Compressed Air System

KOBELCO AIR COMPRESSOR DRYER
FILTER AIR TANK PIPING VENTILATION

ENERGY SAVING MAINTENCE KOBELCO
AIR COMPRESSOR DRYER FILTER AIR
TANK PIPING VENTILATION ENERGY
SAVING MAINTENCE KOBELCO AIR
COMPRESSOR DRYER FILTER AIR
MPRESSOR DRYER FILTER AIR TANK
PIPING VENTILATION ENERGY SAVING
MAINTENCE KOBELCO AIR
Compressed Air System

KOBELCO
COMPRESSORS
Outline
1. Introduction of Compressed air
2. Basic knowledge of Compressors
3. About KOBELCO Compressors

Introduction of Compressed air

Introduction to Compressed air
Index
１ 2 3
How can air Advantages of Facts about
generate power? Compressed Air Compressed Air
Introduction to Compressed Air
Index
１ 2 3
How air generate power?
Compressed Air
When air is compressed, it is under pressure greater than that of the normal
atmospheric pressure and it characteristically attempts to return to its normal
state. Since energy is required to compress the air, energy is released as the air
expands and returns to atmospheric pressure.
In industry, Ambient Air

compressed air is so
widely used that it is
often regarded as Gasses
the fourth utility,
after electricity, Oil vapor
natural gas and
water.
Particles
Moisture
Bacterias
Standard State Compressed State
The “content” in the air don’t change when it’s compressed

- just the amount of space those molecules take up
１ 2 3
Advantages of Compressed Air
Air Power vs Electric Power
Air Power Electric Power

• Cost  • Cost
• Flexibility  • Flexibility
• Safety  • Safety
• Usability  • Usability
Air Power vs Hydraulic Power
Air Power Hydraulic Power

• Cost  • Cost
• Flexibility  • Flexibility
• Safety  • Safety
• Usability  • Usability
• Easily transported
• Easily stored
• Clean and dry
• Lightweight
• Safe to use
• Accident-proof
• Rational and economical
• Simple
• Overload-proof
• Fully adjustable
１ 2 3
Facts about Compressed Air
Proper design enhancing energy saving
- Compressor’s energy consumption is about 25%
of a whole manufacturing power consumption
Manufacturing factory’s energy consumption
- Machinery : 40%
- Compressor : 25%
- AC : 8%
- Lighting : 4%
- Others : 23%
Saving 15% energy in compressor

= saving 3~4% energy in whole factory
Facts about Compressed Air
About 86% of total life cycle cost of compressor is
related to energy
Life Cycle Cost of Compressor

- Electricity Cost : 86%
- Maintenance Cost : 7%
- Initial Cost : 5%
- Labor Charge : 2%
Air leakages potentially

consumes up to an average 20%
of total compressed air demand
Basic Knowledge of Compressor

Index
１ 2 3
What is Classification How to choose
Compressor ? of Compressor Compressor
4 5 6
Air Treatment Installation
Piping
Equipment Location
Index
１ 2 3
4 5 6
Piping
Equipment Location
What is Compressor?
Definition
Air compressors were designed to compress air to higher pressures and
harness this potential energy source.
Compressor
Gas Gas
0.7MPa
0.1013 MPa
800m³/hr @ 1barA 100m³/hr @ 7barG

