Energy efficiency, motor optimisation and the integration of renewable energy and storage were among the technologies highlighted at South African electrical engineering and energy solutions provider WEG Africa’s stand at Electra Mining Africa at the Johannesburg Expo Centre on September 8.

The company used its exhibition stand to showcase a range of technologies, with several of the products on display focused on helping industrial customers manage electricity consumption, improve equipment efficiency and strengthen energy reliability.

One of the key products highlighted was WEG Africa’s new W22 Prime IE5 electric motor.

Electric motors are fundamental to industrial operations, powering equipment such as pumps, conveyors, crushers and processing plants, says WEG Africa electric motors manager Fanie Steyn.

In response to the need for greater motor efficiency, WEG has continued to develop and optimise its electric motor technology, culminating in the W22 Prime IE5 induction motor, which was launched at the exhibition, with plans to extend the range to frame size 450.

The motor was displayed alongside WEG’s W51 heavy-duty electric motors, W22 severe-duty motors and W80 AXgen compact axial-flux motors, giving visitors insight into the company’s motor offering.

The IE5 classification represents a higher level of motor efficiency, with the motor designed to reduce losses, as well as heat generated during operation. This can reduce electricity consumption and associated carbon emissions.

“WEG previously introduced its IE4 motor range at an earlier Electra Mining Africa exhibition and has since seen significant uptake from the mining industry, with thousands of units supplied over the past two years,” he adds.

The company’s motor experts at the exhibition also discussed the progression of efficiency standards, including South Africa’s shifting from no regulation to IE3 Premium Efficiency motors.

A key feature of the W22 Prime IE5 is that it remains an induction motor, using a squirrel-cage design without permanent magnets. It can also operate without a variable-speed drive (VSD) using conventional starting methods.

Steyn says other efficiency improvements have been achieved through changes including additional copper and magnetic steel, improved cooling and a more efficient fan.

Meanwhile, the company highlighted its W80 AXgen axial-flux permanent-magnet motor, which achieves IE5 efficiency and offers high power density. The water-cooled motor can be used in pumping applications where clean cooling water is available.

Energy Control

The stand highlighted WEG’s automation and motor-control technologies, including VSDs, which can help control the amount of energy used based on the process requirements.

The company’s CFW11 remains its primary industrial drive for applications in sectors including mining, petrochemicals, sugar and cement, says WEG Africa automation sales executive Johan van Niekerk.

“If you have a pump that is pumping into a dam, for example, you can control the speed of that pump according to the level of the dam,” he elaborates.

The company also showcased its CFW900 system drive – “intended for more sophisticated industrial applications” – for the first time, ahead of its planned launch early next year.

WEG’s soft starters – providing controlled starts for motors to reduce the stresses associated with startups – were also on display.

Renewables and Storage

Renewable energy and battery storage formed another part of WEG Africa’s energy efficiency offering presented at Electra.

The company is focusing on integrated solutions combining solar generation, inverters, battery energy storage systems (BESSs) and conventional generation, says WEG Africa solar sales supervisor Oscar Harbs.

The solar offering on display included three-phase inverters and BESSs, with the company also engaging with solar system integrators through support and training.

Rather than replacing generator sets entirely, hybrid systems can combine existing generation capacity with solar and batteries to optimise energy use and reduce diesel consumption while improving reliability.

“WEG is targeting commercial solar projects ranging from 1 MW to 100 MW, including mining applications, where reliable electricity is required for baseload and critical operations,” he adds.

The company’s BESS offering covers commercial, industrial, and utility-scale applications, with systems designed for demanding environments.

The company also highlighted generator power plant designs that integrate several gensets with management technologies to provide power based on demand.

For example, the Ummbila Emoyeni Wind Farm, developed by Seriti Green near Bethal, in Mpumalanga, combined a WEG generator, solar panels, battery storage and electric vehicle chargers.

“Excess energy can be stored in the batteries, which can provide about two to three hours of backup when the municipal or [State-owned utility] Eskom connection is unavailable. The generator then provides further backup when the batteries are depleted or solar generation is unavailable,” Harbs adds.

The technologies displayed at Electra demonstrated the focus on managing energy as an integrated system, from improving the efficiency of individual motors to matching equipment output to demand and combining renewable generation, storage and conventional power.

Harbs says this combination of generation, storage and energy-management technologies forms part of its broader focus on improving the efficiency and reliability with which energy is used by African industries.