Company

ABB

Technology

ABB's IE6 SynRM (Synchronus Reluctance) electric motor, paired with a variable speed drive (VSD), operates at the peak of industrial motor efficiency. The portfolio of motors includes variants for safe areas and hazardous locations (ATEX/IECEx-certified).

Development, design and purpose

ABB developed magnet-free SynRM technology in 2011 and has continuously evolved the platform to meet the demands of energy-intensive industries. The motor's innovation lies in its rotor: precision-laminated flux barriers create reluctance torque by aligning the rotor with the rotating stator field, enabling synchronous operation with almost no rotor losses. Unlike permanent magnet motors, SynRM rotors contain no rare-earth elements, which can simplify maintenance and minimize supply chain risk. Always paired with a VSD, the system delivers up to IE6 Hyper-Efficiency across a wide operating range, including partial loads, where most motors typically spend their working lives.

Significance in chemical plants

According to the International Energy Agency, the chemical industry is the largest industrial energy consumer and the third-largest industry in terms of direct CO₂ emissions. Motor-driven systems, predominantly pumps, fans and compressors, account for the majority of that consumption. IE6 SynRM motors deliver 40% fewer energy losses than an IE4 motor. In a 110 kW motor application running 8,760 hours a year at around 75% load, that means using ABB’s IE6 SynRM package could potentially save roughly $58,200 and 92,200 kg of CO₂ over a typical 20-year service life, with an eight-month payback period.

Also, with winding temperatures up to 30°C lower and bearing temperatures up to 15°C lower than a comparable induction motor, reduced heat means fewer unplanned outages, critical in continuous chemical production environments. ABB's ATEX and IECEx certification extends these benefits into potentially explosive atmospheres common across the sector.

Unique features

• IE6 Hyper-Efficiency as standard from 110 kW to 450 kW in safe areas, and 110 kW to 400 kW in hazardous areas – with IE5 Ultra-Premium Efficiency options also available
• No rare earth elements or rotor windings, potentially reducing maintenance complexity and environmental impact
• ATEX/IECEx-certified Increased Safety variants enabling deployment in explosive atmospheres for Zone 1 and Zone 2 applications
• Drop-in replacement compatibility with standard IEC induction motors
• ABB Ability Digital Powertrain integration for remote monitoring and predictive maintenance
• EcoSolutions portfolio membership, with third-party-verified environmental product declarations
• Built using low‑carbon and recycled copper, reducing embedded emissions by up to 200 kg of CO₂ per 75 kW motor

Real-world success: GSK, Singapore

In 2025, GlaxoSmithKline (GSK) partnered with ABB to upgrade legacy motors at its vaccine manufacturing facility in Tuas South, Singapore.

Sixty-five SynRM motors paired with ACH580 VSDs are projected to deliver annual savings of 615 MWh of electricity and 246 tonnes of CO₂, reducing energy costs by up to USD 130,000 and exceeding the site's original decarbonisation target by 25%.

The project carries a 2.5-year payback period and supports GSK's commitment to an 80% absolute reduction in greenhouse gas emissions by 2030, with full value chain net-zero targeted by 2045.