The Carbon Zero compressor recovers 100% of the input energy · The Carbon Zero compressor recovers...

The first air compressor certified “net zero energy consumption”

www.atlascopco.com

The Carbon Zero compressor recovers 100% of the input energy

The first air compressors TÜV-certified “net zero energy consumption”CARB

ON Z

ERO

Combining forces to save our planet

Combining forces to

All around the world, companies rely on our expertise and innovations to help grow their businesses. They count on us to cut their costs without cutting their productivity. We help them invigorate their production processes in a way that doesn’t drain the life from our environment. We supply solutions that are adapted to specifi c circumstances all around the world. We take our responsibilities seriously: toward our customers, toward their future, and toward the future of our world.

We are Atlas Copco. And we energize business!

Country Compressed Air Systems con sumption TWh

% of industrial electricity consumption

France 12 11

Germany 14 7

Italy 12 11

United Kingdom 10 10

Rest of the EU 32 11

Yearly energy consumption by compressed air systems*

* Blaustein, Edgar; Radgen, Peter (Ed.): Compressed Air Systems in the European Union. Energy, Emissions, Savings Potential and Policy Actions. Stuttgart 2001

Why is energy important?Compressed air is one of the most important utilities for industry. It is also one of the largest consumers of energy. Therefore, any savings made in compressed air systems have a signifi cant impact on costs and on the environment.

While compressed air systems in general account for about 10% of total industrial electricity consumption, this can amount to as much as 40% of the electricity bill for certain plants.In view of this, Atlas Copco has been innovating in energy-effi cient compressed air solutions for many years.

Climate change is one of the most serious environmental threats facing our planet. The Kyoto Protocol sets the standard around the world, which means that countries and industries today face stringent targets to reduce carbon dioxide emissions. Commercial and legislative pressures to preserve the envi-ronment are driving industry to strive for energy effi ciency. By achieving these targets, companies not only enhance their own green credentials, but they also improve their bottom line by reducing energy costs.

Energy savings on compressed air benefi t your bottom line and the planetAtlas Copco seeks to reduce the CO2 footprint at every stage of a compressor’s life time from ‘cradle to grave’. From the design phase right through to the equipment’s manufacture, distribution, consumer use, disposal and recycling.Though when looking at the typical carbon footprint of an air compressor, the energy consumed in its use accounts for 99% of CO2 emissions. As energy consumption also typically represents over 80% of a compressor’s lifecycle cost, energy savings in compressed air systems will have a signifi cant impact towards preserving not only the environment but also your bottom line.

the

chal

leng

eth

e ch

alle

nge

the

chal

leng

e Energytypically : 80%

Total cost of ownershipTypical CO2 footprint of air compressors

InvestmentOthers MaintenanceOthers

CO2 emission in use: 99%

Launch of the ZH, the world’s fi rst packaged

and ready-to-run centrifugal turbo

compressors

The fi rst worldwide Full Feature

compressors with integrated dryers, reducing

energy use and CO2 emissions

Atlas Copco’s fi rst oil-injected screw

compressor

The world’s fi rst water-cooled

two-stage piston compressor, with effi ciency gains of

10-15%

Atlas Copco introduces its fi rst

oil-free piston compressor

The fi rst silencing canopies on oil-

injected GA units, reducing noise

emissions.

Additional energy savings are achieved by

improving inter- and aftercooling on the

ZR coolers.

The fi rst integrated Variable Speed

Drive (VSD).This revolutionary innovation allows energy savings of

up to 35%

Launch ofthe Elektronikon™,

the world’s fi rst energy saving

electronic control and monitoring

system.

Atlas Copco is the fi rst to introduce a

patentedMD adsorption

dryer, today widely installed and adopted by

industries due to its enormeous energy

savings.

The fi rstZ compressor with asymmetric screw design, resulting

in a very low Specifi c Energy

Requirement.

First oil-freescrew compressor,

the UR4

savings.

Atlas Copco is the fi rstto be awarded a “net zero energy consumption” certifi cation

A century of innovation incompressors results in another breakthrough in energy effi ciency

1952 1966 1969 1986 1994 1995 2002 20051904 1964 1967 1973 1993 1995 2002 2003 2006

Innovation is one of Atlas Copco’s key values. Throughout the years, the company has been at the forefront of compressor technology with a number of important innovations.Hundreds of patents related to both compressors and air treatment equipment have contributed to Atlas Copco’s becoming and remaining First in Mind-First in Choice® with its customers.

