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Congrès International sur l’Analyse du Cycle de Vie Lille, Novembre 2011
Comparative environmental assessment of the electrical machines winding using the Life
cycle assessment
W.Boughanmi 1, 2 , J.P.Manata 1, 2 , D.Roger 1, 2 , T.Jacq 3 , F.Streiff 4
1 Univ. Lille Nord de France, F-59000 Lille, France
2 UArtois, LSEE, F-62400 Béthune, France
3 EDF - R&D- THEMIS Department - R21, F-92141 Clamart Cedex, France
4 ADEME - SEET Department - 20, Av Grésillé BP 90405, F-49004 Angers Cedex 01, France
E-mail: mwalid.boughanmi@gmail.com, daniel-roger@univ-artois.fr
Disciplinary section of the CNU: Electrical Engineering - 63
Keywords: electrical motor – environmental impact – winding- LCA- impregnation varnishes.
Abstract –
The proposed article describes a comparative LCA study of the electrical machines winding
resulting of two different technologies. The conventional process for realizing winding consists to use
enameled wire with insulation based on monomer that deposited on the wire using solvents often harmful.
The coils are made with this wire usually impregnated with varnishes that also use other solvents. The new
manufacturing process for enameled wire is based on a UV polymerization process without solvent, also
provides a thermo adherent composition for coil wire, which eliminates the final impregnation of the
windings. This article assesses global environmental impact of the machine winding made with this new
wire and compares it with that of a machine made with conventional wire using a LCA approach.
Introduction
Each year, approximately 30 million of new electric motors of all sizes, are sold worldwide, the total
number of motors in the industry, infrastructure and large buildings is around 300 million. These motors
use an enameled wire to realize its coils. An improvement even low of energy or environmental
performance of each unit involves significant environmental benefits at the level of very large quantities
associated. Enameled wire manufacture is a complex operation, energetically costly and relatively
polluting, so this requires substantial environmental impacts. The conventional process of enameling
consists of applying successive layers of very thin varnish on the copper wire [1]. The resins are
monomers dissolved in solvents classified as harmful or carcinogenic products (cresols, aromatic solvents
such as xylene, N-methyl pyrrolidone ...). The concentration of the resin in solvents is between 15 and
40%, i.e. about 60% of the product used evaporates and must be treated which does not prevent a small
part to be discharged directly in the atmosphere. In addition, the combustion of these solvents naturally
generates a lot of CO2, which we know the environmental impact. An alternative solution has been
developed in recent years; it is based on a UV polymerization process that uses no solvents. This new
technology also allows a simple way to add an overlay over varnish-bonding. The aim is to remove the
subsequent impregnation of the windings with varnish and other solvents. The electrical properties of new
wire polymerized by UV were tested, they comply with requirements of IEC 60 317-8 standard. The
purpose is to evaluate and compare the environmental impacts of conventional wire and thermo adherent
wire using a life cycle assessment (LCA) approach.
Comparative environmental assessment of the winding
Eco-design of products and materials is described in ISO 14044 standard, which proposes a
definition of life cycle analysis. The evaluation criteria of product environment impact are numerous, they
provide quantitative and qualitative comparisons. This study follows the method developed by CML Leiden
University (NL) in 1992, revised in 2000. Ten impact indicators are chosen. This study was carried out with
SIMAPRO for the software side. The database used is version 2.2 of ECOINVENT which has several data
on materials, processes, products and energies [2]. The comparative analysis is done using the example
of an induction motor of 10 kW. Table 1 summarizes the different data used on the wire necessary for the
winding. Except the specific values of table 1, other data used are those provided by the database
ECOINVENT, both in the design phase as the end of life phase (for which a scenario of French waste
standard was used).The materials used for coating copper wire in the manufacture of enameled wire,
insulators are specific to highly specialized manufacturing process. They are not yet included in the
databases that summarize the environmental impacts of materials more ‘’general public’’. Nevertheless,
these insulators are modeled by a process of chemical similarity relying on data of simpler components
that compose them. The environmental impact obtained in this way is obviously approximate and certainly
minus from reality because the process that transforms these simples elements to resins ready for using is
neglected.
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