on average than their standard counterparts

Most efficient motors operate more quietly than standard motors

Contact Person
KN Hemanth Kumar
Chief Manager, EE Motors & Transformers

+91 22 6114 7300

What We Do Video
Energy efficiency brings a competitive advantage. Improving energy efficiency contributes significantly to the reduction of greenhouse gas emissions arising from fossil-fuel generated electricity. The concept of High Efficiency Motors (HEMs) is well known in India, however, its practice & adoption is another matter altogether. The penetration of energy efficient motors remains low in India and at the same time, below IE1 motors have a substantial market share.
ICA India adopted focused market transformation approach through
Updating Standards which are harmonized to global standards
With support of supply chain create awareness among the industrial end users to switch to IE2 and IE3 Energy Efficient Motors & adopting revised standards