The new certifi cation is yet another milestone in Atlas Copco’s history of innovating for energy-effi cient compressed air solutions.

Introduction of the Z Full Feature

compressors with integrated

MD dryer, saving energy up to 20%.

AirscanTM allows customers to assess their

compressed air needs and tailor

their installations to save more energy.

Highly energy effi cient XD heat of compression

adsorption dryer range developed.

Launch ofthe ES system/

controller, which optimizes

the operation of multiple

compressor installations.

The Z compressors are the fi rst to

be awarded ISO 8573-1 Class 0 (no oil traces in

the air stream as measured by the

TÜV)

The Z compressors

Atlas Copco is the fi rstto be awarded a “net zero energy consumption” certifi cation

1952 1966 1969 1986 1994 1995 2002 20051904 1964 1967 1973 1993 1995 2002 2003 2006 a n

ew m

ilest

one

a new

mile

ston

eAtlas Copco is the fi rst

manufacturer to offer certifi ed ‘net zero energy consumption’

compressors with its‘Carbon Zero’ range.

2009

CARB

ON Z

ERO

The TÜV supervised the type-testing and certifi ed Atlas Copco’s ZR 55-750 range of water-cooled oil-free screw compressors with built-in energy recovery systems.

The testing process involved the real-time measurement ofthe electrical input power and the output power as hot water.

It was proven that under the specifi c design conditions of40°C ambient temperature, 70% relative humidity, 20°C cooling water temperature, 100% of the electrical input power could be recovered.

Save

100%

Energy inputelectricity

Air inputatmospheric

Air outputcompressed

Energy outputhot water

TÜV test result:net zero energy consumption

What is the TÜV?

the

proo

f

The TÜV, Germany’s Technischer ÜberwachungsVerein or Technical Inspection Association, is an independent, international organization that specializes in evaluating the safety and quality of technology. The TÜV is recognized worldwide for its independence, neutrality, professional expertise and strict standards.

CARB

ON Z

ERO

Low pressure element

Atmospheric air at specifi c design

conditionsOil cooler

IntercoolerHigh pressure

element Aftercooler

Atmospheric air at specifi c design

conditionsOil cooler

100% heat recovery

100% energy recovery,that’s a great idea

The electric energy used by a compressor is transformed into heat,which is usually lost from the system. The challenge consists in recovering this heat from all of the compressor’s components: the compression elements, the oil cooler, the intercooler and the aftercooler.

The unique built-in energy recovery system of the Carbon Zero compressor circulates cooling water through all these compo-nents and, as a result of the heat transfer, yields hot water at up to 90°C. While in

most industrial conditions 90 to 95% ofthe energy can be recovered, in specifi c design conditions the ‘Carbon Zero’ compressor goes even further:it recovers 100%!

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Most industries can make use of hot water for space heating, showers and other such applications.

1. Process Heating: hot waterSeveral industrial processes require hot water between 70° and 90°C.The Energy Recovery system is capable of a continuous delivery of hot water at 90°C for the processes.

As such, a boiler may no longer be required. That means saving on investments as well as on boiler fuel.

2. Process Heating: steamSeveral industrial processes also require steam at different temperatures and pressures. In such cases, the hot water delivered is passed through a boiler as preheated feed water to generate steam. This results in substantial savingsin boiler fuel.

Low level applications (intermediate and seasonal use - low utilization)

High level applications (continuous use - maximum utilization)

Compressed air

Water inEnergy

RecoveryControl

Unit

Compressed air

Water inEnergy

RecoveryControl

UnitBoiler

Steam

Compressed air

Water in

Shower

Space heating

Hot water out 70° - 90° C




EnergyRecoveryControl

Unit

Process heating applications:a few examples

Steam is a preferred medium due to its high heat carrying capacity. It is alsointrinsically safe (non-fl ammable). High-level applications such as process hot water and process steam also require large amounts of hot water. Instead of generating hot water or steam with an industrial boiler, the use of hot water from the compressor can dramatically reduce or even eliminate heating fuel consumption in this regard.

Food & beverageHot water and steam are used in many dairy processes. Steam is commonly used for pasteurization, scalding, cleaning and sterilizing cooking vessels, drying products, etc.

In larger dairies, huge amounts of hot water and steam are required in continuous processes. Here, the hot water energy recovery system of the compressor can provide substantial energy savings.

PharmaceuticalsLarge amounts of steam are used in the pharmaceutical industry and in manufacturing processes.

Fermentation temperature control, drying and sterilization processes are part of the daily routine of the pharmaceutical industry.

