In Australia’s chemicals processing and oil and gas industries, operators face a dual challenge: maintaining the highest safety standards in hazardous environments while achieving aggressive energy efficiency and decarbonisation targets.
As energy costs rise and regulatory expectations tighten, the need for advanced motor technology is becoming more urgent than ever.
Hazardous areas — where flammable gases, vapours or dust may be present — demand motors that deliver uncompromising safety, reliability and compliance. At the same time, these industries are increasingly electrifying operations to reduce emissions and improve operational performance.
This convergence is driving strong demand for next-generation motor solutions that can meet both safety and sustainability requirements.
ABB’s IE6 hyper-efficiency synchronous reluctance (SynRM) Increased Safety motor represents a significant step forward. As the world’s first IE6 magnet- and rare earth-free motor fully compliant for explosive atmospheres (zones 1 and 2), it combines certified protection with industry-leading energy performance.
Certified to IECEx standards and for use with variable speed drives (VSDs), the motor maintains high efficiency across the entire speed range – even at partial loads – making it ideal for applications such as pumps, compressors, fans and mixers.
The impact on energy consumption is substantial. Compared to commonly used IE3 induction motors, ABB’s IE6 SynRM technology can reduce energy losses by up to 60 percent. For Australian operators managing large fleets of motors across refineries, processing plants and offshore facilities, this translates into significant cost savings and reduced carbon emissions.
Over a motor’s lifecycle, energy usage typically accounts for around 97 per cent of total cost of ownership (TCO), meaning efficiency gains deliver both rapid payback and long-term operational value.
As illustrated in the infographic above, between a traditional IE3 motor and an IE6 SynRM motor with drive technology, a single 110kW motor can deliver substantial lifetime benefits.
Over a 20-year operating period, the upgrade can generate energy cost savings of approximately $118,342 while reducing carbon emissions by 197,237kg of CO₂. This environmental impact is equivalent to removing 28 petrol-powered cars from the road for an entire year.
The investment also offers a rapid return, with a payback period of around 21 months. These figures demonstrate how high-efficiency motor solutions can help industrial organisations lower operating costs, and advance decarbonisation goals.
Beyond energy savings, SynRM motors offer additional operational advantages. In zone 1, their cooler running characteristics can enable the use of increased safety designs in applications where flameproof motors were traditionally required, simplifying installation and reducing costs.
Cool running means reduced maintenance requirements for further enhanced reliability and uptime – critical factors in remote or continuous-process environments. In zone 2, they can also deliver greater power density, allowing operators to achieve the same output with a smaller motor footprint.
Flexibility is another key strength. ABB’s hazardous areas motor portfolio spans a broad range of protection types and efficiency classes, enabling tailored solutions for diverse and harsh Australian operating conditions, from offshore platforms to remote installations, and chemical processing facilities. This ensures operators can balance safety compliance, performance and energy efficiency without compromise.
As Australia continues its transition toward a lower-carbon industrial future, technologies like ABB’s IE6 SynRM Increased Safety motor provide a practical pathway to align productivity with sustainability. By integrating hyper-efficient motor systems into hazardous area operations, in industries such as oil and gas, chemicals, pharmaceuticals, and food and beverage, operators can enhance safety, reduce operating costs and accelerate their decarbonisation strategies – turning regulatory pressure and energy challenges into a competitive advantage.
This is supported by ABB Australia-wide.
“ABB is the trusted partner for IEC LV motors, providing end-to-end expertise,” ABB Motion Australia head Rory Paltridge said. “We have an expert team in Australia with decades of experience who work closely with our customers to create customised solutions for even the most challenging environments.”
ABB is helping industries in Australia run leaner and cleaner with its comprehensive portfolio of IEC LV motors for hazardous areas.
To discover more, please visit the ABB website.
