Kaeser Kompressoren SE

High-efficiency

Compressed air for jet milling applications

When it comes to generating compressed air, operators of jet milling equipment for the production of very fine powders can achieve significant energy cost savings through the skilful use of heat recovery. It is for this very reason that Kaeser has recently expanded the options palette for its range of oil-free compression rotary screw compressors from the CSG, DSG and FSG series.

Aside from steam, jet mills are most commonly operated using nitrogen or compressed air. In the case of the latter, heat energy can be recovered from the compressed air inside the jet nozzles and subsequently reused for the milling process. Exhaust heat arises as a by-product of compressed air generation, which essentially makes it a cost-free source of energy.

With the specific needs of jet milling applications in mind, Kaeser has now extended the options palette available for its two-stage, oil-free compression rotary screw compressors to include such features as compressed air discharge temperature control. Operating via flexible, controlled adjustments to the intercooler, this option can lead to a clear reduction in specific energy consumption per tonne of the final product, depending on the type of material being processed.

Kaeser offers the option of compressed air discharge temperature control on compressors from the CSG, DSG and FSG model range, featuring a power range from 37 - 355 kW and pressure from 4 - 11 bar. Both air-cooled and water-cooled versions are available.

Furthermore, Kaeser also offers compressors specially adapted for operation with nitrogen, in which the compressor can be individually configured to the specific nitrogen circuit.

Screw blowers

Quiet and efficient

The DBS-series screw blowers promise big energy savings. With power ratings from 15 to 37 kW and flow rates from 4 to 22.5 m³/min, they are currently the most efficient screw blowers available.

Like the other Kaeser screw blower series, the DBS screw blowers deliver unparalleled efficiency. They are up to 35-percent more efficient than conventional rotary blowers and also provide energy savings in the double digit range compared with many commonly available screw and turbo blowers.

These benefits are made possible in no small part by the proven Sigma Profile rotor technology used in the rotary screw compressor sector. Another key factor is the innovative non-slip direct drive with speed transmission integrated into the airend, which delivers maximum speed with minimal transmission losses. The result: lower energy costs.

These screw blowers are in two different versions available to meet the needs of requiring pressures up to 700 mbar or up to 1100 mbar respectively. The new blowers are exceptionally quiet, with sound levels in primary applications not exceeding 72 dB, which is equivalent to a modern vacuum cleaner.

The Kaeser screw blowers are designed for use over long duty cycles, including continuous operation, require little maintenance, and can be installed side by side. Upon request they can be delivered with an integrated frequency converter or a star-delta starter. The non-slip synchronous reluctance motors in versions equipped with a frequency converter also increase overall efficiency. On both versions, power transmission from the motor to the airend takes place via loss-free and maintenance-free gearing. The screw blowers are delivered as turnkey systems (including power electronics and the Sigma Control 2 controller) that are ready for commissioning straight “out of the box”.

Intelligent control

Also integrated into the DBS blowers is the Sigma Control 2 system controller, which provides extensive monitoring functionality and makes it easy to connect each individual piece of equipment to communications networks. Going forward, this integrated controller will also make it possible to integrate the blowers into a Sigma Network, if desired. This is now possible since the Sigma Air Manager 4.0 (SAM 4.0) master controller – so well-proven in the compressor segment – is now also available for blower systems.

Integrated energy and cost efficiency

Kaeser completes its blower product portfolio with the BBC and FBC series. These compact rotary blowers are ready to connect with integrated mains power supply equipment and the proven Sigma Control 2 controller for comprehensive system monitoring and communication. Kaeser’s high-efficiency, energy-saving rotary blower range now covers air deliveries from 2 to 72 m³/min at up to 1000 mbar gauge pressure and 500 mbar vacuum. Key applications for these blowers include pneumatic conveying.

"Ready-to-connect" means that the units are supplied complete with all sensors, controls and a choice of star-delta starter or variable speed drive.     The complete system packages are CE and EMC certified, which means less work for both the operator and system provider when it comes to planning, installation, certification, documentation and commissioning, because the machines and the electrics are preconfigured and ready-adjusted at the factory.

But that’s not all; these rotary blowers feature even more integrated intelligence: Highly effective broadband sound and pulsation damping ensure quiet operation at all times, which applies to both the machine and the pipework.

