Offering complete air and gas solutions with the lowest service life cost, the company continues to meet the needs of its customers with quality air solutions such as compressors, blowers and booster, air dryer, cooler, nitrogen generator, filter and energy recovery ways.
With energy efficiency, innovation, patented technologies and compact designs, it continuously renews itself in order to increase the productivity of its customers and to contribute to its production and its successes.
Atlas Copco, which supports every sector and production area, also has special solutions for cement.
Blowers with lobed and screwed technology are intensively used in the heavy industrial applications like limestone exploration and mining, cement production, storage and transportation.
Low-pressure blower systems, which are called “big bag filling system” and used in pneumatic transportation in cement sector, generally have tri-lobe technology. In the roots type blowers, the air enters the compaction chamber, while the air volume remains constant as the lobe rotors rotate. Due to the counter pressure of the connected pipeline, the air is externally compressed and pushed towards the pipeline.
Another series of blowers used in the cement sector comes to the forefront with screwed technology. It is compressed and pressurized by air screws in screwed blower technology designed by Atlas Copco and developed in accordance with ISO 9001 standard.
In the Atlas Copco ZS screwdriver series, as the rotors move toward each other, the volume of air is reduced and the air is pushed towards the pipeline. In screwed technology, there is no loss because the air is internally compressed. Since compressed air production can generate more than 40 percent of a plant’s total electricity costs, energy saving is at the forefront of the features to consider when investing. Screwed blowers offer advantages in terms of total cost of ownership with energy savings of up to 35% compared to high initial investment costs.
Today, a large majority of the compressed air needs of cement plants is supplied by blowers. Most of the blowers used in boilers, fuels, silo boiling processes etc. are made up of blower driven pulleys, known as lobed or roots type. The “low initial investment cost” plays an important role in favoring lobed type blowers, which cause very noisy running, high energy consumption and more frequent maintenance periods. However, it is clear that lobed systems are a more cost-effective technology, given the cost of the blowers during their entire working life in system preferences.
Atlas Copco is the only company in the world that manufactures all types of blowers (roots, turntable with magnetic bearing, multi-stage centrifuge). With more than 145 years of experience and experience in the field of compressor, the company offers ZS screw type positive displacement blowers to replace lobed/ roots type blowers.
The ZS screw type blowers have a compression unit consisting of a worm screw system. Thanks to this screwed system, instead of external compression as in lobe technology, compression occurs inside the gear (screw). In this case, the problem of backbreaking in the high pressures of the lobed blowers is lifted out of the way and can be reached with screw technology up to 1.5 bar pressure values. In ZS screw type blowers, the compression unit and the motor are directly coupled to each other. This eliminates the need to use belt pulleys and saves energy at a high rate compared to lobed blowers.
The screw-in type blowers, which have higher initial investment costs, meet the depreciation period in 1.5 – 2.5 years due to energy savings of up to 30%. In some cases, this average term seems to have amortized the investment costs in less than 1 year.
Atlas Copco offers solutions for a total package requirement, 5 years guarantee for screw group of ZS screw type blowers with starter, frequency converter and sound cabin.
Innovations in the world-renowned GA series that have not sacrificed performance and efficiency for years are among the solutions offered in Smart AIR. The most prominent features of the newly developed GA 90+ – 160 and GA 110- 160 VSD + series are as follows:
• Oil-cooled motor with high efficiency IE4 class IP66 protection standard
• Standard operation up to 46°C or optional VSD solution up to 50°C (high temperature version) with constant speed up to 55°C.
• Minimal service life with brand new design and service parts facilitated by accessibility
• Less than 2 ppm oil in compressed air (new generation oil separators of the multi-cartridge type)
• Optional integrated type gas dryer (FF option)
• Next-generation color and touch-friendly display
• Energy recovery option (energy recovery as hot water up to 78%)
• 5 year warranty from top to bottom with the agreement.
With these properties, the company continues to maintain sustainable productivity, keeping in mind the needs of its customers, ensuring productivity at the highest level for the toughest conditions of cement production.