Energy Efficiency
Solutions

Aurubis needed to lift the temperature of concentrated sulphuric acid by 50°C to feed Hamburg HafenCity’s district heating network without corrosion failures.

Eight customised Alfa Laval plate heat exchangers, including three semi-welded D-205 Hastelloy units for highly corrosive intermediate absorption towers.

Smelters, refineries, chemical producers, and any heavy industry with high-grade waste heat near district heating networks.

Rio Tinto wanted to cut vessel fuel use and CO₂ emissions by reducing friction between hulls and water across its bulk carrier fleet.

Alfa Laval OceanGlide fluidic air lubrication creates an efficient air layer along the hull to cut drag with no major structural retrofits.

Bulk shipping, container shipping, tankers, and ferry operators looking for retrofit-friendly fuel-saving technologies.

Preem’s refining process was highly energy-intensive and traditional shell-and-tube heat exchangers fouled often, lowering efficiency and uptime.

A single Alfa Laval Compabloc welded plate heat exchanger replaced four shell-and-tube units in the atmospheric distillation process.

Oil refineries, petrochemical plants, and energy-intensive processors with high-fouling heat-exchange duties.

Meta wanted to maximise the efficiency of its Odense data centre and recycle vast server waste heat to help the local utility phase out fossil fuels.

Hyper-efficient hardware, indirect evaporative cooling, renewable wind energy, and heat-recovery infrastructure with industrial ammonia heat pumps.

Data centres, hyperscalers, and district heating operators able to capture and repurpose waste heat.

The maritime industry needed reliable methanol-handling systems to support decarbonisation and a shift away from heavy fuel oil.

Alfa Laval FCM Methanol low-flashpoint fuel-supply system, with over 450,000 hours of sea operation across the installed fleet.

Shipowners, container lines, ferries, and any vessel operator transitioning to alternative low-carbon fuels.

The French mill needed to recover dryer condensate to preheat steam-production water, but transferring loaded fluids upstream tended to clog conventional exchangers.

Alfa Laval heat exchangers placed at the dryer outlet and at the sewage-treatment-plant inlet to capture and reuse heat without clogging.

Paper mills, pulp producers, and any process plant recovering heat from condensate or loaded effluent streams.

In the early 1980s the Kemira sulphuric-acid plant lost its waste heat to the sea and needed to redirect it to Helsingborg’s district-heating system.

Semi-welded Alfa Laval D205 plate heat exchangers with FKMS gaskets in a closed-loop demineralised-water cooling circuit.

Chemical producers, refineries, and any heavy industry near a district heating network with usable waste heat.

The European Spallation Source produces fossil-free waste heat that needed to be captured and integrated into Lund’s district heating network.

Alfa Laval heat exchangers in emission-free SSAB Zero steel feed recovered ESS waste heat into the local district heating system.

District heating networks, large research facilities, data centres, and industrial sites with usable waste heat.

Etanol Lab needed an energy-efficient design for a new Serbian ethanol plant, but integrating beer and rectification columns risked exchanger fouling.

Alfa Laval plate heat exchanger as a low-fouling beer-column reboiler integrating the beer and rectification columns.

Ethanol producers, biofuels plants, and food and beverage distillation operations.

Arlanda Airport needed to heat and cool its facilities sustainably without relying on chillers, heat pumps, or fossil fuels.

Underground aquifer thermal storage system using Alfa Laval heat exchangers to store summer heat for winter use and vice versa.

Airports, large campuses, and infrastructure operators with year-round heating and cooling demand near suitable aquifers.

A leading yeast producer used 5 L of water per 50 g of yeast, facing water scarcity and high evaporator energy demand to remove that water.

Alfa Laval cross-flow membrane filtration installed before the evaporator to remove water and recycle it for cleaning.

Food and beverage producers, fermentation operators, and water-intensive process plants.

With 450+ motors on site, Waggeryd Cell could not identify which were wasting power or were wrongly dimensioned across the pulp mill.

ABB Ability Condition Monitoring with 156 smart sensors plus a Digital Powertrain Energy Appraisal, leading to SynRM motor adoption.

Pulp and paper mills, process manufacturers, and operators of large connected motor populations.

Vale lacked a central system to manage multiple substations across vast mine sites, slowing information exchange and exposing operators to electrical hazards.

Fully integrated ABB Ability System 800xA process and power automation with IEC 61850, AC 800M controllers, e-houses and intelligent electronic devices.

Mining and minerals processors, large industrial sites, and operators with distributed substations and electrical assets.

Formula E teams must finish a race on the energy equivalent of just six litres of petrol, demanding extreme drivetrain and energy-management efficiency.

ABB Formula E electric racing platforms, including Gen 2 and Gen 3 powertrains with regenerative braking and energy-management software.

Automotive OEMs, EV component makers, motorsport teams, and any developer of high-efficiency electric drivetrains.

