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Ecodesign of Power Transformers. Environmental Quirk? Or the Evolutionary Stage of Modern Energy?

Ecodesign of Power Transformers. Environmental Quirk? Or the Evolutionary Stage of Modern Energy?

05/04/2024

On a global scale, it is estimated that approximately 2% of total electricity produced is lost in distribution transformers. In the European Union (EU), this percentage amounts to around 50 - 60 TWh/year. Despite the high efficiency of transformers (95 - 99.9%), compared to other static or rotating electrical machines, the cumulative impact of losses from over a million transformers necessitates significant additional electricity generation.

Given the substantial losses in distribution transformers, the EU market has introduced Ecodesign Regulations (Ecodesign - the integration of environmental aspects into the design process of energy-consuming products to improve their environmental performance throughout their lifecycle), such as Commission Regulation (EU) No 548/2014 (2019/1783) and the implementation of Directive 2009/125/EC of the European Parliament and of the Council. The main premises behind the adoption of Directive 2009/125/EC by the European Union include increasing attention to energy efficiency issues, reducing energy consumption, and measures to combat climate change. The use of more energy-efficient transformers is expected to save approximately 16 TWh/year after 2020. This is equivalent to reducing CO2 emissions by 3.7 million tons annually, or half of Denmark's total annual electricity consumption (32 TWh).

As Ukraine is a member state of the Association Agreement with the European Union, the European Atomic Energy Community and their Member States, it is obliged to align its legislation in the energy sector with EU law.

Among the provisions that Ukraine has committed to implementing under the Energy Community Treaty is Commission Regulation (EU) No 548/2014 of 21 May 2014 on implementing Directive 2009/125/EC of the European Parliament and of the Council regarding ecodesign requirements for small, medium, and large power transformers. In Ukraine, this Directive is approved by Resolution No. 152 approving the Technical Regulation on ecodesign requirements for small, medium, and large power transformers, which sets standardized values ​​for no-load losses, short-circuit losses, and efficiency.

Compared to previous standards, ecodesign requirements for short-circuit and no-load losses are increased by 3 - 38% and 49 - 73% for the ECO 1 level, and by 9 - 56% and 54 - 76% for the ECO 2 level depending on the transformer's power and primary to secondary voltage ratios. To comply with loss requirements and environmental requirements, the following technical solutions may be implemented in the design and production of transformers (Table 1).

 

Table 1 - Technical solutions to increase energy efficiency and environmental friendliness of transformers

 

Reducing losses in the transformer:

Increasing service life:

  • use of cores made of amorphous or nanocrystalline alloys;
  • application of high-quality insulation materials;
  • optimization of transformer design;
  • ensuring effective cooling.
  • use of high-quality components;
  • ensuring proper technical maintenance;
  • modernization and reconstruction of old transformers.

 

Use of environmentally friendly materials:

 

Noise reduction:

  • replacement of mineral oils with biodegradable or non-combustible alternatives;
  • use of recycled materials;
  • reducing the use of harmful substances such as lead, mercury, and cadmium.
  • use of noise-absorbing materials;
  • optimization of transformer design.

 

 

Introducing ecological design standards for transformers allows for reduced energy consumption (both primary and final) and CO2 emissions. However, it is evident that in addition to advantages, the introduction of ecological design standards for transformers has several drawbacks, the main ones of which are summarized in Table 2.

 

Table 2 - Advantages and disadvantages of introducing ecological design standards for transformers

Advantages

Disadvantages

Reducing environmental impact:

  • reduction of greenhouse gas emissions;
  • reduction of noise and pollution;
  • preservation of natural resources.

 

Increasing energy efficiency:

  • reduction of energy losses;
  • reduction of operational costs;
  • increased reliability and durability of the transformer.

 

Enhancing competitiveness:

  • compliance with environmental standards and certifications;
  • increased demand for environmentally friendly products;
  • improvement of company image.

 

Increasing initial capital costs:

  • use of more expensive materials and components;
  • implementation of new technologies.

 

Complexity of design and production:

  • need to comply with strict environmental standards;
  • use of new methods and technologies;

 

Need for additional staff training:

  • servicing and operating eco-transformers;
  • compliance with environmental regulations and rules.

 

Possible limitations:

  • not all eco-solutions may be practical or available;
  • difficulties may arise in the disposal of old transformers.

 

 

It is also important to note that the advantages of eco-design of power transformers outweigh the drawbacks in the long term, but the effectiveness of eco-design depends on a comprehensive approach that includes not only the selection of eco-friendly materials and components but also the optimization of transformer design, its operation, and disposal. Overall, compliance with eco-design of power transformers is a beneficial and necessary step towards sustainable development of the energy sector and ensuring environmental safety, especially considering that the technical and economic barriers to eco-design are constantly decreasing, and there is increasing demand for environmentally friendly products from consumers and governments.

Increasing environmental awareness and strengthening environmental standards indicate that eco-design of power transformers is becoming not only an ethical and economic necessity but also a key factor in competitiveness in the energy equipment market.

 

Yevhen KOSARYEV

Ph.D. in Technical Sciences,

Lead Engineer-Designer of the PS and ES Group at LLC "EDS-PROJECT"