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Compressors
Fans and control technology for efficient compressor cooling
Compressors work to compress gases or vapours such as air or compressed air. This is where they get their name, although strictly speaking the actual compressor is only one part of the entire unit. Compressors need to be cooled, as the increase in pressure during compression heats up the gas, which is why without sufficient ventilation and cooling the temperature of the compressor would also keep rising. However, compressors can only operate optimally in a clearly limited temperature range. If this temperature range is exceeded, there is the risk that the compressor will overheat, resulting in damage.
Besides lack of maintenance and incorrect positioning, insufficient ventilation is one of the main causes of compressor malfunctions and damage. To prevent failures and the associated repair and subsequent costs, compressor operating room must be equipped with a ventilation system. These kinds of systems must work absolutely reliably, make as little noise as possible and have all the approvals and certificates that are required in the respective installation situation (e.g. an ATEX or IECEx approval for explosion protection in accordance with applicable regulations). Fans and their drives must also comply with the strict regulations on energy efficiency (ErP Directive) – environmental and climate protection are also becoming increasingly important for ventilation systems.
ZIEHL-ABEGG develops, manufactures and supplies powerful fans for compressor cooling that work reliably even in the harshest conditions (e.g. dust, dirt, humidity or salty air in offshore or coastal installations) and safely prevent overheating-related failures. We also produce the energy-saving drives and control modules for connected, “smart” fans, which means that with our products you can realise optimally coordinated complete systems for the demand-oriented and energy-efficient ventilation and cooling of compressors and machine rooms.
In paint shops or food processing plants, on the other hand, oil-free variants must be used.
The best and most cost-effective cooling medium for indoor compressors is fresh air from outside. Enough cooling fresh air must be available and must also be directed in such a way that it removes any excess heat from the compressor and at the same time supplies it with new air for compression.
Especially on small and medium-sized farms, the adjacent room where the compressor is located is often a small space. This makes the correct placement of the unit and cleverly thought-out air routing particularly important, as air-cooled compressors can only be operated safely if there is sufficient cooling air flow at all times to reliably dissipate the excess thermal energy. Three different ventilation methods are available, depending on the construction and size of the space:
1. Natural ventilation: Here, the air flows through supply and exhaust air openings in walls and/or ceiling without fan support. This concept is only suitable for small compressors.
2. Artificial ventilation: With this method, fans in the wall or ceiling openings support air circulation. For example, high-pressure axial wall fans are well suited. As exhaust air fans, they simultaneously create enough negative pressure to ensure that sufficient fresh air flows in.
3. Duct ventilation: The air is directed through supply and exhaust air ducts with the support of duct fans.
With larger compressors, a further challenge arises when it comes to dissipating heat loss, as the large compressors usually have a sound enclosure so that the noise level in the surrounding area is not unnecessarily increased. This sound enclosure also results in heat generated during compression bringing about a temperature increase inside the enclosure. This is a hazardous and undesirable consequence, so fans are used at this point to remove the warm air and at the same time supply fresh air, which the compressor sucks in and compresses.
Piston compressors are often found in areas where the compressor only needs to be operated intermittently. The robust, low-maintenance devices score highly when it comes to energy-saving operation and are also forgiving of frequent start-ups and shutdowns when the demand for compressed air fluctuates throughout the day. However, piston compressors are quite loud, so they are better in working areas where noise levers are not an issue.
Screw compressors work with rotors and significantly quieter during operation. They are used to supply various industrial processes with compressed air. Screw compressors can also continuously generate pressure over long periods of time, so can cover steady or fluctuating demand.
ZIEHL-ABEGG’s product portfolio also includes a number of axial and centrifugal fans with ATEX or IECEx approval. Therefore, our Ex products meet the European explosion protection directive 2014/34/EU (ATEX Directive). We also offer customised complete solutions in the Ex version for the supply of process air in potentially explosive areas. The fans can be fitted with proven, long-lasting AC technology.
* These ZIEHL-ABEGG products, which are suggested as possible solutions for these applications, are purely informative and serve as a rough guide. Consequently, individual contact with our technical sales experts is necessary and advisable with regard to a specific application so that the individual use can be checked and approved with regard to the explicit conditions.