Plug & play cement air compressor installation cost
When researching overall air compressor installation cost, it's worth looking into the benefits of a plug & play setup. This is a common solution offered by many manufacturers.
When you choose equipment for your cement plant, focus on energy efficiency, easy maintenance, and onboard technology. These are the main cost factors to consider.
All the components in one machine
It used to be the case that you would purchase a compressor and related necessary components separately.
These include an electric motor, engine starters, aftercooler, and intake filter.
With this, it was essential to discuss the requirements and control interface with each supplier. Doing so would ensure all parts were correctly assembled for a properly working compressor.
Now, the majority manufacturers offer plug & play compressor setups.
Engineers build these modern machines on a base frame to mount all components. The manufacturer provides the internal piping and cabling between the various components as standard, guaranteeing maximum compatibility.
Additionally, you can opt for an integrated refrigeration or adsorption dryer. You can also add a heat exchanger to enable a heat recovery system. After adding all components, we cover the entire compressor with an acoustic hood. This reduces the noise level and prevents sound pollution.
This plug & play arrangement has made the installation of a compressor much easier. It also contributes to a lower air compressor installation cost. With this, you ensure that all parts function reliably and more efficiently. You’ll find all-in-one equipment available to meet the unique needs of cement plants.
A maintenance-friendly, reliable design helps on the cost
Modern compressors are designed for energy-efficient operation, reliability, and ease of maintenance. All components are grouped sensibly and arranged for easy access. This reduces the duration of service interventions, minimizing downtime.
One example is new GA 90+-160 (VSD+) series of oil-injected rotary screw compressors. These machines feature newly developed, high-performance screw elements with intelligent injection technology. Engineers build them with highly efficient, oil-cooled motors and maintenance-free gearboxes.
The GA VSD+ models have a variable speed drive (VSD) with an interior permanent magnet motor (iPM). This motor meets the IE5 efficiency standard. They are dust-tight in observance of the industrial protection class IP66 and resistant to strong jets of water.
Our compressors work exceptionally reliably. They perform well in tough, dusty industrial settings. These include cement, mining, metal processing, and power stations.
Regarding air compressor installation cost, it's important to consider the role efficiency and maintenance play in overall operational expenses.
Modern VSD machines may cost more at first than fixed speed compressors. However, they usually pay for themselves over time. This is especially true since electricity makes up to 80% of the cost of owning a compressor.
Component design influences on maintenance frequency
We develop the components of modern compressors for speedy service, which reduces maintenance times. This means that technicians do not need to take apart many compressors during maintenance. Spare parts can be changed in a few minutes.
For example, the modular design of Atlas Copco compressors makes it easy to access all components when necessary.
This reduces maintenance time by half compared to previous designs.
Atlas Copco provides customers with a complete 5-year warranty for the whole compressor. This "Warranty" helps ensure smooth operations, even in tough conditions.
In this case, we will take care of all preventive maintenance, overhaul, repairs, and possible downtime.
Higher level control systems prevents from downtime
You can avoid downtime by using a better control system. The new Optimizer 4.0 is a great option.
The central control system regulates all compressors in an installation. Based on how several compressors make up a larger compressor installation, this helps achieve optimally efficient utilization.
You can divide operating times between different compressors, which reduces the risk of failure and facilitates maintenance work.
If one compressor stops, whether as a breakdown or for maintenance, the control system starts another machine. By doing this, a drop in operating pressure and production downtime is prevented.
Designing the right air compressor installation
In addition to the information covered, sizing is also vital to take care for your cement plant.
Investing in equipment that's either oversized or undersized can result in wasted energy or inefficient operations.
This is particularly relevant with facilities that depend heavily on low-pressure blowers. You need the right mix of equipment to meet your needs.