The CIP (Clean In Place) cleaning method, SIP (Sterilization In Place), direct contact sterilization in bioreactors and fermenters, and steam barriers against bacteria are commonly employed in these manufacturing units.

The energy recovered from theAtlas Copco air compressor contributes toa higher bottom line.

ChemicalsThe chemical industry and refi neries are major users of steam. Some applications are:

• Thermal steam crackers require highly superheated steam at typically 40 bar.

• Re-boilers and stripping employ superheated medium pressure steam at typically 10 bar.

• Heat tracing and other applications require superheated low pressure steam at typically 2 bar.

In some processes, a great deal of hot water is recovered after the steam condenses. Hot water from compressors is used as make-up water to supplement the losses.

appl

icat

ionsTextiles

Coloring of fabric makes use of considerable volumes of hot water at 80° to 90°C. Energy Recovery systems of Atlas Copco’s compressors can directly offer the hot water to the process.

For yarn and fi bre treatment steam is used for heat-setting man-made fi bers to achieve dimensional stability, increased volume, and wrinkle and temperature resistance.

Pulp & paperSignifi cant volumes of compressed air are used in the wood pulp and paper industry. Vast amounts of steam are also used inthe industrial processes.

Typical applications are bleaching, digesters, pulp machines and black liquor evaporators.

Humidity controlSteam is used for humidifi cation since it is clean and inherently sterile.

Clean room humidifi cation in electronics assembly, chip manufacture and in pharmaceutical industry is common practice.As this steam is used as a utility, continuous replenishment water is required. Hot water from the air compressor can pre-heat the replenishment water, and consequently, reduce the energy consumption of the steam boiler.

Steam turbinesHighly superheated steam (typically 40 bar) is used for motive applications such as steam turbines.

Turbines are used as prime movers for captive power generation and for several machines.

Preheated boiler feed water reduces fuel consumption in boilers resulting in signifi cant savings.

The Carbon Zero compressor range

Atlas Copco offers you a comprehensive range of compressors. Whatever your compressed air needs, our energy consultants can always recommend the right solution for you.

CARBON ZERO

*Reference Conditions at full load operation

Yearly running hours 8500

Electricity cost €/KWh 0.08

kg CO2/KWh 0.353

Caloric value heating oil Kj/kg 43000

Heating oil cost €/l 0.50

Specifi c weight heating oil kg/l 0.72

Heating oil cost €/kg 0.69

Boiler effi ciency 0.7

7.5 bar(e) variants (109 psig)

Model FADNominal cooling

water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual

savings*l/s m³/min l/s kW Tons € €

electricity savings

Heating oil savings

ZR 55 143 8.6 0.24 55 165 37400 38829ZR 75 194 11.6 0.31 75 225 51000 52949ZR 90 234 14.0 0.37 90 270 61200 63538

ZR 110 318 19.1 0.44 110 330 74800 77658ZR 132 367 22.0 0.52 132 396 89760 93189ZR 145 394 23.6 0.56 145 435 98600 102367ZR 160 471 28.3 0.66 160 480 108800 112957ZR 200 607 36.4 0.84 200 600 136000 141196ZR 250 726 43.6 1.03 250 750 170000 176495ZR 275 780 46.8 1.11 275 825 187000 194145ZR 300 775 46.5 1.19 265 795 180200 187085ZR 315 855 51.3 1.29 293 879 199240 206852ZR 355 949 56.9 1.41 328 984 223040 231561ZR 400 1049 62.9 1.58 367 1101 249560 259095ZR 425 1162 69.7 1.74 420 1260 285600 296512ZR 450 1257 75.4 1.71 429 1287 291720 302865ZR 500 1387 83.2 1.88 469 1407 318920 331105ZR 630 1726 103.6 2.33 585 1755 397800 412998ZR 750 2075 124.5 2.87 721 2163 490280 509012CA

RBON

ZER

O

the

ZR 5

0Hz r

ange



water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 55 131 7.9 0.24 55 165 37400 38829ZR 75 184 11.0 0.31 75 225 51000 52949ZR 90 220 13.2 0.37 90 270 61200 63538

ZR 110 285 17.1 0.44 110 330 74800 77658ZR 132 326 19.6 0.52 121 363 82280 85424

ZR 132 VSD 376 22.6 0.57 122 366 82960 86130ZR 145 362 21.7 0.56 134 402 91120 94601ZR 160 435 26.1 0.66 154 462 104720 108721