Index
１ 2 3
4 5 6
Piping
Equipment Location
Index
１ 2 3
4 5 6
Piping
Equipment Location
Classification of Compressor
Classification by compression method
Positive
Compressor Reciprocating
Displacement
Screw
Rotary
Compressor
Scroll
Compressor
Centrifugal
Dynamic
Compressor
Reciprocating Compressor
Mechanism
Compressed air by changing
capacity of compression chamber
with a piston that moves up and
down inside a cylinder
Pros Cons
 Affordable Price  Big noise & vibration
 Suitable for small size (Less  Unsuitable for more then
than 11kW) middle size
 Many portable model  Friction & easy to wear
Centrifugal Compressor
Mechanism
Compressed air by rotating
Impeller at high speed
(20,000rpm or more)
Pros Cons
 High efficiency in large size  Surging may happen in lower
(300kW or more) volume
 Less friction
Classification by compression method
Positive
Compressor Reciprocating
Displacement
Screw
Rotary
Compressor
Scroll
Compressor
Centrifugal
Dynamic
Compressor
Screw Compressor
Mechanism
Compressed air by rotating male
and female screw rotors and
changing capacity of the space of
screw grooves
Pros Cons
 Most widely used for plants
 High efficiency in wide range
(15kW-300kW)
 Small noise & vibration
Classification of Screw Compressor
Oil-Flooded Compressor Oil-Free Compressor
 Oil injected inside compression  Oil-less structure

chamber for lubrication, cooling,  Used in industries need high
sealing purity compressed air
 Widely used in general industry (electronics, food, etc)
Oil Flooded Screw System Diagram
Oil Free Screw System Diagram
Types of control method
Characteristic of capacity control method
100
90 Inlet modulation
80
70
Inlet modulation
+ purge
Power consumption (%)
60
50 Load/Unload
40
30
Inverter
20
10
0 10 20 30 40 50 60 70 80 90 100
Air consumption (%)

Inlet modulation (+ purge)
Inlet modulation (+purge)
100
Feature
90
80
• Controlling suction valve
throttle.
70 • Widely used in oil-flooded
60
compressors
Power consumption
50
40
• Work load : 70%
30 • Power consumption : 91%
(𝑦 = 10 𝑥 + 0.7)
3
20
• Low efficiency at middle load

10
0 10 20 30 40 50 60 70 80 90 100
Air consumption (%)

Load/Unload
Load/Unload
100
Feature
90
80
• Controlling suction valve with
fully open / fully closed
70 • Used in a part of oil-flooded
60
and oil-free compressors
Power consumption
50
40
• Work load : 70%
30 Power consumption : 85%
20
• 10% more efficiency than inlet
10 modulation
0 10 20 30 40 50 60 70 80 90 100
Air consumption (%)

Inverter
Inverter
100
Feature
90
80
• Controlling capacity with
various speed driven motor
70 • Widely used in high-end screw
60
compressor
Power consumption
50
40
• Work load : 70%
30 • Power consumption : 70%
20
(𝑦 = 𝑥) most ideal curb
10 • Most efficiency controlling

method
0 10 20 30 40 50 60 70 80 90 100
Air consumption (%)

Group control
Optimal controlling system of multiple units
Air volume demand changing depending on factory’s production situation
- Important to control multiple compressors as the situation demands
Group Control
Endless circle method By installing group controlling panel, efficiency
multiple controlling method can be realized
500
400
Individual operate
300
Endless circle + Inverter Endless circle (standard)

200
Inverter
Endless circle + Inverter
100
ideal controlling system
0 100 200 300 400 500
Air consumption (%)

Merit of group control
Trial calculation of multiple compressors’ electricity cost
Condition
1 0 0 % = 6 1 .5 m 3 /m in
100
80
Air consumption (%)
60
40
20
0:00 2:00 4:00 6:00 8:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 0:00
Condition
Compressor : 75kW * 5units Electricity unit cost : 0.35MYR / kWh
Running hour : 6,000 hour/year Air consumption : As above graph shows
Merit of group control
Trial calculation of multiple compressors’ electricity cost
Reference : 100% load of all 5 units compressor

2,418,000 kWh
Individual operating
2,164,200 kWh
757,470 MYR
Saving
Endless circle controlling 171,885 MYR
1,673,100 kWh
585,585 MYR
Saving
Endless circle + Inverter 203,385 MYR
1,583,100 kWh
554,085 myr
######### ######### #########
Electricity power consumption (kWh/year)

Market Configuration
Oil-Flooded Screw Oil-Free Screw Scroll Centrifugal Reciprocating
100%
90%
Centrifugal
80%
Reciprocating
70% Oil-Free Screw
60%
50%
40%
Oil-Flooded Screw
30%
20% Scroll
10%
0%
Small Middle Large