The blower block with its proven Omega profile rotors significantly enhances operational reliability and uptime, whilst adaptive compression reduces energy consumption, and long bearing life minimises maintenance costs.

Moreover, space-saving component layout results in an exceptionally compact footprint. Also, as these blowers have been designed to allow all service work to be carried out from the front of the unit, it is possible with star-delta equipped models to install several blowers side by side. Components such as control valves and exhaust silencers, which would normally be installed externally, are already integrated.

The internal Sigma Control 2 controller makes blower mode selection, such as remote speed control or pressure control, quick and easy with just the press of a button.  Performance parameters relevant for dependable blower performance are monitored by sensors, and warning or fault signals are automatically generated accordingly. Optional communication via databus (multiple databus systems can be connected) allows operational status read out and enables the machine to be remotely controlled.

Of course, operating costs do not just depend on the efficiency and reliability of the individual components within the station. Various other factors play a key role, such as actual pressure and air demand, selection of appropriate and suitably matched blowers and drive systems, as well as tailored sequencing control. This is where an Air Demand Analysis (ADA) can prove invaluable: With help from such detailed analysis it is possible to determine how compressed air demand varies over time, how efficiently a blower station is operating, and to what extent availability and efficiency can be further enhanced. The “Kaeser Energy Saving System” (KESS) is another powerful optimisation tool. This specialised planning software enables different system variants to be simulated and compared with one another, and their respective potential savings to be calculated. Transparency of future servicing and maintenance costs is also essential when considering the total life cycle costs of both individual blowers and stations as a whole. Needless to say, this task requires the kind of knowledge and expertise that only an experienced compressed air system provider such as Kaeser Kompressoren can offer.

By choosing Kaeser, planners and operators not only profit from all of the advantages that Kaeser's latest generation of blowers deliver, but also benefit from the company's decades of experience in system planning and optimisation. As a result, they can enjoy the rewards of enhanced system efficiency and maximum dependability.  

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Caption:

Kaeser’s Compact series BBC/FBC rotary blowers combine clever design with exceptional efficiency and dependability. Their access-friendly configuration enables side-by-side installation of multiple units.

Space-saving, efficient compressed air production

No matter whether for a smaller business where space is at a premium, or a larger business requiring a decentralised compressed air supply, Kaeser’s compact Aircenter systems are the perfect choice for an efficient and environmentally-friendly source of quality compressed air. With a minimal footprint of approximately 1m², these energy saving systems are available for flow rates from 0.34 to 2.7 m³/min and also provide application-specific compressed air treatment and storage.

All Aircenter models are characterised by their exceptional efficiency. At the heart of the two largest models, the Aircenter 22 (11 kW) and the Aircenter 25 (15 kW). is an optimised SK series rotary screw compressor from Kaeser. With a maximum flow rate of 2.7 m³/min the SK models deliver up to 11 and 14 percent more compressed air, respectively, than their predecessors. This impressive performance boost has been achieved both through airend optimisation and the minimisation of internal pressure losses. In turn, these improvements have lead to a reduction in specific power of up to 5 percent. The use of premium efficiency IE3 electrical motors has also contributed to additional energy savings. A further important efficiency-enhancing component is the “Sigma Control 2” internal controller: equipped as standard and assuring maximum communication capability, this advanced system not only enables demand-oriented performance matching and dependable monitoring, but - through its numerous interfaces - also ensures even greater flexibility when it comes to connection to the energy-saving Sigma Air Manager 4.0 master control system. The compressed air system can therefore be seamlessly integrated into Industrie 4.0 environments since the necessary interfaces for connection to the Kaeser-Sigma Network are provided as standard. The addition of an integrated RFID reader assures service continuity, increases security and significantly raises service quality.

Moreover, all models share logical and user-friendly design throughout. For example, the left enclosure panel can be removed in a few simple steps and allows excellent visibility of the system's intelligently laid out components. As one might expect, all service points are easy to access. With the sound-damping enclosure panels in place, the already low operational sound levels from these compressors are reduced to a super-quiet background hum. In addition, the enclosure features four inlet openings for separate airflow cooling of the compressor, the motor and the switching cabinet and for compressor intake air. Kaeser's unique cooling system is equipped with a patented premium-efficiency dual-flow fan with separate cooling air flows for the motor and compressor. This not only achieves optimum cooling performance, low compressed air discharge temperatures and minimal sound levels, but also promotes efficient air compression.

