World-first motor concept promises efficiency gains

Introducing a world-first medium voltage, speed-controlled motor concept that promises huge strides in energy efficiency

With global electricity energy demand growing 10 times faster than any other form of energy demand, it is vital for industries to address the way existing energy is consumed as we shift towards a more sustainable, low-carbon world. One area that holds huge potential for improving efficiency is electric motors, which currently consume around 45% of the world’s electricity.

Less than 20% of all electric motors around the world – roughly 300 million – are connected to a drive that enables variable speed control.

“Think of it like driving your car with the full throttle on and only controlling your speed by braking – this is not very energy efficient,” says Heikki Vepsäläinen, President of ABB Large Motors and Generators. “If you put this in perspective for electric motors, there is huge opportunity for energy efficiency improvements. Energy efficiency measures of speed-controlled motors have gained significant traction in small size motors for low voltage applications. But large motors have so far been left behind, due to initial cost and complexity.”

To address this challenge, ABB Motion, a global leader in motors and drives, has introduced a new medium voltage (MV), speed-controlled motor concept that could deliver energy savings of up to 40% for pumps, compressors, fans and other applications across multiple industries.

“Our new MV Titanium concept makes it cost-effective and straightforward to install a suitable matched motor with increased control, monitoring, and connectivity in a single package,” Vepsäläinen says. “It is the right upgrade solution for existing direct-on-line motors, and the potential savings in energy costs and CO2 emissions are huge – if we retrofitted the entire installed base, it would be like taking just over 1,000 coal-fired power stations offline.”

RETHINKING POWER CONVERSION

With 140 years of motor design and half a century of drives technology experience at its back, ABB is one of the leaders in the motion field. Taking this responsibility seriously, the company has emboldened its mission to help not only its customers, but also the industries in which they operate, to embrace the journey towards a Net Zero carbon-free society.

Two years in development, the MV Titanium concept is the result of an overhaul of thinking at ABB to offer a completely new approach to the power conversion process. Led by Technology Manager Jari Jäppinen, the team began the design from a customer and process point of view to create a totally new motor concept that addresses the main perceived obstacles related to installing a drive with a large motor.

These challenges include not only the initial cost of a separate drive, but also its associated electrical house, transformers, switchgear and cabling that increase both cost and complexity of installation. The MV Titanium consolidates all of these aspects into a single, easy to install package that offers enhanced connectivity and control features for MV motor-driven processes. As a result, the motor can be seamlessly integrated into existing systems to provide software libraries and interfaces for process monitoring and optimisation.

“MV Titanium targets a gap in the marketplace by making it feasible for end users to invest and receive economical payback,” Vepsäläinen explains. “We now have the capability to upgrade existing installations and offer huge benefits not only for our customers but for society as a whole with the energy efficiency potential. MV Titanium is changing the entire philosophy of motor design and control by rethinking the whole topology and structure of the motor and its components.”

RETROFIT MADE SIMPLER

“One of the big challenges today is awareness of the technology and what’s possible,” says Jäppinen. “The retrofit market will be a huge focus for us as we bring MV Titanium to market. With the opportunity for customers to save energy consumption by 40%, there is a lot of interest in the technology from end users across multiple industries. Many customers are interested in pilot set ups because they can see the value for money.”

MV Titanium is currently in prototype stage and undergoing testing at ABB’s Helsinki factory, with Jäppinen expecting the first sales to take place in 2025. Initial sales will most likely be for retrofitting and upgrading existing installations and systems, with the new build market developing later on, he says. While engineered with standardised components, the MV Titanium can be customised to suit specific customer and application requirements, ensuring a seamless integration across a wide range of industries, from power and renewables to mining, processing, cement and water.

Offering significant energy efficiency and operating expense (OPEX) savings for customers looking to retrofit their operations, MV Titanium promises to deliver substantial return on investment (ROI) especially for existing sites where space is at premium.

“Beyond its technical progress, this next-generation motor concept represents a significant step towards productivity in a low carbon world,” Vepsäläinen adds. “It puts ABB well on the road to support changing large, fixed speed motors to fully electrically controlled motors, one by one.”