Index
１ 2 3
4 5 6
Piping
Equipment Location
Index
１ 2 3
4 5 6
Piping
Equipment Location
4 Steps to Choose Compressor
1st Step Check required air quality & cooling system
2nd Step Check pressure of compressed air required
3rd Step Check amount of compressed air required
4th Step Choose right compressor based on Step 1-3
Next
Choose relevant equipment (Tank, Dryer, Filter)
Step
Step1 : Air Quality & Compressor type
Compressor type (Oil-flooded, Oil-Free)
• Compressor type is chosen by intended use & required air quality
• Important to know how purity air is required for your use
Oil-flooded Oil-free
model ? model ?
Water-
Air-Cooled?
Cooled?
Step 1: Air Quality & Compressor Type
Sceneario: What about oil-free generated air?
NOX VOC
SO2
CO
CO2
Compressor
NH3
O3
Compressed Air
Atmospheric Air
VOC CO2
SO2 NOX O3
CO
NOX VOC
NH3 CO2
VOC
NH3
Particles
H2 O
Even Oil-free generated air needs purification

• Water separators + filters (downstream coolers)
• Dryers (removal of water vapor)
• Activated carbon adsorbers / filters (removal of contaminants
of ambient air)
Quality of compressed air
• Air contains a lot of contaminations
- Water vapor, solid particles, oil vapor, NOx, SOx….
• Quality of compressed air is defined by ISO
ISO 8573.1 : Compressed Air Quality Standards

S O LID PA R T IC LES H U M ID IT Y O IL
Class PA R T IC LE S IZ E : d (m m ) T O T A L C O N C EN T R A T IO N :
PR ES S U R E D EW PO IN T
0.10< d≤ 0.5 0.5< d≤ 1.0 1.0< d≤ 5.0 A ER O S O L, LIQ U ID , V A PO R
3
N U M B ER O F S O LID PA R T IC LES PER m °C m g/m 3 ppm /w /w
0 A s specified A s specified A s specified
1 100 1 0 ≤ -70 ≤ 0.01 ≤ 0.008
2 100,000 1,000 10 ≤ -40 ≤ 0.1 ≤ 0.08
3 - 10,000 500 ≤ -20 ≤1 ≤ 0.8
4 - - 1,000 ≤+3 ≤5 ≤4
5 - - 20,000 ≤+7 - -
6 - - - ≤ + 10 - -
Required air quality of each industrial use
• Required air quality of each industrial use is designated by PNEUROP
Examples : required air quality of each industrial use by CAGI PNEUROP

Grade Grade
Use Use Oil Solid Particle Humidity
Oil Solid Particle Humidity
Air tool 4 3 5 Clean room 1 1 1
Air motor 4 4 -1 5 Photo film 1 1 1
Pneutmatic
2 3 2 Food 2 3 1
Conveting
Foundary 4 4 5 Sensor 2 2 -1 1
Blasting - 3 3 Textile 4 3 3
Paint 3 3 3 Electronics 1 1 1
Bubbling 3 5 3 Utility air 4 4 5

Step 2 : Required pressure
Required pressure of compressed air
• Check how much pressure production facilities require
• Load starting pressure (bottom of operating pressure) of
compressor must be 0.1-0.2 MPa higher than operating
pressure of production facilities
Industrial Machinery Compressor
Operating Pressure Controlling

bottom pressure
0.4MPa
0.5 ~ 0.6MPa
Step 3 : Required Air Volume
Required air amount
• Check how much air amount production facilities require
• Compressor’s capacity to be 10% higher more than the
demand
Industrial Machinery Compressor
Required air volume Discharge air volume

10 m3/min 11 m3/min
Step 4 : Choose appropriate model
Other points….
1. Energy-saving or Standard Model
- Energy-saving : VSD (Variable-Speed Driven) model
- Standard : Fixed-Speed Driven model
2. Check power supply Voltage