ZR 160 VSD 436 26.2 0.69 156 468 106080 110133ZR 200 553 33.2 0.84 194 582 131920 136960ZR 250 691 41.5 1.03 248 744 168640 175083

ZR 250 VSD 721 43.3 1.11 250 750 170000 176495ZR 275 723 43.4 1.11 262 786 178160 184967ZR 300 723 43.4 1.19 253 759 172040 178613ZR 315 798 47.9 1.29 278 834 189040 196262

ZR 315 VSD 836 50.2 1.14 275 825 187000 194145ZR 355 886 53.2 1.41 310 930 210800 218854ZR 400 978 58.7 1.58 345 1035 234600 243563

ZR 400 VSD 1114 66.8 1.92 358 1074 243440 252741ZR 425 1081 64.9 1.74 389 1167 264520 274626ZR 450 1166 70.0 1.17 403 1209 274040 284510ZR 500 1291 77.5 1.88 440 1320 299200 310631

ZR 500 VSD 1318 79.1 2.20 358 1074 243440 252741ZR 630 1602 96.1 2.33 538 1614 365840 379817

ZR 700 VSD 2063 123.8 3.48 748 2244 508640 528073ZR 750 1850 111.0 2.87 628 1884 427040 443355

9 bar(e) variants (130 psig)


water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 75 VSD 220 13.2 0.36 75 225 51000 52949ZR 90 VSD 258 15.5 0.40 90 270 61200 63538



water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 55 121 7.3 0.24 55 165 37400 38829ZR 75 174 10.4 0.31 75 225 51000 52949ZR 90 209 12.5 0.37 90 270 61200 63538

ZR 110 265 15.9 0.44 110 330 74800 77658ZR 132 313 18.8 0.52 130 390 88400 91777

ZR 132 VSD 333 20.0 0.57 124 372 84320 87542ZR 145 334 20.0 0.56 138 414 93840 97425ZR 160 402 24.1 0.66 160 480 108800 112957

ZR 160 VSD 394 23.6 0.69 156 468 106080 110133ZR 200 504 30.2 0.84 200 600 136000 141196ZR 250 629 37.7 1.03 250 750 170000 176495

ZR 250 VSD 648 38.9 1.11 250 750 170000 176495ZR 275 689 41.3 1.11 275 825 187000 194145ZR 300 689 41.3 1.19 273 819 185640 192733ZR 315 765 45.9 1.29 297 891 201960 209676

ZR 315 VSD 746 44.8 1.14 275 825 187000 194145ZR 355 846 50.8 1.41 324 972 220320 228738ZR 400 939 56.3 1.58 359 1077 244120 253447

ZR 400 VSD 979 58.7 1.92 311 933 211480 219560ZR 450 1047 62.8 1.17 416 1248 282880 293688ZR 500 1199 71.9 1.88 467 1401 317560 329693

ZR 500 VSD 1150 69.0 2.20 336 1008 228480 237209ZR 630 1474 88.4 2.33 567 1701 385560 400291

ZR 700 VSD 1859 111.5 3.48 700 2100 476000 494186ZR 750 1704 102.2 2.87 650 1950 442000 458887



water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 75 VSD 198 11.9 0.36 75 225 51000 52949ZR 90 VSD 232 13.9 0.40 90 270 61200 63538

the

ZR 5

0Hz r

ange

the

ZR 6

0Hz r

ange 7 bar(e) variants (100 psig)


water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 110 352 746 0.45 110 330 74800 77658ZR 160 463 981 0.62 160 480 108800 112957ZR 200 574 1216 0.74 200 600 136000 141196ZR 250 667 1413 0.88 234 702 159120 165199ZR 275 752 1593 1.04 267 801 181560 188497



water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 55 155 328 0.26 55 165 37400 38829ZR 75 213 451 0.34 75 225 51000 52949ZR 90 262 555 0.41 90 270 61200 63538



water fl ow

Nominal Energy

recovery

CO2savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 110 321 680 0.45 110 330 74800 77658ZR 132 VSD 376 797 0.57 122 366 82960 86130

ZR 145 398 843 0.58 145 435 98600 102367ZR 160 419 888 0.62 148 444 100640 104485

ZR 160 VSD 436 924 0.66 156 468 106080 110133ZR 200 516 1093 0.74 180 540 122400 127076ZR 250 619 1312 0.88 217 651 147560 153198

