Scarcer availability of resources, increased use of renewable energy or the revitalised global economy: The reasons for rising energy prices are manyfold.

Whatever the causes, the need for modern industry to save energy is greater now than ever before. This is where advanced compressed air technology can help make a real difference. Kaeser Kompressoren is therefore proud to present its comprehensive range of innovative products and solutions for efficient compressed air supply in the wood processing industry at LIGNA 2011.

Kaeser Kompressoren's extensive range of products and services will be on show at two exhibition stands at this year’s LIGNA in Hanover: The first has its focus on "Trades, Wood and more" and is located in Hall 14, Stand K 21 and the second, which focuses on the furniture industry, can be found in Hall 26, Stand B 35.

“Sigma Air Manager” with new adaptive 3-D-Control

Amongst the many highlights on show will be Kaeser’s latest development in advanced compressed air system management technology: The next generation Sigma Air Manager (SAM). Using its innovative 3-D-Control (patent pending), the SAM is able to consider the three crucial factors that affect energy-efficient compressor control within a compressed air station:
1. Switching losses associated with compressor start-up and shutdown.
2. Additional energy consumption for pressure increases above the required pressure.
3. Control losses resulting from idling and FC losses.

The SAM constantly analyses the relationship between these variables, calculates the best possible result and controls the compressors accordingly. Moreover, this advanced controller provides users with exceptional cost transparency and optimises preventative maintenance for the entire compressed air supply system.

Other points of interest at the Kaeser exhibit:

“Aircenter” now for FADs up to 2.5 m³/min

User's looking for cost-effective compressed air production, treatment and storage with minimal space requirement need look no further than Kaeser’s compact “Aircenter” packages. With a footprint of only about one square metre, these versatile compressor systems operate quietly and efficiently to provide a quality supply of treated compressed air for free air deliveries from 0.34 to 2.5 m³ at 7.5 bar.

All "Aircenter" models are characterised by their exceptional efficiency, and the two largest models - the new “Aircenter 22” (11 kW) and the “Aircenter 25” (15 kW) - are no exception. At the heart of these systems lies an optimised SK series rotary screw compressor from Kaeser. With a maximum FAD of 2.5 m³/min (at 7.5 bar) these new SK models deliver up to 11 and 14 percent more compressed air, respectively, than their predecessors. This impressive performance boost has been achieved both through airend optimisation and the minimisation of internal pressure losses. In turn, these improvements have lead to a reduction in specific power of up to five percent. The use of premium efficiency IE3 electrical motors has also contributed to additional energy savings. Although use of these motors will become compulsory from January 1st, 2015, Kaeser is already installing them in its rotary screw compressors so that operators can benefit from further additional energy savings right now.

Another important efficiency-enhancing component is the new “Sigma Control 2” internal controller: This advanced system not only enables demand-oriented performance matching and dependable monitoring, but ensures even greater flexibility through its numerous interfaces and innovative plug-in communication modules. Therefore, connection to energy-saving master control systems, computer networks and / or remote diagnostics and monitoring systems, such as Kaeser's Teleservice facility, couldn’t be easier. The addition of an integrated RFID reader ensures service continuity, increases security and significantly raises service quality.

Kaeser's unique cooling system is equipped with a patented premium-efficiency dual-flow fan with separate cooling air flows for the motor and compressor. This not only achieves optimum cooling performance, low compressed air discharge temperatures and minimal sound levels, but also promotes efficient air compression.

A thermally shielded refrigeration dryer provides dependable and efficient compressed air drying, and, as you might expect from a leading compressed air system provider such as Kaeser, compressed air quality can be matched to suit requirement via optionally available filters. The compressed air is stored in an underslung 350-l air receiver. The “Aircenter 22” and “Aircenter 25” are also available with an integrated frequency converter (“Sigma Frequency Control” - SFC) for applications where speed control is an advantage.