Index
１ 2 3
4 5 6
Piping
Equipment Location
Index
１ 2 3
4 5 6
Piping
Equipment Location
Air Treatment & Accessories
Water
圧縮空気システムのダイアグラム図を挿入
Separator
各機種紹介の導入にしようする。
Air receiver tank
Function
1. Minimize pressure pulsation
Compressor has pressure pulsation by its
compressing process. By installing receiver
tank, steady pressure can be achieved.
2. Preserve compressor
In the case tank not installed, inching
happens in compressor and potentially
causing damage on the compressor.
3. Buffer for exceed air demands
To take care of sudden & unusual
demands in excess of compressor’s
capacity
Air receiver tank
Formula of sizing receiver tank
𝑡1 + 𝑡2 × 𝑄𝑆 × 𝑃𝑆 × 𝑥(1 − 𝑥)
𝑉𝐸 =
𝐷
Explanation
VR : Air tank capacity (m3/min)
t1 : Unloading time (s)
t2 : Loading time (s)
Qs : Compressed minimum air flow rate (m3/min)
Pa : Absolute Suction Pressure (bar)
D : Pressure difference upper limit and lower limit (bar)
𝑥 : Load factor (ratio of air demand to the compressed air flow
rate)
Air Dryer
Function
Remove water vapor from compressed air
- Compressor air contains lots of water vapor
- Water vapor condensates by ambient

temperature cooled compressed air
- Drain damage pipes and equipment
Main type
1. Refrigerated Air Dryer
2. Adsorption Dryer
Dew point
Dewpoint DP / Atmospheric Dewpoint [°C]
Dewpoint is the temperature at which humid air at atmospheric pressure
becomes saturated when cooled.
At 100% relative humidity, the dewpoint temperature and air temperature are
the same.
Pressure Dewpoint PDP [°C]

is the dewpoint at a certain pressure.
PDP defines the degree of dryness in

compressed air or gas systems. air at atmospheric
pressure
becomes saturated
when being cooled
Air Dryer : Refrigerated Air Dryer
Features
• Pressure dew point : 3°C ~ 10°C
• Most widely used in various industry
• Mechanism
Removing water vapor from compressed
air by cooling with refrigerant. After that
re-heating cold compressed air to the
room temperature.
Air Dryer : Absorption Dryer
Features
• Pressure dew point : -70°C ~ -10°C
• Used in food, pharmaceutical, electronics

industries
• Mechanism
Removing water vapor from compressed
air by passing compressed air through
absorbent process
Amount of water vapor content in air
Amount of saturated water vapor
(Unit : g/m3) Temperature of 2nd digit
0 1 2 3 4 5 6 7 8
50 82.8 86.7 90.8 95 95.5 104 109 114 119 124
40 51.1 53.7 56.4 59.3 62.2 65.3 68.5 71.9 75.4 79
30 30.3 32 33.7 35.6 37.6 39.6 41.7 43.9 46.2 48.6
Temperature of 1st digit
20 17.2 18.3 19.4 20.6 21.8 23 24.4 25.8 27.2 28.7

10 9.39 10 10.7 11.3 12.1 12.8 13.6 14.5 15.4 16.3
0 4.85 5.19 5.56 5.94 6.36 6.79 7.26 7.75 8.27 8.81
-10 2.14 1.96 1.8 1.65 1.51 1.39 1.27 1.16 1.06 0.967
-20 0.882 0.804 0.732 0.667 0.607 0.551 0.501 0.454 0.412 0.373
-30 0.338 0.305 0.276 0.249 0.225 0.203 0.183 0.164 0.148 0.133
-40 0.119 0.107 0.0955 0.0854 0.0763 0.0681 0.0608 0.0541 0.0482 0.0428
-50 0.0381 0.0338 0.0299 0.0265 0.0234 0.0207 0.0183 0.0161 0.0142 0.0125
-60 0.0109 0.0096 0.0084 0.0073 0.0064 0.0056 0.0049 0.0043 0.0037 0.0032
-70 0.0028 0.0024 0.0021 0.0018 0.0015 0.0013 0.0011 0.001 0.0008 0.0007
Drain condensation by dryer

