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THE NEXT STAGE IN COMPRESSED AIR EFFICIENCY

24-01-2018
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According to Southern Cross CEO, Mark Ferguson, if Australian industry really wants to get serious about saving energy then it needs to take a close look at ‘two-stage’, air compressor technology. As energy costs continue to outstrip other business input expenses it is critical, more than ever before, to find new ways to save power. Two-stage compressors may just be one of the answers.

“Many customers get fixated with the capital cost of an air compressor and whilst those that want to save energy costs, will look a little deeper and review service costs, very few understand the long-term total operating cost of compressed air,” says Ferguson. “The largest cost related to producing compressed air is in energy, and this typically represents the highest energy usage in the plant. With continuously rising energy costs it’s an area in which businesses can readily address to achieve substantial potential savings,” he adds. “Two-stage compressors really are low hanging fruit”.

A single-stage compressor typically used in industry is limited by the overall compression ratio across a single airend. This compression ratio in most industrial applications is around 9:1 according Ferguson. High compression ratios, particularly as pressures increase, results in significant internal slippage which leads to loss of capacity and a reduction in efficiency. A high compression ratio also means higher bearing loads as the elevated internal pressures and temperatures mean greater axial and radial bearing loads. This can limit airend bearing life, which can lead to significant long-term maintenance costs.

A two-stage compressor on the other hand allows the compression ratio to be split over two distinct rotary screw airends resulting in compression ratios across each airend of around 3:1. The outcome is less slippage, lower bearing loads and with intercooling, significantly higher outputs for the installed motor power. The output of a two-stage compressor is typically around 20% higher than that of an equivalent single-stage compressor.

To put that into perspective, energy savings mean generally one size smaller compressor, and in most instances a return of the difference in capital cost in only a matter of months. Combine this with a VSD controller, where demand varies significantly, and savings can be even greater.

As a division of one of the world’s largest and most innovative compressor manufacturers, Southern Cross offers the latest in two-stage technology built on traditional heavy-duty design platforms with components produced to last.
When combined with a structured service programme, the Southern Cross range of two stage compressors enjoys a five-year package warranty with a unique, lifetime warranty on the screw airends.

From 75 to 355kW, all Southern Cross two stage compressors are available with fixed or VSD (variable-speed drive) controls.

With specialist technicians offering 24-hour support Australia Wide and with in-house electrical and refrigeration expertise, Southern Cross fully supports every compressor it supplies.

Southern Cross Compressors
1300 098 901
www.southerncrossaircompressors.com.au

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