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Analysis of Energy Saving in Industrial LED Lighti - Es.en
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of Zaragoza, Zaragoza, Spain. anatierz@unizar.es
bUniversityof Zaragoza, Zaragoza, Spain. amiturbe@unizar.es
cUniversity of Zaragoza, Zaragoza, Spain. oguarddon@disenossantelices.com
dUniversity of Zaragoza, Zaragoza, Spain. jlsanto@unizar.es
Received: September 5th, 2014. Received in revised form: April 16th, 2015. Accepted: April 22th, 2015
Abstract
The present study shows the economic savings and environmental advantages of LED lighting technology for industrial applications. For this purpose a
case study in which metal halide lights were replaced with LED lights has been performed. For validating the replacement of 400W metal halide by
200W LED luminaires, there have been performed lighting simulations and field measurements by lux meter. The results indicate that both luminaires
are comparable, obtaining significant energy savings close to 50%. This research demonstrates that LED lighting technology offers high performance
lighting solutions that optimize energy saving, while reducing maintenance costs, with a significantly lower total cost of ownership (TCO), increasing the
life span of the luminaires. From the environmental point of view it means a significant reduction in CO2emissions and the disposal of toxic waste such
as mercury.
Keywords: Industrial LED lighting; High bay LED lighting; LED Vs Metal halide, Total Cost of Ownership (TCO),
Keywords: Industrial LED lighting; Industrial LED high bays; LED Vs Metal Halide, Total Cost of Ownership (TCO).
232
Serrano-Tierz et al /DYNA82 (191), pp. 231-239. June, 2015.
30000
H.M.
25000
Induction 250W
20000
10000
LED 200W
5000
LED 250W
0
Table 1.
Luminous depreciation between luminaires with lamps of different technologies.
Lamp type Lumens Coef. typical of Lumens Lumens at Lumens at Lumens Time of
initials lamp efficiency initials 5000h 10000h at 80% depreciation
luminary luminary luminary luminary luminary lumens at 80%
(llampI)
(LOR)
(lluminaireI)
MH 400W 32500 0.75 24375 19500 17062 19500 5000 hours
Induction 250W 20000 0.75 15000 13200 12750 12000 20000 hours
TL5 4x80W 26200(4x6550) 0.76 19912 18518 18119 15930 22000 hours
LED 200W@ 0.7A 22400 0.89 19800 19206 18810 15840 45000 hours
LED 250W @ 0.7A 28000 0.90 25200 24444 23940 20160 45000 hours
The values that appear in Table 1 for the MH 400W 2.1.3. Comparison of the influence of temperature between
and LED 200W lamp types refer to the proposed case luminaires
study.
Metal halide lamps reach high temperatures of
more than 250°C. This causes a stop
233
Serrano-Tierz et al /DYNA82 (191), pp. 231-239. June, 2015.
heating of the work environment, which can be a problem. results obtained with two types of lamps: a) 400W
An increase in ambient temperature will increase the voltage metal halide and b) 200W LED.
and power on the lamp. It will also increase the degree of a) 400W metal halides
aging and corrosion of the components and may lead to The technical data of the luminaire with HPI Philips
premature failure of the lamp. 400W metal halide bulb is detailed below.
T5 induction or fluorescent lamps use amalgams and
gas with mercury that are strongly dependent on Manufacturer: Philips.
ambient temperature, since they reach their maximum Model: HPK888 P-MB 1xHPI-P400W-BUS RL MB
luminous flux around 35°C. Temperatures above 50°C reflector.
cause a marked decrease in luminosity due to ultraviolet Luminous flux of the lamp at 5000h:
reabsorption in mercury. At low temperatures, the light 32500x0.8=26000 lm.
emitted is drastically reduced, with the minimum working Lighting efficiency ratio: (Light output ratio) LOR=
temperature being -5°C at low frequency and -10°C at 0.77.
high frequency. Initial luminous flux of the luminaire: 20020 lm. Total
The LED luminaires used in the tests have been consumption: 428W.
designed in such a way that they dissipate the heat Simulation conditions:
emitted by the LEDs to the environment, maintaining safe Luminaire centered and suspended 6m high on a
operating temperatures of the semiconductor junction 10m ceiling.
Tj<85°C, in order to avoid light decay due to excess Distance to walls: 7.5m.
temperature and reduce LED aging. An efficient thermal Degree of reflection: GR ceiling 70% GR wall 50% GR
design will ensure adequate temperature under the floor 20%.
specified environmental conditions. Maintenance factor: 0.8.
