Why is integrated variable speed screw air compressor Better?

Dryers are essential in various industries for removing the water created by compressed air, which can lead to corrosion and damage to downstream equipment.  

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The dryers in the air compressor with dryer package help maintain the quality of compressed air by suppressing the dew point and preventing issues such as frozen pipes, contamination, and water buildup. There are different types of air dryers, including refrigerated, desiccant, and deliquescent, each suitable for specific requirements and moisture tolerance levels. 

The importance of using a compressed air dryer lies in the fact that moisture is inevitable in air compression and can lead to significant problems such as corrosion, frozen pipes, and equipment damage. Therefore, air dryers are crucial for maintaining a well-functioning compressed air net and ensuring the production of pure, clean compressed air for various industrial applications. 

Rotary screw air compressors, which are commonly used in industries for material handling, spray painting, and machine tools, benefit from the continuous delivery of air provided by these compressors. The integration of air dryers with rotary screw compressors is important for preventing damage to pneumatic machinery, piping, valves, and other components, as well as avoiding potential contamination of end products. 

Choosing Atlas Copco for your rotary screw air compressor with dryer needs means opting for a blend of reliability, efficiency, and advanced technology. Known for their commitment to innovation.

Taking the step to invest in an Atlas Copco speed rotary screw air compressor with a dryer also means gaining access to unparalleled customer support, comprehensive maintenance programs, and a worldwide network of service professionals. 

Whether you're looking to enhance your facility's operational efficiency, reduce energy consumption, or ensure the highest quality compressed air, Atlas Copco has the expertise and products to support your goals.

Use of a VSD air compressor may allow you to cut energy use and save money.

Deciding to install a VSD air compressor is a major step for any facility. On the positive side, VSD compressors can save energy (and significant amounts of money), earn rebates, allow soft starts and offer better control of your entire compressed air system.

But there are many concerns. VSD air compressors cost more than their fixed-speed counter parts. And, like any electronic device, they can be sensitive to harsh, demanding environments (see the “VSD: The Cons” section below).

Let’s start with the basics.

First, a little background on fixed and variable-speed drive.

A fixed-speed compressor operates at the same speed continuously, cranking along at the same RPM, no matter what the system’s demand. And, unless you change the pressure, the compressor’s output of CFM will also remain the same.

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A VSD air compressor, on the other hand, is equipped with a variable frequency drive or inverter that allows it to adjust its motor speed or RPM (and thus its CFM) to match the real-time demand for compressed air.  When the demand drops, the inverter dials back the motor operation to a lower speed (and lower CFM). It thus consumes proportionately less energy (and money), creating a relatively linear output-to-input efficiency curve.

VSDs are an extremely energy-efficient way to address rapid cycling, which occurs when your air compressor switches back into the loaded state before the transition to the no-load state is complete. If that happens too frequently, it can cause increased wear and reduce compressor reliability and lifespan.

VSDs are recommended when the compressor operates at a load between 30% and 80% of its total capacity most of the time. They are not recommended when your compressor is running at 100% load most of the time as the VSD drive itself has some losses (that can be overcome by optimizing tip speeds). But they are very valuable as a trim compressor complementing a base load compressor (see “System Reconfiguration” section below).

Variable-speed drives complement rotary screw air compressor technology exceptionally well.

VSDs allow the compressor to ramp up to full speed gradually, preventing a high in-rush current (up to six times as high as operating current) that fixed-speed compressors draw during startup. They automatically control acceleration and deceleration to reduce peak amps, thus avoiding utility company penalties for increased power demand. Utilities levy these costs to discourage spikes in usage that can overload the power grid.

This soft start capability saves energy and reduces the startup stress on compressor components. It lengthens the life of the motor by decreasing inrush current, which causes the coils to heat up and reduces the life of the insulation. It thus extends the lifespan of your equipment.

By allowing more finite control of your compressor, VSDs will enable you to calibrate the output to match compressed air demand, enhancing efficiency and performance.

In addition, you can control the pressure more tightly, keeping the pressure band—the gap you set between load pressure and unload pressure—to +/- 1.5 PSIG, according to CAGI. With a fixed-speed unit, that pressure differential will have to be much higher.

That’s a lot of wasted energy, especially if your plant needs 100 PSIG and you're compressing up to 130. The rule of thumb is that for every 2 PSIG increase in pressure, the energy consumption goes up by 1%. You can conserve energy by using a VSD air compressor and setting the header pressure as low as possible.

To combat rapid cycling, we often propose modulation that adjusts the inlet valve to a partially open position. As mentioned previously, variable-speed drives are a more energy-efficient way to address this issue but cost more up front.

While modulation has traditionally been viewed as a waste of money and energy, it may be more cost-effective than VSDs for some users. The key is to balance that potential cost with the negatives of rapid cycling.

Neither modulation nor VSDs, however, take the place of an appropriately sized compressor and storage tank. It’s a best practice to have both wet and dry storage to remove moisture and maintain stable header pressure. For more on tank storage, see our post, A Quick Guide to Accurately Size Air Compressor Tanks. 

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