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New Developments in Compressor Technology
September 3rd , 2010CII, Chennai
Rajesh Ganjoo, Product Manager
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Compressed Air Energy
• Inefficient power source even if well maintained
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Eight compressor horsepower
One horsepower of compressed air
yields . . .
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New Designs to improve efficiency
• Reduce the heat of compression : Multistage( 2-Stage Rotary Screw compressor )
• Eliminate Unloading : Variable Speed( Integrated VSD Rotary Screw compressor )
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( Integrated VSD Rotary Screw compressor )
• Improve motor efficiency : HPM Technology( Nirvana HPM Technology )
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MULTISTAGE FOR OPTIMIZED COMPRESSOR EFFICIENCY
TWO STAGE AIR-ENDTWO STAGE AIR-END
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TWO STAGETWO STAGECOMPRESSION MODULECOMPRESSION MODULE
•• TWO STAGETWO STAGEEFFICIENCY:EFFICIENCY:⇒ The compression is
shared between thefirst & second stages
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first & second stagesflowing in series.
⇒This increases theoverall compressionefficiency up to 15% ofthe total full load powerconsumption.
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Two Stage EfficiencyTwo Stage Efficiency
Pressure BC2
1st stage: DA132nd stage: 342C
Savings: 1B24
Two Stage
Single Stage: DABC
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Volume
AD
134
Inter-cooling
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TWO STAGETWO STAGECOMPRESSION MODULECOMPRESSION MODULE
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TWO STAGETWO STAGECOMPRESSION MODULECOMPRESSION MODULE
•• COOLANT CURTAINCOOLANT CURTAIN⇒ Coolant is injected at 1st
stage discharge port.
⇒Contact cooling /
Intercooling of compressed
air lowers 2nd stage inlet
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air lowers 2nd stage inlet
temperature.
⇒ This patented processeliminates the need for
complex Heat exchanges.
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TWO STAGETWO STAGECOMPRESSION RATIOSCOMPRESSION RATIOS
•• Reduced Load on EachReduced Load on EachAir EndAir End .
•• COMPRESSION RATIOCOMPRESSION RATIO⇒ The compression is shared
between the first & secondstages flowing in series.
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stages flowing in series.⇒This drastically reduces the
load (i.e. compression ratio)on each air-end.
⇒ This increases the overallcompression efficiency upto 15% of the total full loadpower consumption.
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Performance
• 2-stage delivers an average of 15% more air- 200KW - 1250 v/s 1465 cfm
• Payback is often less than 2 years
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Nirvana Nirvana –– The true VSD technologyThe true VSD technologyNirvana Oil Free Rotary Screw Compressors
2007
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Inverter Induction MotorConventional Induction Motor
•What Happens to a conventional Induction Motor when speed is reduced by a Variable drive
•Cooling decreases
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•Cooling decreases
•Temperature rises
•Efficiency & power
factor decays
•Torque may be effected
•Turndown is limited to 50%
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Innovation of HPM Motor
• Virtually no wearing parts• Excellent weight to power ratio • Unlimited starts and stops• No bearings• High starting torque• Weight to power ratio
New Innovative HPM Motor
Stator Wrappedin Coil
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• Weight to power ratio enables shaft mount
• Linear motor efficiency throughout the range
Older Induction Motor
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The HPM-Airend DesignThe Drive Train
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Rotor MagnetsStator Coils
Motor Rotor Motor Stator
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CONVENTIONAL
NIRVANA
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What Happens to a Nirvana when speed is reduced
•Salient poles
•Permanent magnets
•8 Pole, Synchronous design
•Small size, excellent power to weight ratio (high power density)
•No bearings- no lubrication
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•No bearings- no lubrication
••9595--97.2% efficiency, 97.2% efficiency,
••0.96 power factor at all load points0.96 power factor at all load points
•Constant torque
•Unlimited motor Start / Stops.
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