Air Compressors for Industrial Applications
Air compressors are the heart of your compressed air system. They are responsible for starting the process, keeping it running, and powering the system. Variables need to line up from the compressor to the point of use. Finding the right compressor is an intensive process; there is no one-size-fits-all answer, and I wish there was. You have to make sure your air has the proper flow, the pressure isn’t too far off in either direction, you have the power to run the machine, and many other things that are integral to making high-quality compressed air.
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Selecting the right air compressor can result in endless headaches or consistent compressed air with minimal problems. Multiple variables, from CFM, PSI, and volume to material used in piping, can change how your system functions. Identifying these variables is an investment of your time. Investing your time before the compressor is in place will allow you to focus on using the compressor rather than fixing it.
Selecting the Right Air Compressor
Adequately sizing your air compressor is important, but some things need to be addressed first. Aligning these variables is a necessity, not an option if you want it to work. The most crucial ones to pay attention to are:
Identifying the flow rate, pressure, space, and air needs will lead you in the right direction to figure out what kind of machine you need. The horsepower of the air end typically determines CFM, so if you know your CFM, you will have an idea of what horsepower you need to run and vice versa. Knowing these factors will greatly limit your options to ensure you get the best compressor for your application. After you know these things, you can focus a little more on the details of your compressor:
Type of Compressor
Technology
Power
Utilization
Storage
Noise
Industry Air Standards
They may be less critical than CFM and PSI, but the type of compressor you choose, power level/availability, and even noise can throw off the flow. Different applications require different equipment. Compressor pumps have strengths and weaknesses, environments and situations where they excel, and applications where they fail.
Piston compressors are an industry staple for many operations; they are cheaper, consistent, and have been around for a long time; however, their run time is restricted by the need to rest. Piston compressors need to rest for as long as they run; if you run these machines too much, the components will overheat, ruining the machine. Meanwhile, rotary screw compressors waste your money if you do not run them enough.
Different Types of Air Compressors
Most workshops that rely on compressed air will use a piston compressor. They are reliable and consistent: if you treat them right, a piston compressor can last you over 20 years. But an overworked piston compressor might not make it through a single shift. One slight difference, the pump style, can determine what scenarios the compressor succeeds in. Rather than worrying about trying to make the wrong compressor work, focus on what type of compressor will work the best in your environment.
The most common air compressor, piston air compressors, are an industry staple with a reliable track record. They are the go-to machine for most compressed air users. When given adequate care and attention, these compressors can last 15 to 20 years. Not only are they reliable, but they also operate nearly identically to internal combustion engines. You know, the engines that power most of our cars are the model used for piston compressors, but instead of combustion, the byproduct is highly pressurized air.
Pistons operate with a crankshaft and a compression cylinder. As the crankshaft rotates, the piston moves as well. When the piston moves up, the valve at the top is sealed, creating a vacuum. Once the piston has reached the apex of its rotation, it begins moving back down as the compressed air exits the previously closed-off valve. Once the compressed air has exited the chamber, the chamber refills with air, and the process is repeated.
A compliment to the run time restrictions of piston compressors, rotary screw compressors were built to run. With an ideal duty cycle of 80-100%, these compressors work better with no breaks. Screw compressors are capable of continuously compressing air due to the nature of rotary screw pumps. There are two intermeshing screws, consisting of one male and one female, that rotate to create compressed air. Air enters the space between the two helically opposed screws, and as they spin, the volume of space decreases, compressing the air as a result.
By constantly spinning the rotors, the air is always being compressed, unlike other compressors, which have a period of refilling the compression chamber. There is no downtime between compression periods, meaning production never has to stop with a rotary screw compressor. All these benefits do come with a downside: these compressors will cost you more upfront, but the energy savings will pay for themselves.
The silent sibling of compressors, scrolls are the face of oil-free compressed air. It operates similarly to the rotary screw, except rather than rotors, it is a set of scrolls. One scroll is stagnant as the other rotates in a circular motion to compress the air as it moves along, and the pocket of space shrinks, forcing the air into a continuously smaller space until it is released at the desired pressure.
As the moving scroll rotates around, it comes nearly into contact with the stagnant scroll but never quite touches it. This makes the rotary scroll the quietest and the cleanest of the bunch. These compressors are often used in places like dentists’ and doctors’ offices to power their tools with air clean enough to be used in a person’s mouth.
Additional Air Compressor Considerations
After settling on a pump, there are a few more things to consider when selecting a suitable compressor: technology, power, utilization, storage, industry standards, and noise.
When deciding on additional variables for your compressed air system, it is crucial to weigh the investment and lifetime costs of the equipment. Some technologies, like Variable Speed Drive compressors, will increase the initial cost of your compressor, but the energy savings from a variable speed can quickly make up for that difference.
Alongside technology differences, the power provided in your facility can affect the type of compressor you need. Power comes in different phases and voltage levels; breakers are rated for certain amps. Sometimes, you might not even rely on electricity to power your equipment. If you are unsure of your facility’s phase and voltage, double-check before getting a new compressor.
