Compressed Air Trends : Cement Industry

Milind Gaydhankar Date : 8 th May 2009

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ATLAS COP CO in brief

Established in 1873 M ore than 135 years of ric h experi ence Turnover more than 8.5 billion USD Biggest manufacturer of air c ompr ess ors in the worl d ..T wice the turnover of next competitor Operations in 135 c ountries 26000 empl oyees worldwi de Spends 4% of tur nover on R &D Princi pal c ompr ess or plant in Belgium worlds largest compr ess or manufac turi ng set up Atl as C opco India was establis hed in 1961
Employees 1100 people T urnover ove r 850 cro res Factories in Pune and Nasik Manuf acturer oil injected, oil free screw, pistons, blowers, packaged of cent rifugals

Piston
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Scroll

Screw

Centrifugal

A centur y of Innov ation in compressors

First UR oil-free s c rew symetric profile

MD energy less dry ers

Proc es s turbo range

First full feature mac hines

Star insert c oolers in Z

Firs t oil-free VSD

XD energy less dry ers

First water cooled two stage piston

Sc roll oilfree c ompres s ors

Firs t Elek tronik on control

Z integration

Double tooth introduc tion

ZB high s peed driv es

195 2 190 4

196 4 196 6

197 0 197 3

197 3 197 9

198 0 198 0

198 6 198 7

199 3 199 4

199 5 199 5

199 6 199 7

200 1 200 2

200 3 200 3

200 4 200 5

200 5 200 6

195 4

Firs t OIS

Firs t s ilenc ed c ompres s ors

Plant air turbo range

Firs t V SD c ompres s ors

High pres sure 40 bar(e) mac hines

AirSc an introduc ed

Z screw gets ISO 8573 Class 0

Firs t oilfree piston

Firs t Z o ilfree screw as s y metric profile

Z tooth c ompres s ors

High pres sure mac hines

Firs t pac k aged and s ilenc ed turbo c ompres s ors

Z full fea ture with I MD

AirOpti mizer introduc ed

.Over 1000 patents

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Com pressed air applica tion i n Ceme nt i ndus tr y

Medi um Pr ess ure applications [4 to 6 bar] Field Instr umentation Dedus ting s ystems Shoc k bl as ters Pneumatic g ates Sealing

Low Pr ess ur e applic ati on [bel ow 4 bar] Pneumatic materi al handling Bi n aer ati ons Cleani ng Cooling

Com pressor types & w orking princi pals

Scre w compressors is the latest trend

Medi um pressure Low pressur e

Life Cyc le Co st [LCC]

Energ y c ons umption of c ompr ess ors contri butes to 77% of it s LCC Emphasis on package ene rgy consumption is ve ry important
Evaluate for comp ressors with least specific power requirement [SER]
7 7%

Installation

Maintenance
2% 9%

Investment
12%

Proper sizing of comp ressors VSD to cater to fluctuating load

Energy Consumption

Selec tion of appropriate tec hnol og y

Better specific energy re quirement [ kw / cfm ] No capacity deration o ve r period of running years Lower unload po wer Lower noise levels. .meets noise pollution norms High reliability Ease of monitoring Capability to opera te in cement plants environ ment

Screw compressors technology has been the m ost preferred s oluti on

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Life Cyc le Co st [LCC]

Mai ntenanc e as pect Compress ors to have l ess er moving parts Less wear and tear Better lif e of c onsumables Mor e availability / upti me of mac hines Lower man hours Installati on & c omplete sc ope Ski d mounted compr ess ors Eli minati on of heavy foundati ons c os t Pac kaged c ompress ors with ac oustic c anopy Complete sc ope incl uding motor, c ool ers, moisture tr ap

Screw compressors technology has been the m ost preferred s oluti on

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A pplicat io n Pre ssure Requireme nt

