ABB has shattered its previous world record for energy efficiency in large synchronous motors, achieving an unprecedented 99.13% efficiency with a new motor designed under the company’s Top Industrial Efficiency (TIE) program. This groundbreaking motor surpasses standard performance expectations, helping clients lower energy consumption, reduce operating expenses, and minimize total cost of ownership (TCO) without sacrificing performance or complicating the design.
The motor, set to power a steel plant in India, achieved this impressive efficiency during testing, surpassing ABB’s prior record of 99.05%, which had stood for eight years. Efficiency refers to the proportion of energy a motor converts into motion, with 100% being the theoretical maximum. Approaching this limit is increasingly difficult, as the motor’s design and manufacturing must be near perfect.
By opting for a TIE-optimized motor, the steel plant will save an estimated 61 GWh of energy and $5.9 million in electricity costs over its 25-year operational life. This energy saving is equivalent to four days of peak output from the world’s largest offshore wind farm. Additionally, the motor will help avoid 45,000 tons of CO₂ emissions, which is roughly the same as removing 10,000 cars from the road for a year. In countries with higher electricity costs, the savings and emissions reductions are even greater. The motor will be used to drive an air separation unit (ASU) that separates oxygen and nitrogen from atmospheric air, providing pure gases necessary for the steelmaking process.
“ABB is dedicated to helping industries improve efficiency and sustainability, and this project demonstrates the success of our Top Industrial Efficiency initiative,” said Brandon Spencer, President of ABB Motion. “By improving energy efficiency, we help our customers lower electricity costs, reduce their carbon footprint, and boost their bottom line.”
ABB’s TIE initiative addresses a key gap in energy efficiency standards for large motors (3 MW+), which, despite representing a small fraction of the global motor base, consume approximately 25% of all energy used in motion-related applications. Achieving this new efficiency record underscores ABB’s commitment to further refining both the electrical and mechanical design of motors, drawing from over a century of expertise in motor manufacturing. This achievement is particularly noteworthy given that typical efficiency for this type of motor ranges between 98.2% and 98.5%.
ABB is a global leader in electrification and automation, driving a more sustainable and resource-efficient future. Through its expertise in engineering and digital solutions, ABB helps industries operate at peak performance while becoming more efficient, productive, and sustainable. Founded over 140 years ago, ABB employs around 110,000 people worldwide and is listed on the SIX Swiss Exchange and Nasdaq Stockholm.
ABB Motion, a leader in motors and drives, is at the forefront of advancing sustainable and efficient industrial solutions. Through its innovative products, ABB Motion supports industries in improving energy efficiency, decarbonizing operations, and enhancing productivity. With more than 23,000 employees in over 100 countries, ABB Motion continues to push the boundaries of technology to help industries achieve greater safety, reliability, and performance.