As we touched on earlier, utilization can determine what type of equipment you need. How often you run the compressor, how long you run it, and where you run it can all determine what type of equipment works best. When it comes to utilization and compressors, a simple rule to follow is:
Just remember to check your details before you invest in an air compressor. You can spend a lot of time and money waiting for a compressor that doesn’t match your system. You can spend a lot of extra cash on technology, storage, and noise reduction, but if the compressor doesn’t align, you are paying for an oversized paperweight.
Do all SCC screw compressors have a variable speed drive?
No - and that would not be customer friendly. Although
variable speed compressors are considered to be the most energy efficient, this
doesn't automatically make them the better choice. Instead, depending on the
compressed air demand, a fixed speed compressor or a combination of
non-controlled machines (for base load) and controlled models (for peak demand)
may make sense.
In terms of SCC's current portfolio, the Smart and Storm
series compressors are fixed speed. All other SCC compressors offer variable
speed and are recommended for applications with fluctuating air requirements.
What type of motors drive SCC compressors?
SCC offers compressors with both IE3 asynchronous motors and
IE4 permanent magnet motors. According to the efficiency classification of
mains-powered three-phase motors (IE code), IE3 motors achieve the
"Premium Efficiency" class. Prior to the introduction of IE4 motors,
this was the highest energy efficiency class on the market. IE4 (Super Premium
Efficiency) is fast becoming the new standard. These motors are even more
efficient and are no longer as rare - and therefore expensive - as they were a
few years ago.
Why are SCC compressors so quiet?
Compared to low-cost suppliers from Asia, quality
manufacturers such as Germany's SCC pay attention to workmanship and small
details. For example, to reduce noise levels, SCC compressors have effective
insulation on the doors and a casing made from slightly thicker sheet metal.
What is there to know about the control of SCC air
compressors?
The control of a compressor is to match the production of
compressed air to the actual consumption of compressed air. At SCC, all
compressors are fitted with the same advanced control system as standard.
Operation is intuitive via a colour touch screen. The special feature is that
up to 16 units can be connected and controlled in coordination with each other.
This allows for particularly efficient energy consumption.
Software for real-time condition monitoring and machine data
transfer to mobile devices is also available.
What does it mean to see the abbreviations P, G or AD
2000 on a compressed air tank?
The letters P and G are used to distinguish between painted
(painted=p) and galvanised (galvanised=g) tanks. If there is no specific
indication, the container is a painted standard container.
AD 2000 is the name of a set of technical regulations
developed by the German "Arbeitsgemeinschaft Druckbehälter" under the
auspices of the TÜV. The regulations for pressure vessel construction published
in it are based on the safety and conformity criteria of the European Pressure
Equipment Directive and take these further. It should be noted that the high
requirements of the AD 2000 leaflets go beyond the minimum specifications of
the international CE mark. With its containers in accordance with AD 2000, SCC
thus offers products that meet a special safety requirement and underline the
quality feature "Made in Germany". Companies that decide to purchase
such a higher-quality tank benefit, among other things, from longer maintenance
intervals and the resulting better plant availability.
What is the meaning of the TD code that can be selected
as a variant on some SCC compressors?
The abbreviation TD stands for "Tank" and
"Dryer". SCC's TD compressors are therefore 3-in-1 solutions
consisting of a compressor, refrigerant dryer and matching compressed air tank.
With these practical complete packages we can simplify and speed up the
selection and ordering process for our customers. As plug and play solutions,
the TD models also make it easier to commission the air system on site.
What air filters are supplied with the TD models?
All TD compressors automatically come with built-in pre and
after filters. As the customer, you decide on the type of filter element. We
are happy to advise you!
Why are some AQUARIUS sizes available with an integrated
dryer and others without?
The difference in equipment is quite simply due to
historical reasons. Aquarius models 31-46 were the first units in the range and
were designed with a dryer as standard. It has to be taken into account that
the space requirement increases when a dryer is integrated. Experience from
discussions with customers has shown that many users prefer compact models.
This is because smaller dimensions give them more freedom in choosing a
location. Another factor is that companies often already have filter lines to
which the Aquarius compressor can be connected. The following models have
therefore been designed without a dryer.
Which SCC compressors meet the BAFA criteria and are
therefore eligible for a grant?
At present, the SMART and FOCUS series of rotary screw
compressors are eligible for an investment grant. However, as both the
technical specifications of the compressors and the test criteria may change
from time to time, we recommend that you contact our technical sales
department. They will be able to advise you on which model not only meets the
current BAFA requirements, but is also the best choice for your process.
Is there a heat recovery option for SCC compressors?
Yes, a complete heat recovery kit is available, specifically
designed for use with SCC compressors. This option is particularly worthwhile
for units of 22 kW and above. The ready-to-install heat recovery kit is
integrated directly into the compressor to save space. Prices and further
information available on request.
For more Permanent Magnet Screw Compressorinformation, please contact us. We will provide professional answers.
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