New Developments in Compressor Technology

September 3rd , 2010CII, Chennai

Rajesh Ganjoo, Product Manager

Compressed Air Energy

• Inefficient power source even if well maintained

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Eight compressor horsepower

One horsepower of compressed air

yields . . .

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 )

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.

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

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.

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.

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

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%

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

The HPM-Airend DesignThe Drive Train

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Rotor MagnetsStator Coils

Motor Rotor Motor Stator

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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