Go with the flow

The legacy of that era remains in many areas of industry, whereby the common benchmark for equipment performance comparison, especially in like-for-like replacement purchase scenarios, is restricted solely to the kW power rating of the installed motor drive. This figure is still deemed by some to provide sufficient information, as opposed to calculating the actual pressure and flow required to optimise productivity and energy-efficiency. The compressed air equipment in an installation determines the requisite working pressure of the system. This does not just depend on the air compressor, but also on the design of the compressed air system and all of its pipework, valves, dryers, receivers, and filters. At the same time, the nominal air requirement for an application should be determined by calculating the air consumption for all the tools, machines and processes that will be connected. In addition, it should include an estimate of their individual utilisation factors. What must also be taken into consideration at the outset are additions for leakage, wear, and future changes in the compressed air requirement, which, experience shows, should be based on a probability factor that is close to 60 per cent.

The laws of physics state that an increase in pressure creates a decrease in flow. This correlation is important to bear in mind when suppliers seek to determine the required size of an air compressor based on its rated motor power. For example, a basic 7 bar air compressor, driven by a 15 kW motor, will deliver compressed air at a maximum volume of approximately 45 l/s. However, the free air delivery from a 10 bar version will deliver only 37 l/s from the same power unit. Therefore, an increase in working pressure by 1 bar increases the power requirement by approximately 6 per cent.

For this reason, energy conscious manufacturers of stationary oil-injected air compressors should seek to offer potential customers a number of pressure/flow variants in each kW category, and encourage installers to adopt the mantra: pressure + flow = energy = cost. Atlas Copco, for example, offers four options in each kW category across its entire range of rotary screw compressors. In the 11 kW range alone that can represent a 30 per cent differential in flow rate and over 32 per cent difference in unit costs. To illustrate this further, a 26 kW model is available that is unique to the marketplace as all other offerings in this power sector are limited to a choice of 22 and 30 kW machines.

When it comes to replacing existing equipment, most companies would agree that to get the best return from their capital investment it pays to carry out due diligence. One way to ensure a new compressed air system will be optimised, and provide the efficiency improvements that are promised, is by conducting an energy audit. This should be done both prior to replacement and at regular intervals after new equipment has been installed. Applying simple and non-intrusive air audit data logging techniques to compressed air systems provides a true indication of an installation’s air use. Ultimately, it will flag up any wastage factors such as leakage and pressure drops. Most importantly, an audit establishes how well a compressed air system is actually performing and will highlight opportunities to increase production uptime, reduce maintenance and improve operating costs. Monitoring techniques for compressor systems have been applied to countless diverse applications throughout industry and as a result of implementing these energy-efficient measures, it is not uncommon for operating cost savings of as much as 40 per cent to be realised.

Modern compressed air equipment, when correctly matched in terms of pressure and flow to process demands, can offer the benefits of reduced specific energy requirements (SER), improved productivity, and lower lifecycle costs. Their enhanced performance may actually allow a lower kW rated machine to be specified at a correspondingly smaller purchase price and reduced running costs in comparison to higher rated equipment. In recent years, a number of new oil-lubricated rotary screw compressors have been introduced that offer significantly increased performance across these areas.

To take full advantage of what these advanced machines can offer, it pays to apply a few essential rules when deciding on a new compressor: Assess present and future needs by first checking out the existing system with a thorough air audit. Take account of all variables from air end output right through to point of use. Do not rely solely on stated motor power rating to match the compressor performance to the process air demand. Start with the pressure and flow requirement and then find the best fit in terms of drive motor power. Always keep in mind: pressure + flow = energy = cost.

Keith Barron is National Sales Manager of Atlas Copco Compressors.

Editor's Notes:

Atlas Copco Compressors is the GB sales and service operation of the Atlas Copco Group providing oil-free and oil-injected stationary air compressors,  gas and process compressors, vacuum pumps, turbo expanders, nitrogen generators, air treatment equipment (such as compressed air dryers, coolers, and filters) air management systems, and custom designed engineered packages. 

Atlas Copco Compressors’ sales and distribution network means that specialist compressed air advice and service is always within easy reach. A team of over 80 service engineers operates across the country, to ensure maximum running efficiency and minimum downtime at its customers' sites.

In the United Kingdom, Atlas Copco also handles the sales and marketing of construction and mining equipment, portable compressors and electric power generators, industrial power tools and assembly systems – all backed up by a nationwide sales, distribution, service and maintenance network. 

Atlas Copco is a world-leading provider of sustainable productivity solutions. The Group serves customers with innovative compressors, vacuum solutions and air treatment systems, construction and mining equipment, power tools and assembly systems. Atlas Copco develops products and service focused on productivity, energy efficiency, safety and ergonomics. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 180 countries. In 2016, Atlas Copco had revenues of BSEK 101 (BEUR 11) and about 45 000 employees. Learn more at https://www.atlascopco.com/en-uk/compressors. 

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• For further editorial information contact Chris Butcher on 01582 390980.
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