Turbocompressors: ADVANTAGES as opposed to Prejudices!

Although turbocompressors are predestined for use in compressed air systems, it is relatively rare that they are found in this area. One reason for this is doubtlessly the fact that they are only available for flow rates in excess of approx. 27 m³/min. Another reason is the fact that a consultation with sales staff is often unilaterally focused towards displacement compressors, which generate considerably higher levels of turnover.

kmo turbo would like to dispel the widespread prejudices against turbocompressors:

1. prejudice: "Only suitable for use as a base load machine" - click!

kmo turbo:
Because of their incomparably high level of efficiency, turbocompressors are indeed ideal base load machines. Because of their excellent control characteristics and the wide control range, however, they also make ideal control systems.

Conventional compound controls disregard the control potential of a turbocompressor and reduce it to a mere base load machine.

The compressed air management of kmo turbo, on the other hand, completely exploits the potential of a turbocompressor.

2. prejudice: "High acquisition costs" -click!

kmo turbo:
This statement is simply too general. More than 3/4 of the overall costs related to compressed air can be attributed to energy consumption. The costs of acquisition are actually quite low in comparison. Therefore, cost-saving measures should be primarily focused on energy consumption.

The following criteria are influential with regard to choosing the appropriate compressor:

  • flow rate
  • control range
  • energy efficiency
  • required air purity
  • maintenance costs
  • wear
  • reliability

In systems with a compressed air requirement > 27 m³/min. a turbocompressor is at an advantage in all respects in comparison with a displacement compressor. If the intake air is well-filtered and the lubricating oil is kept clean, a turbocompressor is virtually wear-free, which means that hardly any maintenance costs are incurred. The efficiency of a turbocompressor is superior to that of any other kind of compressor. It supplies guaranteed oil-free air. The wide control range ensures that consumption fluctuations can be balanced efficiently; energy-consuming idling and start-stop operation is omitted.

The supposed "high investment costs" are amortized within a short period of time.

3. prejudice: "The flow rate is extremely dependent on pressure and temperature" – click!

kmo turbo: The dependence of suction pressure and intake temperature on the feed capacity is basically due to thermodynamics and equally applies to displacement compressors:

 

 

A 10°C increase of the temperature reduces the flow rate by approx. 7% (= ratio of absolute temperatures)

Within a year, the air pressure fluctuates by up to 50 mbar; this causes a 5% fluctuation of the flow rate (volume ~ absolute pressure).


In contrast to a displacement compressor, a turbocompressor is dependent on the final pressure. Due to the self-regulating effect, however, this is considered more of an advantage than a disadvantage: A consumption decrease leads to a system pressure increase, which means that the final pressure of the compressor also increases; an increase of the final pressure subsequently leads to a reduction of the flow rate. A new state of equilibrium is achieved without the requirement of a control intervention. The volume of the flow rate reduction is dependent on both the characteristic curve of the compressor and the respective current operating point. The following example diagram demonstrates how a pressure increase of 0.6 bar causes a flow rate reduction of 12%.

4. prejudice: "Operational limitations due to destructive surging" – click!

kmo turbo:
Persistent surging can lead to the destruction of a turbocompressor. The proven Anti-Surge Control and Reverse-flow Protection by kmo turbo provide not only reliable protection, but even double protection.

The characteristics map of a turbocompressor is divided into a stable and an unstable area by the surge line.

"Surging" occurs when the operating point of the compressor is driven out of the stable area of the characteristics map, either due to a reduction of the flow rate or due to an increase of the final pressure. "Surging" is characterized by a cyclic flow and reverse flow of the compressed medium, accompanied by high levels of vibration, pressure surges and a rapid temperature increase within the compressor.

The most Important Advantages of Turbocompressors:

  • The produced compressed air is absolutely oil-free
  • Top efficiency of all compressor types in the design point, good degree of efficiency over a wide control range
  • Good degree of controllability
  • Low maintenance costs due to low wear
  • High level of reliability