PETpla.net Insider 05 / 2019

COMPRESSORS PET planet Insider Vol. 20 No. 05/19 www.petpla.net 37 AF Compressors launches new compressor range Low pressure, high savings AF Compressors considers the trend towards more sustainable machinery and presents its new oil-free 58m 3 /min OPC45-355 range, developed in response to customer demand. The trends towards cleaner manu- facturing solutions are driving demand for compressed air machinery that is free from contaminants, including oil, with low dewpoints and achieving food- level Class 1 ISO8573-1 standards. Levels of sustainability in com- pressed air installations have to be higher than in the past. Key perfor- mance indicators include: energy consumption across full and partial loads and the full range of conditions, wastage, equipment lifetime, and machinery disposal. Oil and oil-free Oil-injected and oil-flooded com- pressors produce waste in the form of oil vented into the air, contamination of filter cartridges, and polluted con- densate. Individual components wear out in use and tend to be disposed of, rather than recycled. Rotary compres- sors require comprehensive compres- sor block overhaul every two to five years; centrifugal machines need major core overhaul every five years. Useful life is 10-15 years. As refur- bishment costs are high, operators tend to dispose of existing machinery and replace it entirely. Oil-free compressors, which are available in industrial piston, rotary, and centrifugal forms, produce less waste. Their condensate is pure water, there is no oil to contaminate filters and they obviously do not require oil changes. Cost, compliance and maintenance Increasing complexity, raw material costs and legislative compliance are driving up the cost of compressed air. Energy prices are on an upward trend for a number of reasons, including rising demand, more expensive resources leading to supply constraints, and the cost of compliance with climate change regulations. Maintenance costs can spiral upwards as well. Energy Electricity accounts for the overwhelming majority - around 80% - of the running cost of compressed air systems. While optimal usage is achieved at near full load, very few compressors run at that level. Variable-speed drives help reduce consumption but do not elimi- nate losses completely; partial loads deliver less than maximum efficiency. Running at varying loads and speeds also raises the risk of expen- sive breakdowns and reduces the life of electronic components. Extending range AF’s introduction of advanced technology into its standard 6-15 bar oil-free applications has helped to boost energy efficiency and reduce maintenance requirements. They offer longer working lifetimes even under extreme environmental conditions, such as ambient temperatures in excess of 50 °C and high humidity. At idle, the OPC90-132’s specific energy consumption is below 7 kW/ m 3 /min. It is claimed to be one of the most energy-efficient compressors under full load conditions, consum- ing just 5.5 kW/m 3 /min at 8 bar. This is 29% below BAFA (German organisa- tion for subsidising Energy projects) minimum requirements. AF Compressors claims that its new range offers savings of up to € 10,000 a year, depending on machine size and usage. The new dual flow adjustable airflow system (AFS) digital control on the OPC90- 132 does not need a frequency con- verter, cutting costs and eliminating the need for expensive, frequently replaced electronics. Extending service intervals and reducing waste The OPC90-132 has been designed to minimise component wear, lubrica- tion, waste and maintenance require- ments. Service intervals have been extended: second-stage seals must be replaced and valves refurbished every 8,000 hours; first-stage seals and valves require service at 16,000. Extending compressed air system lifetimes The OPC90-132’s designed lifetime is 40 years – four times the length of current systems. It should require no major overhaul during its working life; just normal maintenance, supported by approved, genuine parts. The company says that the new OPC range offers a substantial carbon footprint reduction, compared with previous models. www.afcompressors.com COMPRESSORS 10bar compressor OPC200 AF 10 bar oil free compressor at Coca- Cola Al Ain in the UAE