The use of the LED at low temperatures favors its Table 2 and Fig. 3 show the results of the
efficiency and duration, in which case the power supply simulation of the described metal halide luminaire.
must be designed to operate in these conditions.
available Dialux 4.12.0.1 program [15] has been used, to 73 5.96 327 0.081 0.018
which the models provided by the manufacturers have Source: self made.
been incorporated. In this way they have confronted
Figure 3: a) Left. Light distribution graph (lux) of 400W metal halides using isolines on the ground plane (15x15m). b) Right.
Light distribution graph (lux) of 400W metal halides using color grading (0-500 lux).
Source: self made.
2. 3. 4
Serrano-Tierz et al /DYNA82 (191), pp. 231-239. June, 2015.
Fig. 3, right, shows a three-dimensional representation of the lighting efficiency ratio: (Light output ratio)
LOR= of the scene to be illuminated (width, depth, 0.884.
height, 15m*15m*10m). The floor shows the average Initial luminous flux of the luminaire: 19800 lm. Total
illumination (lux) obtained on it in a color scale. Fig. 3, consumption: 220W.
left, shows a distribution of isolux lines on the ground Simulation conditions identical to the previous
plane. Table 2 shows the average value of the case. Table 3 and Fig. 4 show the results of the
illumination, the extreme values, the maximum/ simulation of a luminaire with 200W LED.
average and minimum/maximum ratio.
b) Luminaire with 200W LED Table 3.
The simulation is carried out with a luminaire that has 200W LED simulation results.
Philips Lumileds SMD Rebel ES 200W LED chips. ANDm(lx) ANDmin(lx) ANDmax(lx) ANDmin/Em ANDmin/Emax
Manufacturer: DSLED. 73 4.37 593 0.060 0.007
Model: CL14200 5000k 120° reflector. Source: self made.
Lamp luminous flux: 22400 lm.
Figure 4: a) Left. Light distribution graph (lux) of 200W LED using isolines on the ground plane (15x15m). b)
Right. Light distribution graph (lux) of 200W LED using color grading (0-500 lux).
Source: self made.
235
Serrano-Tierz et al /DYNA82 (191), pp. 231-239. June, 2015.
15m*15m*10m. The luminaire is centered in the room belonging to orthogonal axes intersecting with and placed at a
height of 6m. Measurements have been taken of concentric circles from 1 to 5 meters in diameter with a step
the luminosity using a Cablematic LX-1010BS lux meter. of 1m. The average illuminance of each zone (Em) has been
The measurements on the 400W luminaire have been calculated by averaging the four measurements located at
made when it has 5000 hours of use. The measurements the points of the circle described above.
have been made on the ground plane. The first of them The results are shown in Table 4. The simulation
directly on its vertical axis and at points results have also been included in this table.
Table 4.
Simulation and experimental measurements of the average illuminance obtained on the ground plane with a 400W HM luminaire and a 200W LED.
Luminary ANDmmax(lux) ANDmR=1m ANDmR=2m ANDmR=3m ANDmR=4m ANDmR=5m
400W HM 317 275 235 180 110 68
400W simulation 327 292 251 195 120 72
200W LED 605 450 285 185 110 70
200W simulation 593 430 275 176 107 67
Source: self made.
Table 4 shows that the average illuminance values of the Calculation of the energy savings obtained by replacing MH400W with
metal halide luminaire are slightly lower than the simulated LED200W.
P(W) Hour kWh/ Days Hour kWh/
model, while in the case of the LED luminaire they are higher. s/day day working days healthy year
The causes of this slight average deviation of 5% are MH400W 428 24 10.27 220 5280 2259.8
attributed to the usual tolerance in the manufacture of
LED200W 220 24 5.28 220 5280 1161.6
components and bulbs. It has not been taken into account
that the number of times the metal halide lamp is turned on Saving 208 4.99 1098.2
energetic
can affect its useful life and lighting performance. This is an
Source: self made.
aspect in favor of LED technology that is not affected by the
number of ignitions.
The simulation results are similar to the real Table 5 shows the energy savings per luminaire
measurements, so the simulation models used are obtained for an installation with 5280h. of annual
validated. Table 4 shows that for radii equal to or operation. This savings is close to 50%.
