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Energy Efficiency Optimization of Motor-Driven Pump Systems: A Case Study in a Moroccan Manufacturing Plant

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Abstract:

This study presents a comprehensive energy audit and optimization strategy for six motor-driven pumps supplying hot water to essential production circuits in a food manufacturing facility. A Level II audit was conducted to diagnose network inefficiencies, including current and voltage harmonic distortions, power factor issues, and motor load conditions. A complementary demand-side analysis was also performed to align pump operations with actual process requirements and reduce energy losses. Adopting a systems approach, the study focuses on optimizing the overall motor system rather than analyzing components in isolation. Three energy-saving measures were proposed: (i) avoiding idle operations through solenoid valves, (ii) reducing motor power consumption with variable speed drives (VSDs) to match the process-required flow rates, and (iii) optimizing heating to prevent excess water temperature and unnecessary energy consumption. These measures led to substantial energy and cost savings—specifically, annual reductions of 44,079.25 kWh of electricity and 2,921 GJ of thermal energy, equivalent to $67,187 in financial savings and a 214.38-tonne reduction in CO₂ emissions. With payback periods as short as 0.7 years, the proposed actions are economically viable and practically implementable. This research contributes to filling the gap in real-world case studies on industrial energy optimization, particularly in developing countries, by demonstrating that significant savings can be achieved through simple, low-cost interventions. It thereby helps break down the barriers that prevent industries from adopting energy efficiency measures. Despite the specific industrial context, the findings are broadly applicable across sectors due to the widespread use of motor systems. Moreover, the study supports both the African Union’s Agenda 2063 and the United Nations Sustainable Development Goals (SDGs) by offering actionable insights for enhancing energy efficiency and sustainability in the industrial sector.

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International Journal of Engineering Research in Africa Vol. 75 View Preview

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Periodical:

International Journal of Engineering Research in Africa (Volume 75)

Pages:

117-140

DOI:

https://doi.org/10.4028/p-c849Yi

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Online since:

October 2025

Authors:

Kawtar Ibn Batouta*, Sarah Aouhassi, khalifa Mansouri

Keywords:

Energy Efficiency, Energy Saving, Energy Transition, Motor System Optimization, Power Quality Analysis, Sustainable Development

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© 2025 Trans Tech Publications Ltd. All Rights Reserved

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