ABB Sets New Record with 99.13% Efficient Motor at Indian Steel Plant
ABB has raised the bar in industrial motor efficiency by setting a new world record with a large synchronous electric motor that achieved an unprecedented 99.13% energy efficiency. This breakthrough, part of ABB’s Top Industrial Efficiency (TIE) initiative, marks a significant step forward in energy-saving technologies for heavy industry. ABB’s TIE motors and generators are engineered to surpass current efficiency benchmarks, helping customers reduce electricity usage, operating costs, and total cost of ownership (TCO) without compromising performance or adding complexity.
Designed for a steel plant in India, the motor surpasses ABB’s previous record of 99.05%, set in 2017. This achievement highlights the difficulty of approaching the theoretical efficiency ceiling of 100%, where every incremental gain demands advanced engineering and precision manufacturing.
According to ABB, opting for a TIE-optimized motor, rather than the standard design with 98.64% efficiency level, will enable the customer to save around 61 GWh of energy and $5.9 million in electricity costs over a 25-year lifespan – equivalent to four days of peak output from the world’s largest offshore wind farm. It will also support avoiding 45,000 tons of CO₂ emissions, comparable to removing 10,000 cars from the road for a year. The scope for savings and avoided emissions is even greater in other countries where electricity is more expensive.
The motor will drive an air separation unit (ASU) that will liquify atmospheric air so that the oxygen and nitrogen can be separated out to provide pure gases for the steelmaking process.
“ABB is on a mission to help industries outrun – leaner and cleaner – and this project shows how our products go beyond standards with our Top Industrial Efficiency (TIE) initiative which delivers large motors and generators with the highest possible energy efficiency,” said Brandon Spencer, President of ABB Motion. “This initiative helps our customers boost profitability since electricity costs are, by far, the largest component in the total cost of ownership (TCO) of this type of motor, at the same time they are also cutting their carbon emissions.”
ABB’s TIE initiative addresses a major gap in energy efficiency standards for large motors (3 MW+), which, despite being a small part of the global motor base, consume about 25% of all motion-related energy.
“Setting the new world record on efficiency reflects ABB’s ongoing commitment to further optimizing the motor’s electrical and mechanical construction, drawing on extensive application knowledge and over a century of experience in manufacturing electric motors. This achievement is particularly significant given that the average efficiency for this type of synchronous motor typically ranges between 98.2 and 98.5%,” ABB said issuing a statement.