(Compressor:13.05m3/min 0.7MPa, Temperature:30°C, R.H.:70%, Pressure dew point of dryer : -10°C )
(30.3 𝑔 𝑚3 × 70% − 1.16 𝑔 𝑚3) × 13.05 𝑚3 𝑚𝑖𝑛 × 60 min × 12ℎ𝑜𝑢𝑟/𝑑𝑎𝑦
= 188,390 𝑔 𝑐𝑐
Filters
Features
Removing oil vapor, particles & microorganism
from compressed air.
Pre Filter Oil Mist Filter Activated carbon filter

• Remove dust and • Capture oil mist and • Capture oil vapor
particles which size reduce them from by passing through
is more than 3 μm. 0.01~0.5 mg/m3 activated carbon
filter (0.003mg/m³)
Sterile Filter
• High Retention rate of
microorganism up to 3 Nano
micron suitably for
pharmaceutical & Food industry
Filters
Rust particles at compressed air inlet
If there is corrosion in pipe line, pre-filter

is a MUST, to avoid accumulative at
dryer’s heat exchanger as pictures shown
above causing efficiency drop & potential
damages to the dryer
Filters
Oil at compressed air inlet
Emulsion found on dryer inlet
without pre filter, 4 weeks in
operation with a poor
conditioned oil flooded
compressor.
Index
１ 2 3
4 5 6
Piping
Equipment Location
Index
１ 2 3
4 5 6
Piping
Equipment Location
Piping
Three points to consider for piping
1. Pressure Optimization
- Pressure drop generated by air treatment equipment, pipes,
& joints
- Optimization operating pressure to production facilities,
important to identify pressure drop of air system
2. Drain condensates
- Risk of water carry over into compressed air system
- Necessity to consider condensates for piping system
3. Main Pipe System

- Selection of Pipe size
- Piping Distribution System
Piping : Pressure Optimization
Pressure drop is generated by….
Pressure Drop
Air Treatment equipment Piping

(Dryer, Filters) (Pipe, Joint)
A reduction of 1 bar in operating

pressure potentially reducing
energy consumption by 7%
Pressure Loss by Air Treatment Equipment
Pressure loss of each Air Treatment equipment
(Unit : MPa) Dryer Filter
Refrigerated Absorption Oil-mist Activated carbon

Prefilter
Dryer Dryer Filter Filter
Initial Pressure 0.02 0.02 0.005 0.02 0.005

Loss
Pressure loss prior 0.02 0.02 0.07 0.07 0.005

to replacement
Example Activated
Receiver
tank
carbon filter
Compressor Pre Filter Ref. Dryer Oil mist filter
Discharge
Compressor Pre filter Ref. dryer O. filter A.C.. filter pressure
0.005 MPa 0.02 MPa 0.02 MPa 0.005 MPa 0.65 MPa
0.7 MPa
0.07 MPa 0.02 MPa 0.07 MPa 0.005 MPa 0.535 MPa
(a) (b) (c) (d) (e) (a-b-c-d-e)

Pressure Loss by Piping
Pressure loss of each diameter of pipe
A 15 20 25 40 50 65 80 100 150 200
1 3 1 1
B /2 /4 1 1 /2 2 2 /2 3 4 6 8
Optimal Nm3/min 0.5 1 1.5 4 7 13 20 30 80 140

Volume ΔMPa/10m 0.0038 0.0032 0.0032 0.0017 0.0014 0.0014 0.0013 0.0007 0.0006 0.0005
Maximum Nm3/min 1.8 3.1 4.2 11 15.4 22.3 31.4 53.5 100 173
Volume ΔMPa/10m 0.0431 0.0284 0.021 0.0106 0.0063 0.0035 0.0028 0.0026 0.001 0.0007
*ΔMPa = Pressure Loss(Mpa) per 10 meter, Discharge air prssure=0,6MPa
Conversion of joint parts to length of straight pipe