According to data published by the Institute for
greater than 2m, the average illuminance values are
Energy Diversification and Saving (IDAE), the industrial
of the same order. Table 1 shows that the total lumens
sector consumes 31% of the energy in Spain [16]. With
at 5000h are comparable. The average illuminance of
reference to electrical consumption in industrial lighting,
both luminaires will therefore be comparable.
this represents 15% of it [17]. The implementation of LED
Depending on the type of luminaire analyzed, type of
lighting in industry could reduce companies' electricity
reflector and its aging, different distributions and average
consumption by around 7.5%.
illuminances will be obtained. In this case, it is verified
Taking into account that in the period 2003-2013 the
through the measurements carried out (Table 4), that it is
price of electrical energy in Spain has increased by 77.39%
possible to replace a 400W metal halide luminaire with an
and that the price of energy in Europe doubles that of the
average use of 5000h of use, with a 200W LED luminaire,
USA [17], it is considered a priority to apply actions that
obtaining a significant energy saving of close to 50%. A
involve energy savings that improve the competitiveness of
longer life will also be obtained from the LED luminaires due
the Spanish industrial sector.
to their slow aging compared to metal halide luminaires that
suffer rapid degradation. According to the manufacturer's
data, the useful life of the LED luminaire exceeds 50,000
2.3.3. Economic savings
hours, so the investment would be amortized with a return
period based on the hours of use and subsequently a benefit The economic savings of the investment are calculated
would be obtained until the end of its life. based on the factors shown in Table 6. These factors are:
Energy savings, savings on light bulbs and savings on
maintenance. The main saving factor is energy, although the
2.3.2. Energy savings
costs of maintenance and replacement of light bulbs
Luminaires can be elevated depending on the type of installation;
The difference in consumption between
especially in those that are difficult to access due to their location.
previously described metal halide and LED is 208W,
The calculations in Table 6 use the energy savings
therefore, a 48.6% saving in energy consumption is
obtained in Table 5, valued at a cost of €0.14/kWh plus
obtained. It is possible that depending on the power
taxes and an estimate of the costs of light bulbs and
source and ballast used, the efficiency of the luminaire
maintenance based on the replacement period defined
and therefore the savings rate may vary slightly.
Table 5. by their useful life. .
236
Serrano-Tierz et al /DYNA82 (191), pp. 231-239. June, 2015.
Table 6. Table 8.
Calculation of the average annual savings from replacing MH400W with TCO calculation for LED200W and HM400W.
LED200W. Cumulative cost over service LED 200W HM 400W
Saving Year 1 Average 10 years (CPI 5%) life (10 years)
Accumulated cost of luminaire 601.92 227.04
Annual savings €195.53 €245.94 purchase
energetic Cumulative cost of energy 2601.24 5297.05
Annual savings in €22.70 €28.56 consumption
light bulbs
Cumulative cost of light bulbs 0 285.52
Annual savings €47.24 €59.42
maintenance Cumulative maintenance cost 321.49 915.67
Total annual savings €265.47 €333.91
Total cost of ownership (TCO) 3524.65 6725.28
Source: self made.
Source: self made.
Save of
maintenance 8000.00
average
7000.00
18%
6000.00
Savings on
light bulbs 5000.00
Saving
average energetic 4000.00
8% average Total cost of
74% 3000.00 ownership (TCO)
2000.00
1000.00
0.00
LED 200W HM 400W
Figure 5. Percentage distribution of the average total savings
obtained. Source: self made.
Figure 6. Comparison of total cost of ownership for LED200W and
HM400W.
Table 7. Source: self made.
LED200W investment parameters.
Investment parameters
Investment cost LED200W €570 Cost of Cost of
Lifespan LED200W 50,000 hours maintenance luminary
Average annual total savings €333.91 9% 17%
Payback period Investment 1.71 years
benefit in 10 years €2,592.03
Cost of
Source: self made. light bulbs
0%
Cost of
As shown in Fig. 5, the percentage distribution of each consumption
energetic
type of savings can be seen with respect to the total 74%
obtained.
Table 7 calculates the return period of the investment in
LED200W taking the average annual savings obtained in Table 6.
The total benefit of the investment takes into consideration the
useful life of the luminaire for its calculation.
A detailed analysis of the long-term savings of a Figure 7. Percentage distribution of total cost of ownership for
facility requires the quantification of the Total Cost of LED200W.
Source: self made.
Ownership (TCO = Total Cost of Ownership). This indicator
defines the total cost associated with the purchase and
maintenance of the product during the period of use. Its
c) Energy consumption and contracted power.
calculation depends on various direct and indirect factors
such as [18]: d) Carbon footprint and recycling taxes. In addition to
energy savings, another notable factor is the large
a) Total purchase cost of the luminaire and bulbs
reduction in Total Cost of Ownership compared to
during the years of operation of the installation.
traditional lighting technologies that can produce returns
b) Total cost of maintenance, cleaning, replacement of
on investment of less than two years [19].
equipment and lifting platforms.
237
Serrano-Tierz et al /DYNA82 (191), pp. 231-239. June, 2015.
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239