Segregate c ompr ess ors on applic ati on pr ess ur es i. e. medi um & l ow Narrow pres sur e band Pr ess ure setti ngs cl os e to operati ng r equirement Multi ple c ompr ess or contr oller to ens ur e l eas t oper ati ng pr ess ur e band Variable Speed Dri ve [VSD] machi nes to c ater to fluc tuating demand Scr ew c ompressor s offer better s ol uti on Pr ecise pres sur e s ettings possi ble VSD options avail abl e with mor e than 70% tur ndown Low press ure applic ati on Selec tion of scr ew c ompress ors [ 1 to 4 bar ] Better specific power Pr oper sizi ng of compr ess or

Blowers for bi n aer ati on s ystem [below 1 bar] Scr ew type bl ower s Lobe type blowers

Optim ization of c ompre ssed a ir system

Correc t sizi ng of compr ess ors with opti mum margins Pr oper c apacity sizing understanding the r equired flow rates nm3/min, F AD Ter ms li ke ACF M, ICFM, Inlet volume etc c an be misl eadi ng Oversiz ed machi nes c an be idl e i nvestment Undue higher sizing l eads to higher unl oad power c onsumption Higher el ectric als sizing Pr oper sizi ng and r outi ng of air pi ping s ys tem to ac hieve least pr ess ur e drop Leakag es Energ y waste: 20 30% of output Drop in s ys tem pr ess ur e Common leakage ar eas Coupli ngs, hoses, tubes, fittings , Pres sur e r egul ators, Open con dens ate traps , shut-off val ves , Pipe j oi nts, disc onnects , thr ead seal ants Energ y opti miz ati on wit h c entr al c ontroll ers Right mac hi nes operating to meet s pecific load demand

DIFFERENT STANDARDS OF MEASUREMENT

ISO 1217

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ISO1217

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ISO1217

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Atlas Copcos offering for Cement Industry

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Med ium Pre ssure Com pres sors

P ( bar ) 20

N e w G A 1- 1 8 0 3 2 V S D D S V

GR 11 0-2 00 211 - 44 2 l/s GA 90- 16 0 185 - 47 2 l/s GA 20 0 - 25 0 436 - 73 0 l/s

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10 8.5 7.5

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8.5 7.5

GA 315 VSD 210 - 854 l/s

6 5 -4 s 8 / 2 l

GA 315-500W 640-1518 l/s

Aircooled
700 800 900 100 0 110 0 120 0 130 0 140 0

100

200

300

400

500

600

FAD ( l / s )

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Flow Diagram
4 no oil pum p 4 simple & e ffici ent regulati on syste m 4 minim um maint enanc e & maxim um relia bility

Air Air/Oi l mixture Oil Condensate

AIR FLOW
A - A ir i ntake fi lter B - A ir i ntake va lve C - C ompr essor elem ent D - Non-r etur n valve E - A ir/o il sep arato r vessel F - Min imum pressure va lve G - Aftercoo ler H - Water separ ator w ith a uto- drai n

OIL FL OW
I - Oil su mp J - Ther mostatic by -pass val ve K - Oi l coole r L - Oil fi lter M - Oi l scavengi ng l ine N - Oil stop va lve

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Features offered
Per for mance s pecific ation ac cor ding to ISO 1217, ed3 annex C 1996 FAD at the outl et of the pac kage, net of l oss es Pres sur e measur ed at mois tur e trap after aftercool er, outlet of pac kag e Total electric al pac kag e power cons umption (motor, fans) Total pac kage SER AC scr ew el ements Designed for maxi mum FAD for l ess power c onsumpti on, guar anteei ng maxi mum compr ess or pac kage efficienc y Latest g ener ati on Atlas Copc o as ymmetric r otor profil e Designed for l ow wear and tear High lifeti me Aircooled or waterc ooled versi ons Effici ent pis ton type unl oader val ve
Unload power is 25% of the full load powe r

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Features offered

El ektr oni kon

-DSS Function minimizes idle time -Anticipated start function -T imer based start/stop -Dual pressure settings