The space-saving combination of a compressor, a thermally shielded refrigeration dryer and an underslung 350-l air receiver provides dependable and efficient compressed air production, treatment and storage within a single unit. As you might expect from a leading compressed air system provider such as Kaeser, these versatile units can also be equipped with air filters as required. The Aircenter 22 and Aircenter 25 are also available with an integrated frequency converter (“Sigma Frequency Control” - SFC) for applications where speed control is an advantage.

The smaller Aircenter models are based on Kaeser’s SX or SM series rotary screw compressors. Equipped with a 200-l or a 270-l air receiver, these versions cover flow rates from 0.34 to 1.5 m³/min (at 8 bar) and ensure super-quiet, efficient performance. As with the two largest models, 11- and 15-bar versions are available for applications requiring larger volumes of compressed air. Furthermore, the Aircenter 12 can also be equipped with variable speed control.

Users who require not just an efficient compressor, but an all-in-one, compact compressed air system need look no further than an Aircente system from Kaeser. True to Kaeser’s “Plug and Work” maxim, every model is ready for immediate operation once connected to the electrical supply and compressed air distribution network.

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Covering flow rates from 0.26 to 2.7 m³/min, Kaeser’s Aircenter series models provide dependable and efficient compressed air production, treatment and storage within a single compact unit (Aircenter 22 shown in image).

Technology of the future

Low Pressure 4.0

Intelligent and straightforward blower control: the Sigma Air Manager 4.0 is the solution for blower station automation. This sophisticated controller delivers maximum energy efficiency and cost savings whilst making the station ready for Industrie 4.0 applications.

The Sigma Air Manager 4.0 is the core component of a blower station and the key technology needed in order to take advantage of the Industrie 4.0 services of the future. It acts as the central mastermind and controls the individual machines with maximum efficiency whilst perfectly adjusting the flow capacity to match flow rate demand. All it needs from the process control system is the desired differential pressure value – the SAM 4.0 then ensures optimal control of all blowers. Partial-load bridging and individual solutions are therefore things of the past, along with complicated setups. Now, all applications are supplied by one central blower station with master a controller that analyses operating data in seconds and simulates various scenarios in order to select the most efficient solution. The result? Previously unimaginable energy efficiency.

All components within the station are optimally matched and controlled to meet the customer’s specific needs. Real-time process monitoring provides valuable operating data, which are forwarded for detailed evaluation. The analysis results help to predict potential faults as early as possible and prevent them by taking timely action.

The SAM 4.0 offers communication in 30 languages whilst the easy-to-operate 12-inch colour touchscreen display shows at a glance whether the station is operating in the “green zone” for optimal energy performance. It’s incredibly easy to display and analyse a wealth of data, such as operating status, pressure curve, flow rate and power, as well as maintenance and any fault messages. And, thanks to a network connection, this can be done not only at the machine itself, but also conveniently from a PC at the office or elsewhere. This powerful capability therefore provides peace of mind and lays the foundation for predictive maintenance; it also enables sophisticated energy management per ISO 50001.

The master controller also makes it possible to take advantage of new options for predictive maintenance of blowers. Previously, maintenance could only be performed on the basis of a regular scheduled service date and repairs would be made only after a fault message had occurred. The SAM 4.0 now makes it possible to initiate maintenance before a fault occurs, thereby avoiding costly downtime and consequential damage.

The sensors and Sigma Control 2 controller integrated into the machine collect process data, which are immediately forwarded to the Sigma Air Manager 4.0. Specialised software is then used to transfer the information to the Kaeser Data Center for real-time analysis. The Kaeser Data Center performs central monitoring and processing of operating messages. Required predictive maintenance measures are then initiated as needed based on this information.

Ultimately this enables maintenance and necessary repairs to be performed at the precise moment they are actually needed. This saves time, minimises costs and ensures reliable blower availability, which in turn benefits all associated downstream processes.