In a major engineering breakthrough, ABB has developed the world’s most energy-efficient large synchronous electric motor, achieving a record-setting efficiency of 99.13%. The motor was custom-designed for a steel plant in India and is expected to deliver significant long-term savings and environmental benefits.
This latest innovation is part of ABB’s Top Industrial Efficiency (TIE) initiative, a program focused on creating motors and generators that go beyond existing performance standards. The newly developed 56 MW synchronous motor is set to power an air separation unit (ASU) at the steel plant, which will process atmospheric air into separate oxygen and nitrogen streams, essential components in steel production.
The motor’s efficiency was validated during testing, surpassing ABB’s own previous record of 99.05%, which had remained unmatched since 2017. For context, most motors of this type operate in the 98.2% to 98.5% range. While the theoretical efficiency limit is 100%, each incremental improvement presents growing challenges in engineering design and manufacturing precision.
By choosing this TIE-optimized motor over a standard design with a typical 98.64% efficiency, the steel plant is set to reduce energy consumption by around 61 GWh and cut electricity expenses by nearly $6 million across the motor’s projected 25-year lifespan. The carbon impact is equally impressive, with an estimated reduction of 45,000 tons of CO₂ emissions, equivalent to taking 10,000 cars off the road for an entire year. The payback period for this investment is calculated at just over three months.
Brandon Spencer, President of ABB Motion, commented: “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. 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.”
Large industrial motors above 3 MW account for a small share of global motor installations but are responsible for converting roughly a quarter of all motion-related energy. Despite their impact, energy efficiency standards for motors of this size remain limited. ABB’s achievement not only addresses this gap but sets a new global benchmark for performance and sustainability.
With over a century of experience in electric motor manufacturing, ABB continues to lead in electrification and automation technologies. The company’s focus on advanced engineering and digital solutions aims to make industrial operations more efficient and sustainable, embodying ABB’s long-term vision of helping industries outrun.