Pressure

Pres sur e trans ducer (PT20) - Precise setting with

transducers
Time

Power Consumption

Atlas Copco DSS

Ener gy Savin g

Ener gy Savin g

Ener gy Savin g

Time

Power Consumption

T1

T1
Time

T1

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Features offered
Heavy duty air i nlet filter Two s teps dus t r emoval 1. Separation of big particles by means of centrifugal forc es 2. Removal of s mall par ticles in the high effi cienc y filter c artridg e 99,9% efficienc y on removal of particl es > 3 micr on high lifeti me Proven thr ee stage oil separation: cyclonic ac tion c entrifugal force gravi tation and c hange of direc tion fine filtering in O.S.E All units are fitted with Water Separ ator / mois ture trap Final Outl et pr ess ures are meas ured after the Water Separator ( Pac kage end) as per the recommendations of ISO 1217, Ed.03, Annex C : 1996 Compl ete pac kage s ki d mounted
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Features offered
The main motor
4 GA 90-500 is dri ve n by e fficie nt, TEFC el ectric m otor (I P- 55, class-F i nsul atio n) 4 HT mot or o ptio ns also are a vail abl e 3. 3 K V / 6.6KV 4 HT Mot or mak es - Si eme ns, ABB, Alstom (M arat ho n), C GL. 4 LT M otor m akes Si eme ns, ABB, Alstom (M arat ho n), CGL. 4 All mot ors ha ve goo d e ffici encies (t ypical ly 94.5% to 96% - depends o n m odels)

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Components Layout
INT EGRA TE D DRYER FAN CO OL ER ASSEMBLY INT EGRA TE D DRYER BY-PASS VALVE

AIR INTAK E FILT ER OIL FIL TE R

AIR/OI L SEPARAT OR VESSEL

EL EKTR ONIK ON CONT ROL

ROTA RY SCREW EL EME NT

DRIVE MO TO R UNL OAD ER VALV E

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VARIABLE SPEED DRIVE Compressor working

Frequenc y C onverter Elektroni kon C ontrol M k III

SET P OI N T

Pres sur e Sens or Air Net Free Air D eli ver y Compr ess or Scr ew Element VSD Mai n M otor

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VARIABLE SPEED DRIVE compressors

Siemens Master Driv e Frequency Conv erter

Atlas Copco VSD -Dedicated VSD design -Latest generation inve rter duty motors and d rives -Wide turndown range > 7 5% (tested & certified) -VSD cooling fans

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MASTER DRIVE FREQUENCY CONVERTER

Electro Magnetic Compatibility EMC Directive 8C9/336/EEC Voltage Range 380 - 500 V Frequency Range 50 - 60 Hz

conv erter rack

rf i filter

incoming po we r supply

power supply to driv e motor

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Atlas Copco Global Service

High Q uality Service Every where Everyt ime
Wherever you are in the world and whatever industry, Atlas Copco is there to back you up with service unrivalled in the business.

GLO BAL Co mpeten ce ensures tha t our highly

trained engineers are able to offer the best possible guidance and assistance in operating your equipment

GLO BAL Invest men t ensures tha t our field

support engineers have the most modern diagnostic equipment available to them

GLO BAL log ist ic s ensures tha t we can deliver

in a timely manner our range of guaranteed quality spare parts
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Strengths of Atlas Copco

Wide pr oduct portfoli o:

Capabilit y to offer compr ess ors from 5 CFM upto 225,000 CFM Pr ess ures upto 90 Bar Scr ew C ompres sors Low Pressur e C ompressor s Bl owers Centrifugal Compr ess ors Dr yers Centr al moni tori ng s ys tems Product + c oncepts s uc h as ES, Air Sc an, Air Opti miz er, Total
(Compr ehensi ve mai ntenanc e c ontracts)

responsi bility plan

Customer Value :
Standar dization, leads to lowes t s par es cos t Shor tes t l ead ti me for deli veries Solutions wi th Pl ug & R un conc epts : means

No hidden capital costs Proven design Superior packaging Better Ae sthetic looks Easy to install Easy to operate Easy to maintain Easy to relocate Lower operating costs Lower maintenance costs

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We are committed to your superior productivity through interaction and innovation.

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Milind Gaydhankar (Cell no: 99704 32320) Thank You

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