ABB Motor Sets New Efficiency Record
29 May 2025 CW Team
A massive synchronous electric motor, developed by ABB for an Indian steel plant, has achieved a new world record for energy efficiency. Designed under ABB's Top Industrial Efficiency (TIE) initiative, the motor registered an unprecedented 99.13 per cent efficiency rating during testing. This achievement surpasses ABB's own previous record of 99.05 per cent, set in 2017, and highlights the company's commitment to pushing the boundaries of industrial efficiency.
The motor's exceptional efficiency is projected to deliver significant cost savings for the steel plant. Over its 25-year lifespan, the customer is expected to save approximately $5.9 million (around £4.7 million) in electricity costs, representing an energy saving of 61 GWh. This investment in energy efficiency is anticipated to have a rapid payback period of just over three months.
Beyond the financial benefits, the new motor will also contribute substantially to environmental sustainability. The projected energy savings are equivalent to preventing 45,000 tonnes of CO$_2$ emissions, comparable to removing 10,000 cars from the road for a year. The potential for even greater savings and emission reductions exists in countries with higher electricity prices.
The motor is destined to power an air separation unit (ASU), which will liquefy atmospheric air to separate oxygen and nitrogen � essential 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,� stated 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.�
The TIE initiative specifically addresses a notable gap in energy efficiency standards for large motors (3 MW and above). While these motors represent a small fraction of the global motor base, they account for roughly 25 per cent of all motion-related energy consumption.
This new world record underscores ABB's ongoing dedication to optimising both the electrical and mechanical aspects of motor design. The achievement is particularly impressive given that the typical efficiency for this type of synchronous motor generally ranges between 98.2 and 98.5 per cent, reflecting ABB's century of expertise in manufacturing electric motors and extensive application knowledge.