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ABB motor for Indian steel plant sets world record with 99.13% energy efficiency

ABB motor for Indian steel plant sets world record with 99.13% energy efficiency

Time of India29-05-2025

New Delhi: ABB has set a new world record for
energy efficiency
in large
synchronous electric motors
, with a motor designed for a steel plant in India achieving an efficiency rating of 99.13 per cent.
The motor, developed under ABB's Top Industrial Efficiency (TIE) initiative, surpassed the company's previous record of 99.05 per cent set in 2017. ABB said the new design will help the steel plant save an estimated 61 GWh of electricity and approximately USD 5.9 million in power costs over a 25-year operational lifespan.
The efficiency rating of 99.13 per cent was recorded during testing. The previous benchmark stood for eight years. ABB said the improvement represents a significant technical achievement as motors approach the theoretical efficiency limit of 100 per cent.
The company stated that opting for the TIE-optimized motor instead of a standard design with 98.64 per cent efficiency would also support avoidance of 45,000 tons of CO₂ emissions over the motor's life. This is equivalent to removing 10,000 cars from the road for one year. ABB estimated that the investment would have a payback period of just over three months.
The motor will drive an air separation unit (ASU) at the steel plant. The unit will liquify atmospheric air to separate oxygen and nitrogen for use in the steel production 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,' Brandon Spencer, President of ABB Motion, said.
'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,' he added.
The TIE initiative targets high-performance designs that exceed standard benchmarks. ABB noted that large motors rated 3 MW and above constitute a small share of the global motor base but account for around 25 per cent of all motion-related energy consumption.
The company said that achieving the new efficiency level required optimization of both electrical and mechanical design elements. The average efficiency for this type of synchronous motor typically ranges between 98.2 per cent and 98.5 per cent.

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