(unit : m) Gate 45° 90° T joint T joint Glove
Valve Elbow Elbow
20A (3/4B) 0.2 0.3 1.3 0.3 1.4 7.3
25A (1B) 0.3 0.4 1.6 0.5 1.6 8.8
40A (1 1/2B) 0.4 0.7 2.3 0.7 2.5 12.8
50A (2B) 0.5 0.8 2.6 1.0 3.2 16.5
65A (2 1/2B) 0.5 1.0 2.9 1.2 4.0 18.9
80A (3B) 0.6 1.2 3.4 1.5 5.3 24.4

Example
<Example>
Air volume : 7.0 m3 / min
Discharge P. : 0.6MPa
Pipe diameter : 50A (2B)
Length : 100 m
Joint parts : Gate valve*1, Glove valve*1
Calculation
Calculation
i. Conversion of joint parts to straight pipe length.
Gate valve*1 = 0.5m*1, glove valve*1 = 16.5m*1
ii. Sum total of piping including joint parts
Piping length + Joint parts = 100m + 0.5m +16.5m = 117m
iii. Calculating pressure loss based on the total length
Pressure loss = 0.0014MPa/10m * 117m = 0.16 MPa
∴ Pressure loss = 0.16 MPa

Loop piping system
Design loop piping system
0.7MPa 0.65MPa 0.60MPa
0.49MPa 0.49MPa
0.49MPa 0.49MPa
By structuring a loop piping

0.49MPa 0.55MPa
system, pressure of the whole
air system is equalized,
potentially eliminating
0.60MPa 0.55MPa 0.50MPa reducing pressure of
compressors
0.49MPa 0.49MPa
0.49MPa 0.49MPa
0.55MPa 0.50MPa
Piping : Avoiding Water Carry over
Compressed air contains water vapor and risk of drain troubles
Usage Potential Issues caused by drain
Painting Pinhole, Uneven paint
Sand blasting Rust in products
Powder conveying Cogging branch pipe, quality decrease
Important points to avoid drain troubles

Points
1. Tilting main pipe 1degree not to
Discharge air backflow drain
Drain Separator Union 2. Setting drain valve at the lowest point

of piping system
3. Outlet should be taken from top of

Drain Valve main pipe
Air Velocity
The most overlooked area in piping layout and
design is the velocity of the compressed air. High
velocity can be a significant cause of backpressure,
erratic control signals and turbulence.
Velocity for compressed air should be <15m/sec,

Recommended 6m/sec to avoid water carry over.
Index
１ 2 3
4 5 6
Piping
Equipment Location
Index
１ 2 3
4 5 6
Piping
Equipment Location
Installation Location
• The air compressor location should be as close as possible to the point where the
compressed air is to be used. It is also important to locate the compressor in a
dry, clean, cool and well-ventilated area. Keep it away from dirt, vapour and
volatile fumes that may clog the intake filter and valves. If a dry, clean space is
unavailable, a remote air intake is recommended.
Installation Location
• The air compressor intended floor space should be levelled,
avoiding excessive vibrations and do consider ample space for
compressor operation, maintenance and ingress & egress of parts
in the future, ensuring proper functionality.
Ventilation
• Compressor can be operated up to 45°C
• To keep acceptable condition, proper ventilation is
necessary to remove heat generated by compressor
Entire ventilation Ventilating duct Ventilating duct & fan

Entire ventilation
Entire ventilation Features
- Ventilating by only Exhaust fan & inlet port
- Lower setting cost
- Fan size becomes bigger
Points to make note

1. Air inlet should be lower in the wall, and
exhaust fan should be higher in the wall to
make air flow from bottom to top
2. Air inlet must be wide enough to avoid

negative pressure in the room. (In the
case of negative pressure, enough
ventilation air cannot be obtained)
3. In the case of low ceiling, set ventilation

duct
Ventilating duct
Ventilating duct Features
- Ventilating by duct, fan & air inlet
- Ventilating compressor’s heat exhaust air
to outside directly by duct
Points to make note

