compressed Air

What is the Compressed Air ?

 

Compressed Air is air kept a pressure i.e.greater than atmosphere pressure & its serve so many industrial purpose.  Now compressed air often describe as the fourth utility from small machine shop to big industrial plant.

 

Types of Air Compressor:

1)Reciprocating Air Compressor :

Reciprocating air compressors are positive displacement machine, meaning that they increase the pressure of the air by reducing its volume. 

·        Lubricated / Non – Lubricated

·        No. of Compression Stage

·        Drive Method

·        Cooling Method

 

2)Rotary Screw Air Compressor :

 

Rotary air compressors are positivedisplacement compressors.  The mostcommon rotary air compressor is the single stage helical or spiral lobe oilflooded screw air compressor,  Thecompressors consist of two rotors within a casing where the rotors compress theair internally.  There are novalves.  These units are basically oil cooled (with air cooled or water cooled oil coolers) where the oiled seals the internal clearances.

 

Since the cooling takes place right inside the compressor, the working parts new experience extreme operating temperatures.  The rotary compressor, therefore, is a continuous duty, air cooled or water cooled compressor package.

 

Rotary screw air compressors are easy to maintain and operate. Capacity control for these compressors is accomplished by variable speed and variable compressor displacement. For the latter control technique, a slide valve is positioned in the casing.  As the compressor capacity is reduced, the slide valve opens, bypassing a portion of the compressed air back to the suction.  Advantages of the rotary screw compressor include smooth, pulse-free air output in a compact size with high output volume over a long life.

 

The oil free rotary screw compressor utilize specially designed air ends to compress air without oil in the compression chamber yielding true oil free air,  Oil free rotary screw air compressors are available air cooled and water cooled and provide the same flexibility as oil flooded rotaries when oil free air is required.

 

·        Lubricated / Non – Lubricated

·        No. of Compression Stage

·        Drive Method

·        Cooling Method

3)Centrifugal Compressors :

 

The centrifugal air compressor is a dynamic compressor which depends on transfer of energy from a rotating impeller to the air.

 

Centrifugal compressors produce high-pressure discharge by converting angular momentum imparted by the rotating impeller(dynamic displacement).  In order to do this efficiently, centrifugal compressors rotate at higher speeds than the other types of compressors.  These types of compressors are also designed for higher capacity because flow through the compressor is continuous.

 

Adjusting the inlet guide vanes is the most common method to control capacity of a centrifugal compressor.  By closing the guide vanes, volumetric flows and capacity are reduced.

 

The centrifugal air compressor is an oil free compressor by design.  The oil lubricated running gear is separated from the air by shaft seals and atmospheric vents.

 

·        Non– Lubricated

·        Cooling Method


How to select the correct Compressor ?

 

Analyze the requirement of plant & power source considering the space & portability.

 

Example –

Ø Plant Requirement – 100 cfm.

Ø Dryer& filter losses

Ø Line losses

Ø Compressor rest

Ø Future expansion / artificial / sudden demand – 10% cfm.

TOTAL – 142 cfm. Calculated requirement

 

If plant working on pick that time max 70% to 50% machines in operation & 20% to 30% machines are ideal for various reason.  It means your total plant requirement is 80% of calculated cfm.

 

 

Life cycle cost of compressor :

In a survey found compressor is the biggest source of energy consumption.  Generally the electricity consumption of air compressor 20% to 55% of whole factory.  A properly design compressed air system start from the selection of highly energy efficient equipment product.  Save the electricity energy and reduce maintenance cost, decrease down time, increase production, improve product quality.

In 10 years of life cycle cost of compressors

·        Electricity cost 76%

·        Equipment investment cost 12%

·        Maintenance labor cost 12%

 

Compressed Air Energy Management System :

The compressed air system are complex system,and often “grow overtime”.  With the constant monitoring and systematically analyzing approach for improving efficiency and potentials to save in compressed air.  In :

·        Generation

·        Air Treatment

·        Controlled Management

·        Heat Recovery

·        Leaks

·        Maintenance.

Contact Person
( Proprietor )
Location : Pune
Call : +91 9372919095