Turbine vs. electric motor – a comparison for hazardous areas
Choosing the right drive is crucial. In potentially hazardous production areas—known as EX areas—selecting the right drive technology is a key challenge. For example, in conveyor systems, filling processes, pumps, or underground mining: the drive must not only be powerful and efficient, but also meet the highest safety standards.
This is where companies are often faced with the question:
Should a classic electric motor or a pneumatic drive, such as a highly efficient turbine, be used?
This decision has an impact on many areas:
- Safety and explosion protection
- Service life and reliability
- Energy efficiency and operating costs
- Maintenance requirements and availability
We offer you a clear overview and support you in making the right choice for your application.
Electric motors – the classic standard in industry
Electric motors have been the backbone of industrial drive technology for decades.
They are used in a standardized form in almost all areas—from small machines to complex production lines.
Strengths of electric motors:
- High availability and wide range of sizes
- Easy integration into existing systems
- Precise speed control
- Globally standardized interfaces and standards
- Energy-efficient and virtually maintenance-free
However, electric motors have their limitations in potentially hazardous areas. Even explosion-proof electric motors require complex protective measures:
- Additional housings and seals
- Additional cooling required
- Special certifications
- Temperature classes sometimes cannot be achieved in critical zones
- Risk of failure in case of overload
- Risk of short circuit due to electrical connection cables
Conclusion: Although electric motors are versatile, they require considerable additional effort to meet all safety requirements, especially in highly critical EX areas, or cannot be used at all due to the high temperatures they generate.
Turbines as an example of a pneumatic alternative in hazardous areas
A turbine drive operates with compressed air instead of electricity. The turbine converts the air flow into rotational energy. The expansion of the supply air extracts heat from the environment. Instead of giving off heat, a turbine actually cools down. This principle makes the drive particularly attractive for use in potentially explosive atmospheres.
Advantages of the compressed air turbine:
- No electrical sparking → maximum safety
- No risk of overheating due to overload
- Stall-proof in case of overload
- Very compact design with high power density
- Minimal maintenance required as there are fewer wearing parts
- Durable even in harsh, dusty, or humid environments
Conclusion: Turbine drives are specially designed for hazardous areas and offer high operational safety without additional protective measures.
Direct comparison: turbine vs. electric motor
| Criterion | Turbine drive (compressed air) | Electric motor (EX-protected) |
|---|---|---|
| Safety in EX areas | Spark-free, no ignition source – ideal for Zone 1 and Zone 2 (temperature class 4–6) | Additional protective measures required (temperature class 2 – 4) |
| Overheating | Virtually impossible | Risk exists, complex temperature sensors required |
| Space requirements | Small size | Larger dimensions required |
| Energy efficiency | Particularly efficient at high starting torques | High efficiency |
| Maintenance costs | Minimal, few wearing parts | Regular testing required |
| Service life | Very high, even in harsh environments, overload-proof | Not overload-proof |
| Investment costs | Higher acquisition and operating costs | Lower acquisition and operating costs |
| Positioning accuracy | Low | High |
You can read about what is important in the various industries in the article Explosion-proof drives: Solutions for underground mining, chemicals, pharmaceuticals, and food production.
Energy efficiency – a look at operating costs
A common argument in favor of electric motors is their high energy efficiency in many standard applications. However, in hazardous areas, the perspective shifts:
- Electric motors require additional protection systems that consume energy.
- Turbine drives use compressed air, which is often already available in production facilities.
Practical decision-making aid
The choice between a turbine and an electric motor depends heavily on your operating conditions. Ask yourself the following questions to help you make the right decision:
- Are your systems mainly located in Zone 1 or Zone 2?
- How long are the running times and what are the loads (risk of overload) in daily operation?
- Is a central compressed air supply already available?
- How important is the reliability of your drive?
- How much installation space is available for the drive?
For your reference:
- Turbine drive:
when explosion protection, maximum reliability, and size are paramount and harsh operating conditions prevail.
- Electric motor:
For all standard applications in a normal production environment and when application and operating costs play a major role.
Conclusion: Investing for the future
Safety is non-negotiable in hazardous areas. Turbine drives offer decisive advantages here, especially when safety requirements are high. Electric motors remain a proven solution, but require significantly more effort to be used in explosion-proof applications.
If you would like to learn more about the basics and technical background of ATEX-certified drives, read our feature article ATEX-certified turbine technology: When electric motors reach their limits.
Recommendation: Carefully review your production requirements and rely on a comprehensive assessment of safety, efficiency, and total cost of ownership.
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