16% Energy Saving with SEUNGEM Permanent Magnet Motors

2026-11-05 101

HK Motor has released performance data of permanent magnet motors supplied by SEUNGEM for Shenghong Resources Recycling Co., Ltd. This project covers two permanent magnet motor sets for Flotation Cell No.4 (15kW) and Flotation Cell No.12 (22kW).

This project demonstrates a clear industry trend: for carbon reduction and efficiency improvement in mining mineral processing, the upgrade is not merely equipment replacement, but systematic coordination between the motor body and variable-frequency drive. When mining equipment runs continuously for long hours, low power factor and high current loss become core cost bottlenecks. Permanent magnet motors resolve the energy consumption pain points of mineral processing equipment from a system perspective. Without modifying the original production process, they deliver retrofit solutions that guarantee stable production and energy-saving benefits.

The project lead of SEUNGEM stated: “Energy saving for mining and industrial equipment is not simple replacement of a single component, but collaborative optimization of the whole system. Flotation equipment operates nonstop all year round. Traditional induction motors deliver low power factor under actual working conditions, resulting in substantial reactive power loss. By matching permanent magnet motors with dedicated variable-frequency control systems, we monitor operating current and power factor of the motors in real time. Significant power savings are achieved while keeping the flotation process unchanged. Measured data from the Shenghong project once again proves that permanent magnet retrofit can effectively cut electricity costs for mining operators and realize both steady production and carbon reduction.”

Core Working Condition Comparison Before & After Retrofit (operating speed unchanged)

Flotation Cell No.4 Motor Original induction motor: 708 r/min, real-time current 30 A, average power factor 0.46 New 15kW Motor Model LPPM200L-8E5T-750R: 708 r/min, real-time current 24 A, average power factor 0.95

Flotation Cell No.12 Motor Original induction motor: 950 r/min, real-time current 28 A, average power factor 0.62 New 22kW Motor Model LPPM200L-8E5T-1000R: 950 r/min, real-time current 20 A, average power factor 0.92

Measured Performance Improvements

  • Noticeable current reduction: 15kW motor current reduced by 6 A; 22kW motor current reduced by 8 A
  • Sharp power factor improvement: +0.49 for the 15kW unit; +0.30 for the 22kW unit, greatly cutting grid reactive power loss
  • Energy savings from 168-hour continuous testing: 15kW unit: 308.86 kWh saved, energy-saving rate 16.14% 22kW unit: 309.78 kWh saved, energy-saving rate 16.07%

Annual Benefit Estimation

Based on typical mining operation of 7,000 running hours per year:

  • 15kW motor: annual power saving 12,869.2 kWh
  • 22kW motor: annual power saving 12,907.5 kWh Total annual saving for the two units: 25,776.7 kWh, helping customers reduce electricity expenditure and carbon emissions.

The new motors maintain identical operating conditions. No changes to the flotation process or mechanical structure of existing equipment are required.

Mining flotation is a continuous heavy-duty application. Nonstop operation places stringent requirements on motor reliability, working-condition adaptability and payback period. Key highlights of the SEUNGEM solution:

  1. High power factor output: 0.92–0.95 under real operating loads, lowering reactive loss and reducing stress on transformers and power lines
  2. Full working-condition compatibility: unchanged rotational speed after retrofit, no disruption to flotation production continuity
  3. Proven field validation: long-term loaded operation on flotation cells, adapted to dusty, continuous-duty environments in mineral processing workshops
  4. Attractive return on investment: stable measured energy saving rate of approx. 16%, ideal for high-utilization mining sites with 7,000+ annual operating hours