ABB and NOVENCO target energy waste with a turnkey fan package

Fan and ventilation systems run continuously across every major industry. They rank among the highest energy consumers in any facility, yet in most operations they remain an underserved priority on the efficiency agenda.

For the first time, ABB can now offer a complete axial fan package combining the world-leading efficiency of NOVENCO's ZerAx fan with ABB's IE5 permanent magnet (PM) motor and variable speed drive (VSD). With a system efficiency of up to 85 percent in a typical air handling unit (AHU) installation, the package outperforms EC (electronically commutated) and belt-driven fan alternatives.

At the heart of the package is NOVENCO's ZerAx axial fan that achieves up to 92 percent aerodynamic efficiency at the impeller, the world's highest efficiency for an axial fan, thanks to an optimized blade design and a hub reminiscent of a jet engine. The fan is also designed for simple installation and servicing.

"At ABB, we have a long track record in advancing energy efficiency through our motors, generators, and drives portfolio," said Erich Labuda, President, Motion Services division, ABB. "Now, this collaboration with NOVENCO enables us to take that expertise to the system level, giving customers a complete fan package where the efficiency gains are real and measurable. For businesses under pressure to deliver on their energy targets, that difference matters, and it goes straight to the bottom line."

Long life, reliability and serviceability

The turnkey package is designed to last for 15 to 20 years. In addition, when an EC fan fails, its sealed, molded construction makes field repair impractical: the entire unit must be swapped. The modular architecture of the ZerAx package - with fan, motor, and VSD as separate components - means each element can be independently upgraded, retrofitted, or replaced as needed. When the time comes to retire them, customers can capture economic and material value. For instance, motors are composed of highly recyclable materials, with no less than 98 percent recoverable through specialized processes.

Substantial energy savings, and a short payback

In a typical data centre cooling application - comprising over 1,000 fans - substituting EC fans with ABB's axial fan package will cut energy consumption by 15 to 40 percent annually, depending on the age of the installed solution. A similar efficiency opportunity exists across food and beverage, semiconductor and pharmaceutical production, buildings, and infrastructure industries, wherever ventilation systems run continuously and system-level gains translate directly into operational savings.

"In today's world of challenging energy access and rising net-zero ambitions, energy efficiency has become a business-critical priority," added Lars Erik Knaack, CEO, NOVENCO. "This solution demonstrates how our highly efficient fan technology, combined with advanced motors and drives, can help customers accelerate their efficiency and decarbonisation efforts while strengthening profitability. With current energy costs, many fan retrofit projects can achieve a return on investment (ROI) in less than two years."