Large industries like power generation, renewables, processing, mining, and cement are actively transitioning to low- or no-carbon operations. Each of these sectors faces unique challenges in decarbonizing essential components like pumps, fans, and compressors. However, a common thread connecting them is their dependence on large, megawatt-scale motors, which consume 10% of global electricity demand. Improving the efficiency of these motors is critical, as it can substantially lower emissions and advance the decarbonization efforts of these industries.
While low-voltage applications have seen significant improvements in energy efficiency through using speed-controlled motors, adopting similar technologies in very large motors has been slow. This is primarily due to high initial cost and complex installation requirements, with only an estimated 10–15% of them globally currently equipped with a drive.
ABB has introduced a pioneering solution to overcome these challenges: the MV Titanium. It is the world’s first speed controlled medium voltage (MV) motor in the 1–5-megawatt (MW) range where the whole MV motor and speed control topology has been redefined, leading to a single package that is easy to specify and install. MV Titanium’s revolutionary design addresses the growing global demand for greener alternatives while also enhancing industrial productivity.
"The new MV Titanium all-in-one medium voltage motor and control concept offers up to 40% energy savings for pump-driven industries, making an essential contribution to industrial decarbonization," says Jari Jäppinen, vice president of technology at ABB.
In comparison to traditional Direct-On-Line (DOL) motors, the MV Titanium concept provides unprecedented flexibility and dynamic control by adjusting the motor’s speed to match the precise demand of pumps and fans, significantly avoiding the inefficiencies caused by fixed-speed operations.
Cost savings on CAPEX
The MV Titanium concept tackles the primary barriers traditionally associated with installing a drive with a large motor – the upfront investment in a separate drive, plus the associated costs of an electrical house (e-house), transformers, switchgear, and cabling. These elements add substantially to the capital cost and complicate the installation process, particularly in existing facilities where space is limited.
Moreover, in comparison to conventional installations where separate components need to be sourced, managed, and maintained, the MV Titanium concept streamlines budgeting and supply chains, saving operators not just on the initial CAPEX, but also on operational expenditures (OPEX). By reducing the need for ancillary equipment and the power losses associated with long lengths of low voltage, high current cabling, ABB’s solution reduces both the overall system complexity and maintenance burden in the long run.
Energy savings of up to 40%
The MV Titanium’s integrated design simplifies and reduces installation costs while improving control, monitoring, and connectivity by combining a perfectly matched motor and drive into one package. It serves as an ideal upgrade for existing direct-on-line (DOL) motors. This all-in-one concept can save up to 40% of energy in various applications, such as pumps, across multiple industries. The return on investment for operators is highly attractive, with a typical payback period of 1–3 years. Moreover, the broader implications for global energy cost savings and reductions in CO2 emissions are substantial. Retrofitting the entire installed base of an estimated one million motors could equate to the impact of decommissioning over 1000 coalfired power stations.
Ease of installation and operation
The MV Titanium concept streamlines the specification and procurement process by offering a single, integrated electro-mechanical powertrain unit, rather than separately specified and ordered components. This is not merely an assembly of existing components, but a reengineered approach to converting electricity into motion with greater efficiency.
Setup and commissioning are completed during factory testing before delivery to simplify deployment even more. This ensures that each unit is ready to operate immediately upon installation as a pre-configured solution.
A greener future for large motors
As the sole manufacturer of the entire system, ABB guarantees high efficiency, reliability, availability, maintainability, and safety. Leveraging the company’s 140 years of expertise in motor design, 50 years in drive technology, and top-tier R&D capabilities, ABB has created the MV Titanium — a true next-generation innovation.
Equipped with advanced analytics, monitoring capabilities, and system interfaces, the MV Titanium integrates seamlessly with current industrial environments while offering software libraries for detailed process optimization.
Beyond these technical achievements, this pioneering motor concept is a significant stride towards a more sustainable future. It firmly sets the industry on a course to incrementally replace large, fixed-speed motors with fully electrically controlled motors.
As industries globally face increasing pressure to hit net-zero emissions targets, the importance of innovations like the MV Titanium cannot be overstated. The shift toward a more intelligent and sustainable motor-driven system for large pumps promises to reshape the landscape of industrial energy consumption for years to come.
About the author
This article was provided by ABB.
www.new.abb.com/motors-generators/mv-titanium
This article first appeared in the November/December 2024 issue of World Pumps magazine. To read the full issue, click here.