1. Do not fix the duct with compressor by
screw
2. Setting rain cover in the outlet to prevent

rain from entering duct
3. When pressure loss in the ventilating duct

is over 20Pa, install a ventilating fan at the
duct outlet
Ventilating duct & fan
Ventilating duct & fan Features
- Ventilating by duct & fan
- Ventilating compressor’s heat exhaust air
to outside directly by duct
Points to make note

1. 300 – 400mm gap must be secured
between the ventilation duct inlet and
compressor exhaust outlet
2. Turn on the ventilating fan while the

compressor is running, and vise versa
3. Provide such a size of inlet opening as to

keep the velocity of airflow to be 2m/s or
less.
About KOBELCO Compressors

Foundation : 1905
Business :
Iron & Steel, Welding,
Aluminum & Copper, Machinery,
Engineering, Construction
Machinery, Electric Power
Sales : 1,823 billion JPY
(2016)
(=67.6 billion MYR)
Kobe Steel, also known as KOBELCO, is a major steel
manufacturer in Japan. We lead Japanese industries in each
business area with “Only One” technologies, and selected
“Fortune Global 500” in 2014.
Produced Japan's first reciprocating compressor using our own technologies
and entered the compressor business
• 1915 Manufactured the first high pressure piston
compressor in Japan
• 1955 Broke into screw compressor business with
technological tie-up with SRM( Svenska Rotor Maskiner) *EARLY DAYS OF KOBE STEEL
• 1956 Launched the first Oil-Free Screw in Japan
• 1960 Established a screw compressor production plant in Takasago, Hyogo
• 1961 Started production of oil injection type screw
compressor.
• 1963 Started selling general-purpose compressor "KST series" (single stage).
• 1968 Adopted an asymmetric screw rotor profile to improve performance
• 1971 Started selling package type screw compressor "KST series".
• 1973 Completed a standard compressor production plant in Okubo
• 1974 Launched the packaged screw compressor BT model
• 1978 Broke into the standard small-sized air compressor business (7.5 - 11kW)
• 1979 Marked the 20,000-units in cumulative shipments of screw compressors.
80
• 1980 Started selling energy-saving, standard Super Economy Series compressors
• 1983 Developed KOBELCO proprietary Super Rotor profile to greatly improve
performance
• 1984 Started selling oil-free single-stage compressor "ALS series“
• 1985 Started selling single stage type vacuum pump "KV series"
• 1987 Completed a standard compressor plant in Harima
• 1990 Started selling ultracompact "new air mate series"(1.5 - 5.5kW)
• 1991 Launched Air Mate Series (7.5 - 11kW); all models come standard equipped
with a dryer.
• 1993 Developed Intelligent Total Control System (ITCS) with a self-diagnosis
function.
Completed and launched HandSome Series (22 - 75kW)
• 1994 Started selling two-and-half-stage closed screw refrigerator "SH-F (water
cooling) series"
• 1995 Launched Mach Series (5.5 - 11kW) Kobe Steel sustained
massive damage in
• 1995 Remodelled medium-sized machine the 1995 Hanshin
Earthquake
• "Handsome series" (15.22kW).
• 1996 Launched medium-sized Emeraude Series "FE" (1.5 - 37kW)
• 1997 Launched large-sized Emeraude Series (45kW - )
• 1998 Launched Kobelco Inverter Series with an IPM motor.
• 1998 Started selling large-sized single stage machine "HMJ series" (90 - 150kW)
• 2000 Started selling oil-free scroll machine "ES series" (1.5 - 15kW).
• 2000 Started selling medium-sized inverter "Kobelion" (15 - 75kW).
• 2000 Started selling compact / ultracompact machine "ASCM" (1.5 - 5.5kW)
• 2002 KOBELION received "The Japan Society of Mechanical Engineers Award
(technique)" and "Japan Machinery Federation Chairperson Award " as an
excellent energy-saving instrument.
• 2002 Started selling two oil-free compressor "FE series" (15 - 37kW).
• 2003 Started selling two stage oil-free compressor "(VF/VE) series inverter“
• 2004 Started selling "Kobelion VS multi" (110 - 150kW)
• 2005 "Kobelion series" won "New Machine Promotion Award".
About KOBELCO Compressor
• 2007 Started selling large-sized two stage machine "Kobelion LT/ST" (160 -220kW)
• 2007 Started selling large-sized oil-free type "ALE" (305 - 370kW).
• 2007 Developed and Started selling medium size inverter "KobelionII" (15 -
75kW) to be manufactured in China
• 2008 Started selling water injection type oil-free machine "Aqua series" (22 -
37kW)
• 2012 Started selling oil-free type "ALE II"(55 - 290kW)
• 2013 Changed model of small size oil-injection type "CM" to "SG"(7.5 - 11kW)
• 2013 Developed and Started selling medium size oil-free type "FE" (15 - 55kW) to
be manufactured in China
• 2016 Started selling oil-free type "New ALE" (132 - 160kW)
• 2019 Started selling new oil-flooded compressor “V7 series" (15 - 09kW).
• 2020 Launching oil-free type “New ALE” (132-400kW)
Compressor Manufacturing Plants
TAKASAGO WORKS HARIMA MANUFACTURING
SHANGHAI MANUFACTURING
Global Account
Thank you

