PCN Europe: The new ABB IE6 motors provide an opportunity to upgrade zone 1 and zone 2 applications. In which industry and for which applications will they be used? And what are the power ratings the new motors cover?
David Hawley: The application scope for these high-efficiency motors using synchronous reluctance motor technology (SynRM) is very broad. We see strong relevance across many industry segments, particularly those where hazardous areas such as Zone 1 and Zone 2 are common. In hazardous areas, safety and reliability are non-negotiable. Protecting people and ensuring safe, continuous operation is a key priority. This is especially true when it comes to specifying hazardous areas motors that must operate safely in environments where flammable gases, dust, or vapours can be present - so they are critical for industries like oil & gas, chemicals, marine, pharmaceuticals, and food & beverage.
For example, the oil and gas sector – across upstream extraction, pipeline transport, and downstream refining – relies on a substantial installed base of motors operating in hazardous areas. The chemical industry is another major user, as many processes involve gases, vapors, or powders that create hazardous environments.
We are also seeing increasing demand in the marine sector, particularly for gas transportation. The growing movement of liquefied gases globally has driven the need for reliable explosion proof motor solutions onboard vessels. Industries such as pharmaceuticals and food and beverage might also demand hazardous area solutions – for example in applications involving combustible dusts such as in milling processes for sugar or grain.
In terms of applications, these motors can power pumps, fans, compressors, and mixers across these industries – essentially where continuous operation and high reliability and safety are critical.
In terms of power ratings, ABB’s SynRM hazardous area motors portfolio spans a wide range – from 0.75 kW up to 400 kW – though the efficiency gains are most pronounced at higher ratings, a natural consequence of motor design. This is reflected in the portfolio itself: the new IE6 motor covers 110 kW to 400 kW, while IE5 versions are available up to 90 kW.
PCN Europe: Okay, thank you. How significant are the potential energy savings? What other benefits can users expect in terms of the total cost of ownership?
David Hawley: This is the world’s first IE6 magnet- and rare earth- free motor fully compliant for Zones 1 and 2 and certified to ATEX and IECEx requirements. Certified for use with variable speed drives (VSDs), it offers accurate control and high efficiency throughout the whole speed range even at partial loads. With up to 60% lower energy losses than the IE3 induction motors in common use, operators switching to IE6 can achieve a major boost in energy efficiency and avoid carbon emissions.
Regarding the TCO, it is important to note that the initial purchase price of a motor represents only a small fraction of its total cost of ownership (TCO) throughout its operating life. Around 97% of the motor’s lifecycle cost stems from the energy it uses – meaning that operators that significantly reduce their energy use by adopting high efficiency solutions, like the IE6 SynRM, can boost their productivity with payback often achieved in a matter of months.
To give a concrete example – over a typical 20-year service life, the energy savings from switching just one 110 kW IE3 induction motor up to IE6 would be €87,520, resulting in an eight-month payback period with 157,540 kg CO2 avoided. That’s the equivalent of 37 gasoline powered passenger cars driven for a year. Note that this calculation is based on the motor operating 8,760 hours/year at 75% average load, with an assumed energy cost of €0.20/kWh. These figures show the impact of upgrading just one motor to higher efficiency. But many hazardous areas installations use hundreds or even thousands of motors, so the global energy saving potential is huge.
SynRM benefits extend beyond energy efficiency. As well as increased reliability and reduced maintenance, SynRM technology enables a more cost-effective installation. In Zone 1, cooler running can allow the use of a SynRM Increased safety motor where a Flameproof motor with a special enclosure would be the traditional choice. In Zone 2, the improved loadability of SynRM motors allows more power to be delivered from the same size as an equivalent induction motor. This could enable a smaller, lower-cost motor to fulfil the same duty.
Flexibility is also key. We have adopted a flexible approach to developing our hazardous areas motors portfolio to combine robust construction, high energy efficiency, and reliable operation to deliver trusted performance and certified safety in the most demanding environments. This covers a wide range of protection types, temperature classes, and enclosure options. In addition to SynRM hazardous area motors, ABB’s portfolio also includes induction alternatives up to IE4 efficiency level, such as Flameproof motors, Increased safety induction motors and Dust Ignition proof motors.
But motor technology is only part of our approach. We have an expert team with decades of experience who work with our customers to create customized solutions for even the most challenging environments.
PCN Europe: Thank you. So you already answered what I wanted to ask next, about these benefits. You also can say, with the synchronous reluctance technology you mentioned, another benefit is that the customers have motors without magnets and rare earth metals in it. So given the supply chain challenges of last year's, that is definitely another benefit.
David Hawley: Definitely, that is an important aspect. As manufacturers, we are aware of the challenges associated with permanent magnet materials, including supply chain constraints and broader sustainability considerations.
SynRM motors achieve high efficiency without the use of permanent magnets, a significant advntage when navigating these challenges. At the same time, permanent magnet motor technology remains an important part of the overall portfolio and is used where it is most appropriate. Selecting the right technology for the specific application is the key.
PCN Europe: What would be your recommendation on modernization of motors? How fast should companies think about changing the motor technology in their applications, even if they don't have obvious operational problems?
David Hawley: Traditionally, many users consider upgrading motor systems only when equipment reaches end of life or requires major maintenance, such as rewinding or refurbishment.
But there is a significant installed base of older motors that are still operational yet do not meet the efficiency levels achievable with modern designs. In high-duty applications, these motors can open up a real opportunity for energy savings.
Through energy assessments and system evaluations, we can pinpoint where upgrades, whether motor-only or motor-drive combinations, can deliver tangible benefits. Not all motors are suitable candidates; for example, motors that operate only intermittently will typically have longer payback periods.
However, for continuously operating systems, upgrading to high-efficiency motor technologies can result in relatively short payback periods – often in months – depending on operating conditions.
Beyond energy savings, modern motors also offer improved reliability, longer service intervals, and reduced maintenance requirements, supporting more sustainable and cost-effective operations.
PCN Europe: So the message is at the end, you not only have the right hardware, you also have the service to support potential customers to make the right decision. That sounds really interesting and good news for customers. Thank you, David.
