New challenges for compressor manufacturers

The compressor industry is faced with a series of new application engineering challenges. There are, for example, still questions surrounding the use of compressors to separate out CO₂ at fossil-fuel-based power stations. Compressors and vacuum pumps are also playing an increasingly important role in the exploitation of regenerative energy. Bio (natural) gas fermentation, which produces carbon dioxide, water and hydrogen sulfide, creates different problems eg, the hydrogen sulfide in biogas increases compressor wear.

Energy and cost efficiency during day-to-day operation are a major issue on compressed air systems, and users still have huge opportunities to save money. Experts argue that the best way for users to reduce the cost of compressed air is to install compressors with speed control along with compressed air management systems which control multiple compressors based on predefined energy-saving parameters. Nearly all of the major compressor suppliers have this type of system in their product portfolio.

A reduction in leakage rates offers another opportunity to reduce energy consumption on compressed air systems. Condition monitoring on compressed air networks and new types of sensors can help keep leakage problems to a minimum. Another option is to reduce the pressure in the network and eliminate unnecessary reserves.

The list of product highlights at ACHEMA 2009 includes screw compressors which consume less energy to deliver a higher volume of air and new compressors with air cooling (which is up to 60 % cheaper than water cooling). The undisputed advantages of reciprocating compressors including high efficiency under a range of operating conditions, relatively good control characteristics and much more have led to a resurgence of these machines.