Compressed Air System - en - 200716

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Compressed Air System - en - 200716

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KOBELCO AIR COMPRESSOR DRYER

FILTER AIR TANK PIPING VENTILATION

1. Introduction of Compressed air

2. Basic knowledge of Compressors

3. About KOBELCO Compressors

Introduction of Compressed air

In industry, Ambient Air

The “content” in the air don’t change when it’s compressed

Air Power Electric Power

Air Power Hydraulic Power

Saving 15% energy in compressor

Life Cycle Cost of Compressor

Air leakages potentially

Basic Knowledge of Compressor

800m³/hr @ 1barA 100m³/hr @ 7barG

 Oil injected inside compression  Oil-less structure

Air consumption (%)

• Low efficiency at middle load

Air consumption (%)

Air consumption (%)

10 • Most efficiency controlling

Air consumption (%)

Endless circle + Inverter Endless circle (standard)

0 100 200 300 400 500

Air consumption (%)

Reference : 100% load of all 5 units compressor

######### ######### #########

Electricity power consumption (kWh/year)

Small Middle Large

1st Step Check required air quality & cooling system

2nd Step Check pressure of compressed air required

3rd Step Check amount of compressed air required

4th Step Choose right compressor based on Step 1-3

Even Oil-free generated air needs purification

ISO 8573.1 : Compressed Air Quality Standards

0 A s specified A s specified A s specified

1 100 1 0 ≤ -70 ≤ 0.01 ≤ 0.008

2 100,000 1,000 10 ≤ -40 ≤ 0.1 ≤ 0.08

3 - 10,000 500 ≤ -20 ≤1 ≤ 0.8

Examples : required air quality of each industrial use by CAGI PNEUROP

Air tool 4 3 5 Clean room 1 1 1

Air motor 4 4 -1 5 Photo film 1 1 1

Bubbling 3 5 3 Utility air 4 4 5

Industrial Machinery Compressor

Operating Pressure Controlling

Industrial Machinery Compressor

Required air volume Discharge air volume

2. Check power supply Voltage

- Water vapor condensates by ambient

- Drain damage pipes and equipment

Pressure Dewpoint PDP [°C]

PDP defines the degree of dryness in

• Most widely used in various industry

• Used in food, pharmaceutical, electronics

20 17.2 18.3 19.4 20.6 21.8 23 24.4 25.8 27.2 28.7

Drain condensation by dryer

Pre Filter Oil Mist Filter Activated carbon filter

If there is corrosion in pipe line, pre-filter

3. Main Pipe System

Air Treatment equipment Piping

A reduction of 1 bar in operating

Refrigerated Absorption Oil-mist Activated carbon