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New screw technology blowers are 30% more energy efficient

Posted: Monday 17th May 2010

Atlas Copco Compressors’ latest ZS range of oil-free, energy- saving positive displacement screw blowers is designed to meet today’s low carbon economy needs. The new and proven ZS screw blower technology is, on average, 30 percent more energy efficient than conventional lobe solutions.

The lobe technology widely used at present no longer meets the needs of today’s low carbon economy. Industries and applications such as waste water treatment, pneumatic conveying, power generation, food and beverage, pharmaceuticals, chemicals, paper and pulp, textiles, cement and general manufacturing, can benefit substantially from energy savings through the replacement of conventional lobe equipment with innovative and sustainable screw technology. As a result, the ZS screw blower models will now replace Atlas Copco’s entire range of ‘Roots’ type rotary lobe blowers.

The impact of air blowers on energy usage

Many industries use air blowers for their processes and will benefit from the energy efficiency of screw air blowers. Those that will benefit most are the municipal and industrial wastewater treatment plants, where the aeration air blowers typically represent up to 70 percent of the total electricity costs. Here, millions of bacteria feed on organic waste, breaking it up into carbon dioxide, nitrogen gas and water. Because the bacteria need oxygen, large amounts of air are blown in the aeration tanks.

Today, the majority of these plants use less efficient lobe technology, a technique that has experienced little development since its introduction in the late 19th century. By reducing the energy usage of their aeration blower system, these plants can lower their energy costs while operating in a more environmentally friendly manner.

Proven energy-efficient and reliable technology

The performance of the new ZS screw blower was tested against a tri-lobe blower by the independent Technische Überwachungs-Verein (German Technical Monitoring Association, or TÜV), according to the international standard ISO 1217, edition4. In these tests it was proven that the ZS is 23.8 percent more energy-efficient than a tri-lobe blower at 0.5 bar(e)/7 psig, and 39.7 percent at 0.9 bar(e)/13 psig.

The world-class efficiency of the ZS is mainly attributed to innovative design that integrates all individual components into a plug-and-run solution. Firstly, its superior screw technology – state-of-the-art, oil-free screw elements that incorporate years of experience and innovation, precision timing gears for proven reliability and increased uptime, together with industry proven element coating for closer tolerances and increased lifetime.

Other important features that contribute to increased efficiency and reliability are: the integrated gearbox that does not require belt and pulley replacement and is designed for reduced maintenance costs and increased uptime; the TEFC IP55 motor, designed for continuous operation in dusty and humid environments; and longer lifetime of bearings and gears due to lower oil temperature achieved by an optimum oil system design that includes an oil pump, oil cooler and filter.

Energy consumption typically represents 80 percent of the lifecycle costs of a blower. By introducing more energy-efficient screw technology to its air blower range, Atlas Copco can now offer a complete product portfolio of compressors and blowers for all applications and processes below 4 bar(e)/58 psig . Atlas Copco’s screw technology helps customers to save energy, which is a major advantage in a highly competitive marketplace.

An application video of the Atlas Copco ZS screw blower in a wastewater treatment plant is available on YouTube via the following link, or by searching for “Atlas Copco ZS screw blower in a wastewater treatment plant”: http://www.youtube.com/watch?v=DsBV2sqgi2E&feature=player_embedded




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