Oliver Kent, Product Marketing Manager – Industrial Air and Oil Free Air at Atlas Copco explains that advances in technology mean more air can be delivered from units with smaller footprints, smart connectivity, and less energy cost.
Typically, a fifth of UK industry’s electricity bill is attributed to the production of compressed air, but it is a sobering fact that a substantial portion of the generated power dedicated to its production is energy wasted.
That is why over 25 years ago, compressor technology leader Atlas Copco addressed the problem and was the first to introduce VFD/VSD technology in its screw compressors, which is recognised as the greatest energy saving innovation in the history of compressed air developments.
It is a fact that most operators who decide to purchase a variable speed drive compressor do so primarily because of the prospect of low total cost of ownership. Even though the compressor’s initial price tag is likely to be higher than that of equivalent, fixed-speed models − because of its greater sophistication and advanced components – VSD compressors are actually less expensive to own and operate over their lifetime. That is because they consume far less energy and because the cost of that energy makes up the bulk of a compressor’s total cost of ownership.
The benefits of VSD+ technology
Now, in the form of the latest advanced solutions, compressors with high-tech VSD+ specifications are not only capable of achieving outstanding savings of up to 50% of their energy requirement, but they offer the attributes of total functional reliability and the essential benefit of smart control and monitoring communication technology, such as the OPC UA common language that allows equipment items to ‘speak’ with each other.
Where these advanced compressors come into their own is when air demand fluctuates significantly between jobs, varies by shift on weekends or seasonally, and when manufacturing processes require tight tolerances for operating pressure. But of the three primary benefits that VSD+ technology brings to compressor users − energy efficiency, reliability, and connectivity – it is guaranteed energy efficiency that is the key to affordable air with up to 50% achievable savings, and lower cost of ownership.
Stating the obvious, plant operators can only enjoy improved energy efficiency if the compressor keeps on running reliably. That is why market-leading compressors are built to function unfailingly even in the toughest conditions. Specifically, that means a capability of operating at ambient temperatures of up to 46Åã C and making certain that the electrical cubicle of the inverter, a crucial piece of technology for the efficiency of the compressor, can withstand temperatures of up to 55ÅãC.
Industry 4.0 and designed for smart factories
The net results of all these dependable features are smooth operation, productivity gains, increased uptime, and lower maintenance costs. An additional benefit of this increased efficiency is that it also lowers emission levels and allows for a more sustainable production. As a result, a VSD+ compressor does not just improve a company’s bottom line, it also helps to protect the environment.
The principal game-changing innovation of Atlas Copco’s VSD+ design is in the close-coupled IP66-rated drive train − the combination of a high-efficiency motor and technically advanced, asymmetric compression element. The IP55 motor was designed in-house with special attention to cooling requirements and efficiency.
With no coupling or gears between the motor and screw element the compressors are exceptionally quiet, 73dB (A) in operation and extremely energy-efficient in performance. The vertical aspect drive train of the VSD+ machines is a closed circuit in which both the motor and the element are cooled with oil, thus contributing additional energy savings. Added to this is an impressive 6% increase in free air delivery for improved efficiency and performance, plus a reduction in the compressors’ total lifecycle costs in the order of 37%.
Overall, this new technology in the form of the latest revolutionary, compact and smart VSD+ compressors brings unprecedented levels of industry-leading performance and savings to medium and large-scale operations − attributes that can be summed up as more air, smaller footprint, smart connectivity, and less energy cost.
www.atlascopco.co.uk/compressors
compressorsGB.web@atlascopco.com