The smaller “Aircenter” models are based on Kaeser’s SX or SM series rotary screw compressors. Equipped with a 200-l or a 270-l air receiver, these versions cover FADs from 0.34 to 1.5 m³/min (at 7.5 bar) and ensure super-quiet, efficient performance. As with the two largest models, 10- and 13-bar versions are available for applications requiring larger volumes of compressed air. Furthermore, the “Aircenter 12” can also be equipped with variable speed control.

ASD rotary screw compressors: Optimum efficiency and design

Efficient compressed air production with minimal space requirement - these are the key advantages of Kaeser's ASD series rotary screw compressors. Covering free air deliveries from 3.16 to 5.51 m³/min at 7.5 bar, and capable of 15 bar maximum operating pressure, these compact powerhouses are the perfect choice for smaller volume users who wish to enjoy all of the benefits that modern compressed air technology has to offer.

At the heart of the every ASD compressor is a high performance rotary screw airend equipped with flow-optimised ‘Sigma Profile’ rotors. The ‘D’ in ASD denotes Direct Drive, which means that the airend and the drive motor are directly coupled and turn at exactly the same speed. The drive power is transmitted from the motor to the airend without the losses incurred by gearing or drive belts. The use of premium efficiency IE3 motors provides additional significant energy savings.

A further important efficiency-enhancing component is the new “Sigma Control 2” internal controller: This advanced system not only enables demand-oriented performance matching and dependable monitoring, but ensures even greater flexibility through its numerous interfaces and innovative plug-in communication modules. Therefore, connection to energy-saving master control systems, computer networks and / or remote diagnostics and monitoring systems, such as Kaeser's Teleservice facility, couldn’t be easier. The addition of an integrated RFID reader ensures service continuity, increases security and significantly raises service quality.

Featuring a radial fan and optimised cooling-air flow, the ASD’s clever cooling system ensures low compressed air outlet temperatures and optimum operating temperatures. The fan’s power reserve is sufficient for long lengths of ducting and, consequently, eliminates the need for installation of an additional exhaust fan. Moreover, it consumes less power than a comparable axial fan. In conjunction with exceptional sound insulation, the high performance ventilation system enables low sound levels of only 65 to max. 69 dB (A), depending on model. Furthermore, ASD compressors are optionally available with an integrated refrigeration dryer and / or frequency control module. Models featuring an integrated compressed air dryer are also equipped with a centrifugal separator and an electronic “Eco Drain” condensate drain as standard. These features therefore ensure efficient condensate separation & drainage and further aids effective operation of the downstream refrigeration dryer.

CSD-/CSDX rotary screw compressors:

Impressive performance and efficiency

Kaeser’s new fluid-cooled CSD and CSDX rotary screw compressor ranges combine outstanding performance and energy efficiency with versatile and compact design. Available with motor powers from 45 to 90 kW, these dependable compressors cover FADs from 8.3 to 16.1 m³/min (at 8 bar). They provide significant energy savings in four ways:
1. CSD and CSDX units feature a large, low speed Sigma Profile airend equipped with flow-optimised rotors for superior efficiency. In combination with additional optimisation measures, such as the minimisation of internal pressure losses, Kaeser’s energy-efficient design has enabled specific power to be reduced by between 3 and 5 % compared with previous models.
2. Kaeser rotary screw airends are powered by IE3 drive motors for maximum performance and reliability.
3. Kaeser’s highly efficient 1:1 drive design eliminates the transmission losses associated with gear or V-belt driven systems, as the motor directly drives the airend.
4. The newly developed PC-based “Sigma Control 2” compressor controller enables compressor performance to be precisely matched to actual air demand thereby allowing additional energy savings.

A highly effective cooling system ensures low compressed air discharge temperatures and features a condensate separator with automatic drain monitoring. Consequently, over 95 percent of accumulating condensate can be separated from the air flow. The cooler is located on the rear-side of the unit where a generously sized intake opening is available for the cooling air. This system prevents the cooling air from being pre-warmed and, as a result, optimises the cooling effect. The efficiency and reliability of downstream compressed air treatment equipment is therefore also considerably enhanced.

As well as standard versions, models are available with frequency control and an integrated refrigeration dryer module that allows compressed air production and drying with minimal space requirement.

SOURCE: Kaeser Compressors