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Oil-free compressed air with 35 % less energy

Permanent magnet motors make it possible
Oil-free compressed air with 35 % less energy

The variable-speed drive compressors in the ZR 90-160 VSD+ series generate oil-free compressed air up to 35 % more efficiently than compressors with full load/idle control. They are suitable for use in the food and beverage as well as pharmaceutical industry and for all applications with a high demand for compressed air.

Atlas Copco first presented the ZR 90–160 VSD+ series of water-cooled screw compressors at the Frankfurt Achema in 2018. According to the manufacturer, these oil-free compressors with a variable speed drive allow energy savings of up to 35 % compared to compressors with full load/idle control. Generally speaking, the feature which attracts customers most is probably not oil-free compression but the compressors’ very high efficiency, especially compared to oil-injected compressors of similar sizes. Machines of that type have relatively large quantities of oil in circulation. Removing this oil from the air cycle calls for complex systems. As a result, the specific power requirements of large, oil-lubricated compressors are higher than for dry models. Put simply, they need more energy to deliver the same amount of compressed air. Above a power rating of about 400 kW, oil-free ZR compressors are always more efficient. Particularly with new compressors, this makes a difference of between 10 and 15 %. As filters become fouled and clogged over the course of time, the compressor requires more and more energy to overcome the growing resistance, maintain the set pressure and keep the volume flow rate stable.

Many features designed in-house

The new series of compressors have a large number of design features that contribute to their high efficiency, notably the compressor elements, the new cooler design and the improved controller. All elements are installed in a compact, acoustically insulated housing. The ZR merely needs to be connected to the power, compressed air and cooling water systems.

The compressors are driven by two high-performance permanent magnet electric motors, which are already in accordance with the future IE5 efficiency class and are shipped complete with Neos-VSD+ variable-speed drive technology for the first time in this series. This means that the two compressor elements can be operated at different speeds, further improving efficiency. Adjusting the compressor power to actual requirements considerably reduces the energy consumption of the ZR 90-160 VSD+
as well as the associated costs and environmental impacts. The water-cooled IP 66 permanent magnet motors are designed for high efficiency and reliability. This also applies to the converters; like the permanent magnet motors themselves, these were developed in-house by Atlas Copco. The new converters are intended specifically for use with compressors. This is highly relevant in large sections of the process industry where fine dust collects on machine components.

Integrated rotary drum dryer

In the full-feature version (ZR 90-160 VSD+ FF), the compressors are equipped with an integrated MDG rotary drum dryer. This unit was developed for a stable discharge dew point of -40 °C. As far as residual moisture is concerned, the MDG produces high-quality compressed air much more efficiently than other dryers. As a heat-of-compression dryer, the MDG only needs about 0.2 kW of electric power to operate the dryer motor in addition to the heat of compression. As with all rotary drum dryers from Atlas Copco, the additional energy requirement is therefore very low because the MDG manages without additional heating elements and a blower, and it does not operate with purge air to reach low dew points. In addition, the MDG, as an integrated dryer, saves considerable space compared to an external absorption dryer with the same performance. There is no external piping, no electrical wiring, no hot air intake system and no condensate line.

Class 0 oil-free compressed air

All components in the compressor element of the new ZR compressors, especially the profiles, bearings and rotor coatings, have been redesigned for outstanding efficiency and durability. The design and sealing of the compressed air chamber maintain the physical separation between the oil and air systems, ensuring that no oil can enter the chamber and that the air delivered is absolutely oil-free, corresponding to Class 0 in accordance with ISO 8573-1:2010.

The newly designed coolers are fitted with stainless steel tubes with an enlarged exchange surface to further improve cooling performance. The coolers additionally feature special water separators that improve the efficiency of the unit.

Visualisation of machine status data

The Neos converter communicates directly with the new, user-friendly Elektronikon-Mk5 Touch controller. The controller issues warnings, is programmed with information on maintenance intervals and visualises the actual condition of the compressor unit online. The Smartlink data monitoring programme is a standard feature of the controller. This remote monitoring function allows the entire compressed air system to be analysed with a view to planning preventive maintenance.

Compressors in the ZR 90-160 VSD+ series work with Optimizer 4.0, Atlas Copco’s new higher-level controller. This controller
selects the most efficient combination from among the compressors installed at a compressed air station. That way, all equipment requiring compressed air is supplied with air at the required pressure and with maximum efficiency at all times; the operating hours of the compressors are simultaneously balanced. Optimizer 4.0 can also operate air dryers. Via the intuitive user interface, users can inspect the output and energy consumption of each compressor as well as the entire system. Optimizer 4.0 can moreover be monitored on the customer’s PC. In addition, the new ZR compressors can be included in a premium maintenance contract, in which case Atlas Copco assumes responsibility for all maintenance work, upgrades, repairs and possible failures.

www.cpp-net.com

Online search: cpp0119atlascopco

Hall 4, Booth 357


Author: Jörg Schwittek

Business Line Manager
Oil-Free Air,
Atlas Copco

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