World’s first magnet-free IE6 motor for hazardous areas

Reducing energy consumption in explosion-risk areas remains a challenge for industries such as oil and gas, chemicals, pharmaceuticals, food processing, and maritime. ABB has expanded its portfolio with an IE6 increased safety SynRM motor certified according to ATEX and IECEx requirements, designed for applications involving pumps, compressors, and fans in classified environments.

The motor uses permanent magnet-free and rare earth-free Synchronous Reluctance (SynRM) technology, aiming to improve energy efficiency while reducing emissions associated with industrial processes.

Reducing energy losses in critical industrial systems
According to ABB, the IE6 Hyper-Efficiency SynRM motor reduces energy losses by up to 60% compared to IE3 induction motors commonly used in Zones 1 and 2. Energy efficiency is especially important in continuous operation installations, where electricity consumption accounts for the largest share of total operating costs throughout the motor’s lifecycle.

The company estimates that replacing a single 110 kW motor with an IE6 solution, operating 8,760 hours annually at an average load of 75%, could generate energy savings of €87,520 over 20 years. During the same period, emissions reductions would reach 157,540 kg of CO₂, equivalent to the annual emissions of 37 gasoline-powered cars. The estimated payback period is eight months.

Certification for ATEX areas and operation with variable speed drives
The motor is certified for use with variable speed drives (VSDs), enabling precise speed control and maintaining efficiency even under partial loads. This is particularly relevant in industrial applications with operational fluctuations, where dynamic speed control can reduce energy consumption and mechanical wear.

ATEX and IECEx certification enables use in environments where flammable gases, vapors, or dust may be present. In Zone 1 installations, lower operating temperatures may allow the use of increased safety motors instead of flameproof motors with special configurations. In Zone 2, the declared higher load capacity enables greater power output at the same size compared to equivalent induction motors.

Magnet-free technology to reduce dependence on rare earth materials
The SynRM architecture eliminates the use of permanent magnets and rare earth materials, components subject to cost volatility and geographically concentrated supply chains. Beyond reducing material complexity, the technology aims to simplify installation and maintenance while maintaining high performance in demanding industrial environments.

The IE6 SynRM motor is available for outputs from 110 kW, while IE5 variants cover applications up to 90 kW. Both are part of ABB’s IEC-compliant low-voltage motor portfolio for hazardous areas, which also includes induction alternatives with efficiency up to IE4 class.

Edited by Natania Lyngdoh, Induportals Editor, with AI assistance.

www.abb.com