ABB pushed the boundaries of electric motor technology by setting a 99,13% the record for energy efficiency in large synchronous motors. The achievement was made possible through the company’s Top Industrial Efficiency (TIE) program, designed to create machines that exceed standard performance benchmarks and redefine energy efficiency in heavy industry.
The record-breaking motor, developed for a steel plant in India, reached an unprecedented tested efficiency of 99.13%, surpassing ABB’s own previous record of 99.05% set in 2017. In comparison, the average efficiency for synchronous motors of this size typically ranges between 98.2% and 98.5%, making this milestone particularly significant. Achieving such high performance levels is technically challenging, as the theoretical efficiency limit of 100% leaves very little room for improvement in both design and manufacturing.
Over its projected 25-year operational lifespan, this motor will save approximately 61 gigawatt-hours of electricity and reduce the plant’s operating costs by around 5.9 million dollars. From an environmental perspective, these energy savings translate into preventing about 45,000 tons of CO₂ emissions, equivalent to removing 10,000 cars from the road for an entire year. The return on investment is equally impressive, with a payback period estimated at just over three months.
The motor will be used to drive an air separation unit, an essential stage in steel production where atmospheric air is liquefied and separated into pure oxygen and nitrogen. These gases are critical to the steelmaking process, and the high efficiency of the motor will directly contribute to decreasing the carbon footprint of one of the world’s most energy-intensive industries.
A key aspect of ABB’s TIE initiative is its focus on large motors rated above 3 megawatts—a category that, while representing only a small fraction of the global installed base, accounts for about a quarter of all industrial motion-related energy consumption. Current international efficiency standards are generally less demanding for this size range, leaving significant potential for performance improvements. By exceeding these standards, ABB is setting a new benchmark for what is technically achievable.
Brandon Spencer, President of ABB Motion, highlighted the strategic importance of the project, noting that electricity costs represent the largest share of total cost of ownership for such large motors. By improving efficiency to this level, ABB is helping industries lower both operating expenses and carbon emissions without adding complexity to operations.
