Get more air for your money
May 1st 2005 Ian Clay travelled to Atlas Copco Industrial Air Division’s HQ in Antwerp, Belgium for the launch of a raft of new products, all with energy efficiency as one of their key criteria
Ronnie Leten, President of Atlas Copco Industrial Air Division introduces the company’s Antwerp facility as “the largest compressor plant in the world”. Indeed, he makes the point that “Thanks to the size of our company and our ongoing investments in R&D Atlas Copco is able to build excellent products.” These new products benefit users in the key areas of energy saving, noise reduction, air treatment and system monitoring and control and integration of functionalities.
As well as the new products and technologies one of the most interesting points of the launch was seeing how Atlas Copco is, like many major players across many different areas, now styling itself as a ‘single source provider’. Andrew Walker, marketing manager products of Atlas Copco Industrial Air Division said “Besides a complete range of air compressors, Atlas Copco also offers a wide range of stand alone and integrated air treatment products. We offer our customers the solution to deliver the required quality of compressed air up to the point of use. The product portfolio consists of refrigeration, adsorption and membrane dryers, filters and condensate treatment equipment and our new piping system”. Ronnie Leten also highlighted the company’s investment in the aftermarket. “By doing this we can improve the customer’s efficiency” he said “Atlas Copco and its distributor network provide their customers with trained and certified service engineers, original spare parts, measurement equipment and audits, consulting and monitoring to assure efficiency and reliability of the total compressed air system.”
SD membrane dryers range A new technology, for Atlas Copco, launched in addition to its refrigerant and dryer. The membrane coating is selective and allows water molecules to pass through, not air. Water vapour thus collects in the space between the fibres. A small amount of dry air at the dryer outlet is directed to the space between the fibres where it expands. The purge air flushes the water vapour to ambient through the openings. The standard product range covers two choices of dew point suppression, 32 and 55°C. Flows range from 3 to 32L/s.
BD100-300 dryers series Also launched was a new range of heat blown dessicant air dryers aimed specifically at demanding applications that need a continuous supply of very high quality air. These packaged units, that include complete filtration and microprocessor control are designed for ease of installation and low lifetime costs.
The BD100-300 range consists of five new models with capacities between 100 to 300 L/s and complements the existing range of larger machines. The new models, that can operate in a broad range of ambient conditions, include two stage inlet filtration, single stage outlet filtration, galvanised piping, fork lift slots and a regeneration air manifold as standard. Due to the critical nature of applications that would need a BD dryer, Atlas Copco has paid attention to ensuring the reliability of the new range. Stainless steel check valves, a 100% stainless steel three-way valve and blow off silencer with integrated safety valve all contribute to its durability.
With energy consumption being the major contributor to the lifetime cost, it’s no surprise that the BD range has been designed for maximum efficiency. The standard machine includes an array of temperature and pressure sensors in addition to a pressure dew point monitor.
Signals from all these instruments enable the Electronikon control system to dynamically adjust the dryer’s operation.
Such close control not only optimises the use of the heater and blower, but also ensures maximum use of each desiccant bed. The final result is a significant and measurable reduction in energy consumption.
Aside from the digital annunciation and the standard voltage free contacts provided by the Elektronikon controller, the addition of the optional AirMonitor or communication box provides the possibility for browser based remote monitoring or even complete remote control via PROFIbus or MODbus.
AIRnet piping system A surprising but, given the single source solution drive, sensible introduction was the launch of a new modular piping system –AIRnet. Designed to “Deliver compressed air to the point of use” (according to Andrew Walker) the piping is simple to install and ensures maximum energy savings. AIRnet is suitable for compressed air and inert gases such as nitrogen. The smooth, low friction inner surface of the pipe maintains a minimum of pressure drop throughout the air distribution system. This allows compressors to work at lower operating pressures, thus reducing power consumption and consequently operating costs.
The non-corrosive properties of AIRnet maintain a constant air quality from the compressor room to production equipment.
System cleanliness protects downstream equipment from contamination, for improved reliability. Made from robust lightweight aluminium tube the AIRnet system is designed to be easily installed.
With a large selection of fittings AIRnet can be used to extend existing pipework or to supply complete systems. The system offers a range of powder coated aluminium pipe and engineered polymer fittings that fit together as a ‘double click’ system. Available from 12” to 4” dia, up to 2” it is claimed that there is no need for a tightening tool. AIRnet is compatible with most types of compressor oils. The blue coloured pipes can be submitted to a working temperature from –20 to 70°C and pressures to 13bar.
GA Plus WorkPlace - Air system range As well as the new products described above Atlas Copco also took the opportunity to launch its redesigned range of core products with the introduction of a new range of premium oil-injected rotary screw compressors from 30 to 90kW. The GA Plus WorkPlace Air Systems range, according to President Ronnie Leten “Offer best in class, both on Free Air Delivery and specific power consumption”.
An integrated water separator device reduces the pressure drop, saving on energy. Water separation efficiency of 100% ensures that no condensed moisture goes downstream into customers’ processes and reduces the load on downstream air treatment equipment. The new air/oil separation system, with lower oil carry over and pressure drop, results in lower operating costs and less downstream contamination of equipment.
A no loss electronic condensate drain removes condensate, using virtually no moving parts, without wasting compressed air. The gearbox simplifies the drive system and decreases energy use, resulting in equal efficiency as in direct drive systems.
A new energy saving algorithm built into the Elektronikon regulator minimises the power consumption during lightly loaded conditions.
The GA Plus WorkPlace Air system range offers the choice between three oilinjected screw compressor concepts in the range 30 to 90kW: The GA series is a compact and economic package; The GA Plus offers ‘industry leading’ free air delivery and energy efficiency; The GA VSD (variable speed drive) offers users high energy savings, greater process control and stability, all at lower working pressures. All three are available as part of the company’s WorkPlace Air System concept that allows placement of the compressors virtually anywhere, with or without integrated dryers and filters.
The new GA range is being introduced throughout 2005. The GA55 through to the 90kW and GA 75 and 90VSD are available from June 2005. GA 30 through to 75kW and GA 37, 45 and 55VSD are available from October 2005.
The scope and diversity of products launched by Atlas Copco in Antwerp (not all of which have been covered here) show that the company is determinedly spreading its business beyond just supplying equipment. The mix of new technology (SD series), improved technology (BD series) and movement into wholly new (but associated) product areas (AIRnet pipework) are all part of Andrew Walker’s very simple message to give end users “More air for their money”. | 