Data-centre operator STT GDC aimed for net carbon neutrality by 2030 but cooling systems remain its most energy-intensive component.

AI-based optimisation models for the entire cooling plant, including chillers and distribution, fed by sensors and dynamic data analytics.

Data centres, hyperscalers, and IT operators looking to cut cooling energy with AI-driven controls.

In 2020 the plant needed to replace ageing motors on its sludge pumping and flocculation filtration systems while meeting national climate-protection targets.

Four ABB IE5 SynRM motors paired with ACS880-31 ultra-low harmonic drives, plus impeller geometry adjustments, replaced six older motors.

Wastewater utilities, water-treatment plants, and any pumping facility planning motor and drive renewals.

SCA aimed for an entirely fossil-free value chain and needed to find efficiency in a kraftliner operation running 2,400+ electric motors.

ABB Ability Condition Monitoring on motors and drives, with motor recycling and replacement by higher-efficiency models.

Pulp and paper, packaging, and process manufacturers operating large fleets of motors and rotating equipment.

Vessels at Toulon ran diesel generators while berthed, creating significant pollutant emissions in a port that handles 1,300+ ships and 1.6M passengers a year.

ABB-led turnkey shore-to-ship system with intelligent energy management combining solar, lithium battery storage and grid at 50/60 Hz.

Ports, ferry terminals, and maritime infrastructure operators electrifying berth power.

Vessels at Toulon ran diesel generators while berthed, creating significant pollutant emissions in a port that handles 1,300+ ships and 1.6M passengers a year.

ABB-led turnkey shore-to-ship system with intelligent energy management combining solar, lithium battery storage and grid at 50/60 Hz.

Ports, ferry terminals, and maritime infrastructure operators electrifying berth power.

Norwegian distributor Nasta needed to cut the carbon footprint and noise of heavy construction machinery to support national climate goals.

ABB AMXE motors, HES880 drives, energy management and battery/charging systems delivering up to 300 kWh per machine.

Construction, road-building, mining, and heavy-vehicle operators electrifying off-highway equipment.

An 80-metre paper machine relied on 1991-vintage motors and obsolete frequency converters with no remaining spare parts.

36 ABB IE4 high-efficiency motors and ACS880 Multi-Drive frequency converters retrofitted across the entire paper machine.

Paper, packaging, and process manufacturers running large multi-motor production lines reaching end of life.

Six older 30 kW DC motors driving filter drums in a bleacher ran nearly 8,600 hours per year, presenting a major efficiency opportunity.

Six ABB SynRM motor-drive packages with ACS880 drives replacing the legacy DC motors on the bleacher filter drums.

Pulp and paper mills, packaging producers, and other process manufacturers with continuously running motor loads.

Bangkok’s utility was losing close to 30% of supply (5.47 million m³ daily) through pipeline leakage as of September 2018.

Over 400 ABB AquaMaster flowmeters using GSM-SMS radio for high-resolution data and step testing across the distribution network.

Municipal and metropolitan water utilities, and any large pipeline operator focused on leakage and loss reduction.

Karnataka’s Koppal district faced repeated water shortages and major non-revenue water losses across 620 overhead tanks and 16 reservoirs.

ABB AquaMaster 4 electromagnetic flowmeters, ABB Ability Symphony Plus SCADA and remote terminal units across the dispersed network.

Municipal water utilities, regional water boards, and infrastructure operators tackling distribution losses.

Singapore’s water security depends on energy-intensive desalination, creating tension with its 2050 net-zero ambition.

Joint analysis with ABB defined upgrades in motors, drives, switchgear, flowmeters and 800xA control across the desalination plant.

Water utilities, desalination plants, and large industrial water-treatment operators.

Singapore needed to expand desalination to meet 430 million-gallon-a-day demand without derailing its 2050 net-zero target.

Energy-efficient motors, variable speed drives, switchgear, WaterMaster flowmeters and ABB Ability System 800xA distributed control.

Water utilities, desalination operators, and energy-intensive water-treatment infrastructure.

The Helsingborg site had multiple businesses with disconnected electrical and process control systems, crowded switchgear, and equipment well beyond service life.

Redundant ABB Ability System 800xA with AC 800M controllers, IEC 61850 protocol, Relion relays and unified electrical/process supervision.

Chemical plants, industrial parks, and energy-intensive sites needing integrated electrical and process visibility.

The hotel wanted to improve sustainability without compromising guest comfort, but eight HVAC and hot-water pumps were the largest power consumers.

16 higher-efficiency electric motors paired with 13 ABB ACH550 variable speed drives across the HVAC and hot-water system.

Hotels, hospitals, commercial real estate, and any building with pump-driven HVAC and hot-water loads.

IKEA targeted an 80% emissions cut by 2030 and HVAC accounted for ~40% of energy use in its two largest Spanish stores.