ZR 250 VSD 721 1528 1.11 250 750 170000 176495ZR 275 726 1538 1.04 258 774 175440 182143ZR 300 755 1600 1.12 259 777 176120 182849ZR 315 850 1801 1.23 290 870 197200 204734

ZR 315 VSD 836 1771 1.29 275 825 187000 194145ZR 355 955 2024 1.37 331 993 225080 233679ZR 400 1043 2210 1.51 367 1101 249560 259095

ZR 400 VSD 1114 2361 1.92 358 1074 243440 252741ZR 450 1306 2767 1.81 448 1344 304640 316279ZR 500 1538 3259 2.09 500 1500 340000 352990

ZR 500 VSD 1318 2793 2.28 358 1074 243440 252741ZR 630 1700 3602 2.30 579 1737 393720 408762

ZR 700 VSD 2063 4371 3.48 700 2100 476000 494186ZR 750 1939 4109 2.69 670 2010 455600 473007



water flow

Nominal Energy

recovery

CO2 savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 55 138 292 0.26 55 165 37400 38829ZR 75 194 411 0.34 75 225 51000 52949

ZR 75 VSD 220 466 0.36 75 225 51000 52949ZR 90 235 498 0.41 90 270 61200 63538

ZR 90 VSD 258 547 0.40 90 270 61200 63538



water flow

Nominal Energy

recovery

CO2 savings/

year*

Potential annual

savings*

Potential annual


electricity savings

Heating oil savings

ZR 55 128 271 0.26 55 165 37400 38829ZR 75 185 392 0.34 75 225 51000 52949

ZR 75 VSD 198 420 0.36 75 225 51000 52949ZR 90 224 656 0.41 90 270 61200 63538

ZR 90 VSD 232 492 0.40 90 270 61200 63538ZR 110 287 608 0.45 110 330 74800 77658

ZR 132 VSD 333 706 0.57 124 372 84320 87542ZR 145 336 712 0.58 142 426 96560 100249ZR 160 375 795 0.62 153 459 104040 108015

ZR 160 VSD 394 835 0.66 156 468 106080 110133ZR 200 459 973 0.74 184 552 125120 129900ZR 250 548 1161 0.88 218 654 148240 153904

ZR 250 VSD 648 1373 1.11 250 750 170000 176495ZR 275 641 1358 1.01 254 762 172720 179319ZR 300 677 1435 1.12 270 810 183600 190615ZR 315 762 1615 1.23 295 885 200600 208264

ZR 315 VSD 746 1581 1.29 275 825 187000 194145ZR 355 858 1818 1.37 330 990 224400 232973ZR 400 945 2002 1.51 364 1092 247520 256977

ZR 400 VSD 979 2075 1.92 311 933 211480 219560ZR 450 1144 2424 1.81 450 1350 306000 317691ZR 500 1332 2823 2.09 500 1500 340000 352990

ZR 500 VSD 1150 2437 2.28 336 1008 228480 237209ZR 630 1474 3123 2.30 569 1707 386920 401703

ZR 700 VSD 1859 3939 3.48 700 2100 476000 494186ZR 750 1739 3685 2.69 670 2010 455600 473007

*Reference Conditions at full load operation

Yearly running hours 8500

Electricity cost €/KWh 0.08

kg CO2/KWh 0.353

Caloric value heating oil Kj/kg 43000

Heating oil cost €/l 0.50

Specific weight heating oil kg/l 0.72

Heating oil cost €/kg 0.69

Boiler efficiency 0.7

CARB

ON Z

ERO

Our energy consultants can optimizeyour air-fl owAre you looking for the most environmentally responsible and energy effi cient solution for your compressed air needs? Contact one of our energy consultants today for expert assistance and advice!

The Energy Recovery Control UnitsThe Energy Recovery Control Unit is the interface between the Carbon Zero compressor and the energy consumer.Main features:

• Provides protection to the Carbon Zero compressor.

• Automatically regulates the temperature of the hot water to the process

• Regulates the temperature of the cooling water to the compressor

• Caters to different consumer applications

Control unit forcompressor model

Nominal cooling water fl ow

l/s

ZR 55-1450,24 - 0,69

ZR 75/90/160 VSD

ZR 160-2750,62 - 1,14

ZR 315 VSD

ZR 300-4251,12 - 1,92

ZR 400 VSD

ZR 425-5001,81 - 2,28

ZR 500 VSD

ZR 630 2,30

ZR 750 2,69 - 3,48

ZR 700 VSD

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The Carbon Zero compressor recovers 100% of the input energy · The Carbon Zero compressor recovers...

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