28 0KW Permanent Magnet Motor + VFD Case Study | SCM Chemical Fiber | Large-Scale Process Equipment Retrofit for Energy Efficiency
A major synthetic fiber enterprise experienced significant efficiency degradation and increased maintenance frequency in its original asynchronous motors for core process equipment, leading to rising annual electricity costs. Following on-site surveys and load condition analysis, the system was upgraded by replacing the existing motors with a 280kW permanent magnet synchronous motor paired with a dedicated variable frequency drive (VFD). The installation and commissioning were completed without modifying any mechanical interfaces. Post-upgrade, operating temperature and vibration levels improved markedly, and energy consumption under load decreased significantly. The full investment is expected to be recovered within 18 months.
RESULTS
Transformation Results
SAVING RATE
Overall energy consumption reduction after retrofit
ENERGY COMPARE
Annual Energy Consumption Comparison (Unit: 10,000 kWh)
KEY METRICS
Equipment operating temperature and vibration significantly improved; load energy consumption effectively reduced.
Data Scope and Validation Source: The above metrics are derived from on-site measurements under identical operating conditions before and after the retrofit (comparing energy meter readings with equipment operation logs). The statistical period covers 30 consecutive days of full operation post-retrofit. Motor energy efficiency ratings follow GB 18613-2020 and IEC 60034-30-1, while product efficiency values are cited from the manufacturer's factory test reports. Actual results may vary based on load rate, annual operating hours, and specific operating conditions.
STRUCTURED LINKS
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Products and Solutions in this Project
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The TYCP5 series flotation machine utilizes a low-speed permanent magnet motor for direct drive of the impeller, replacing the traditional "induction motor + pulley + belt" transmission system. Paired with WD200 high-performance vector inverters, ECC variable frequency control cabinets, and system control cabinets, it can optionally connect to the iMotorLinx Shunzhi Cloud industrial internet platform. Under an 8kW load condition (8), total transmission efficiency increases from 76% to 90.5%, achieving energy savings of up to 16.1%.
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The permanent magnet direct-drive motor, designed specifically for cooling towers, is directly coupled to the fan via a coupling, replacing the traditional "induction motor + reducer (belt and pulley)" transmission system. Paired with the WD200 dedicated variable frequency drive, ECC VFD control cabinet, and iMotorLinx industrial IoT platform, the overall transmission efficiency increases from 81.0% to 93.5% under a 55kW load condition, achieving an energy-saving rate of 28.9%.
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TESTIMONIALS
Customer Reviews
After retrofitting, the spinning workshop's air conditioning system operates stably with significant electricity savings. Energy consumption data over one production cycle closely matches the project's commitments, and the technical team provided prompt on-site support.
Equipment Director, a chemical fiber group in East China
Director of Equipment
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