15 ABB ACH580 low-harmonic drives plus a complete package of standard ACH580 and ACH550 drives on HVAC systems.

Retailers, shopping centres, commercial real estate, and any large-format building with HVAC-dominated energy demand.

Vietnamese steelmaker Hoa Phat needed real-time emissions data to lower environmental impact and comply with national steel-manufacturing emissions standards.

Ten ABB Continuous Emissions Monitoring Systems (CEMS) on smoke-exhaust pipes with cold-dry gas analysis and integrated real-time data transmission.

Steel mills, cement plants, power generators, and any heavy industry needing continuous regulated-emissions monitoring.

Helsinki needed cleaner property heating to meet Finland’s 2035 carbon-neutral goal, since heating accounts for over a quarter of national energy demand.

Oilon high-temperature ChillHeat heat pumps for combined heating and cooling, equipped with ABB variable speed drives.

District heating networks, commercial real estate, and any building operator looking to displace fossil heating with heat pumps.

Operators lacked the resolution to attribute methane and greenhouse-gas emissions to specific industrial sources from space.

ABB-built optical greenhouse-gas sensors on GHGSat satellites detect emissions to parts per trillion at 100× the resolution of prior sensors.

Oil and gas, mining, utilities, and government agencies needing accurate site-level emissions monitoring.

Operators lacked the resolution to attribute methane and greenhouse-gas emissions to specific industrial sources from space.

ABB-built optical greenhouse-gas sensors on GHGSat satellites detect emissions to parts per trillion at 100× the resolution of prior sensors.

Oil and gas, mining, utilities, and government agencies needing accurate site-level emissions monitoring.

The library needed an energy-efficient HVAC system to handle Shanghai’s climate while meeting the city’s carbon-neutrality plan, since HVAC drives ~50% of building energy use.

129 ABB ACH580 variable speed drives on HVAC pumps, fans and compressors, plus energy management software, solar panels and heat recovery.

Public buildings, libraries, schools, offices, and commercial real estate with HVAC-dominated energy demand.

Campbell’s Shepparton plant targeted a 20% energy-consumption cut by 2025 and identified an inefficient refrigeration compressor motor as the prime opportunity.

A1 Electric Motors installed 72 kW and 55 kW SynRM IE5 motors with ACS580 variable speed drives on four refrigeration compressors.

Food and beverage producers and any energy-intensive plant running refrigeration or process compressor motors.

AP&T needed to cut wasted energy in servo-hydraulic sheet-metal presses while meeting stricter sustainability requirements from automotive customers.

ABB synchronous reluctance (SynRM) motors integrated into AP&T presses, with up to 16 motors fitted on the largest machines.

Automotive suppliers, metalworking, and manufacturers operating servo-hydraulic presses or other high-duty-cycle motor loads.

Water-supply pumps caused harmonic distortion and grid disturbances, while existing softstarter controls wasted electricity and risked damaging other equipment.

ABB ultra-low harmonic variable speed drives plus replacement of pump motors with modern higher-efficiency models on the water network.

Municipal water utilities, wastewater operators, and any pump-driven facility sensitive to harmonic distortion.

Italian steelmaker AFV Beltrame faced soaring energy prices and 1.3 TWh annual electricity use as its largest operating expense.

ABB motors and drives deployed on water pumping, flue-gas extraction and packing-line systems across multiple production sites.

Steel producers, heavy industry, and energy-intensive manufacturers running large pumping and gas-extraction motor systems.

Indian food and beverage facilities face rising temperatures and refrigeration accounts for over half of plant electricity consumption.

ABB variable speed drives and SynRM motors paired with evaporating condensers, sensors and instruments controlling refrigeration loads.

Food and beverage processors, cold-chain operators, and any energy-intensive site relying on industrial refrigeration.

Logistics and transport drive 30% of global CO₂ emissions, with Formula E moving 450 tonnes of freight up to 17,000 km per championship.

Energy-efficient ABB technologies and digitally connected devices integrated into DHL’s value chain to enable electric mobility and renewable-powered events.

Logistics, freight, motorsport operations, and fleet operators pursuing electric mobility and renewable-energy targets.

ABB needed to manage energy efficiency across a large global property portfolio with many older sites lacking technical documentation and benchmarks.

Rapid Energy Reviews, Building Management Systems, high-efficiency motors, heat recovery, PV modules and ABB Ability connected analytics across sites.

Commercial real estate, industrial sites, hospitality, and any organisation managing a multi-site property portfolio.

The Helsingborg site had multiple businesses with disconnected electrical and process control systems, crowded switchgear, and equipment well beyond service life.
Redundant ABB Ability System 800xA with AC 800M controllers, IEC 61850 protocol, Relion relays and unified electrical/process supervision.

Redundant ABB Ability System 800xA with AC 800M controllers, IEC 61850 protocol, Relion relays and unified electrical/process supervision.