Energy efficiency and green transformation: a VFD case study in an industrial facility

Authors : Mustafa Gençay, Altuğ Bozkurt, Erşan Ömer Yüzer

Pages : 577-589

Doi:10.17714/gumusfenbil.1582904

View : 79 | Download : 50

Publication Date : 2025-06-15

Article Type : Research Paper

Abstract :In today\\\'s world, where competition and change are aggressive and rapid, managing and reducing fixed input costs has become critically important for both the private sector and public institutions. Among these fixed input costs, energy expenses stand out as the most significant and controllable factor. A major portion of energy consumed is attributed to the use of electric motors. These motors, particularly those with high energy consumption, are typically designed to operate at constant speeds and deliver constant output. However, with modern production techniques and practices, many applications now require motors to operate at variable speeds using advanced technological control methods. In this context, Variable Frequency Drives (VFDs), based on power electronics, are used to control motor speed and ensure efficient and economical use of energy and energy resources. By enabling motors to operate more efficiently, VFDs contribute significantly to green transformation in the industrial sector. In addition, they offer several benefits such as extending the service life of motors and electrical cables. However, due to the power electronics components used in their structure, VFDs can cause harmonic distortion. This study aims to demonstrate energy management practices to improve the energy efficiency of induction motors commonly operated with Y-Δ starters in industrial settings and to analyze the effects of harmonic distortion on the power grid. In this context, power consumption, cost analysis and harmonic analysis of different starting methods have been carried out. Furthermore, the energy savings and the level of harmonic distortion resulting from VFD usage have been evaluated and compared with the conventional Y-Δ method. As a result of the study, the payback period was found to be approximately 1.04 years, depending on the motor’s operating frequency and duration, and the total harmonic distortion (THD) was observed to increase from an average of around 13% to 30%.
Keywords : Analiz, Enerji verimliliği, Sanayi tesisi, VFD, Y-Δ yol verme

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