Energy efficiency and selection of Atlas Copco ZR/ZT oil-free screw compressor

Full Feature Integrated Drying - True 'Plug and Play'

Traditional compressed air systems require external post-treatment equipment such as dryers and filters after the compressor, which not only occupies space but also affects the final air source quality due to pipeline pressure drop and secondary pollution of condensed water. The Full Feature configuration integrates the IMD adsorption dryer directly into the compressor. Its working principle is to use the compression heat generated during the compression process (which needs to be discharged) to regenerate the desiccant, without the need for additional electricity or compressed air loss, achieving:

Low energy consumption drying: zero external energy demand and minimal pressure loss.

Constant dew point: can provide dew points at -20 ℃, -40 ℃, or even -70 ℃ pressure according to demand, meeting different process requirements.

Compact design: The standard ZT 110-275 Full Feature model is only about 4-5 meters in length (depending on power), making it suitable for data centers with limited space.

For models that do not have the Full Feature, Atlas Copco also offers matching independent dryers (such as XD, ND, BD, FD series), covering various technologies such as cryogenic, thermal regeneration adsorption, and blast regeneration, making it convenient for users to flexibly configure.

Elektronikon Controller and Intelligent Monitoring

All ZR/ZT models come standard with Elektronikon ™ Intelligent controller, equipped with a 5.7-inch color touch screen, supporting 31 languages. Its main functions include:

Accurate loading/unloading and PID regulation to maintain stable pipeline pressure.

Built in service timer, automatically reminding maintenance intervals (oil filter, air filter, grease, etc.).

Remote communication capability: Connected to the factory LAN through a standard Ethernet port, supporting web access and SMARTLINK cloud platform, enabling remote monitoring, fault warning, and energy efficiency analysis.

Mobile App: Supports iOS/Android, making it easy for operations personnel to check the status of the unit anytime and anywhere.

In addition, the controller can integrate advanced diagnostic functions such as SPM vibration monitoring and PT100/PT1000 winding/bearing temperature detection, providing a data foundation for predictive maintenance.

Key points for engineering selection and deployment

6.1 Interpretation of Selection Parameters

Pages 16-19 of the document provide a detailed performance parameter table, with key fields including:

FAD (l/s, m ³/min, cfm): The actual displacement measured under ISO 1217 Annex C standard conditions (20 ℃, 1 bar absolute pressure, 0% relative humidity) is the core indicator for measuring the gas production capacity of a compressor.

Working pressure (bar (e)): ZR/ZT covers a range of 4-13 bar (e) and needs to be selected based on the maximum required pressure of the gas equipment.

Installed power (kW): Fixed speed models offer multiple levels such as 110~275 kW (50Hz) or 160~315 kW (60Hz); The VSD model provides a pressure flow regulation range.

Noise (dB (A)): All are below 80 dB (A) and equipped with soundproof enclosures, meeting industrial noise standards.

6.2 Selection of Cooling Methods

Water cooling (ZR): Suitable for factories with circulating cooling water. Water cooling has high heat exchange efficiency, is insensitive to ambient temperature, and has a compact unit size.

Air cooling (ZT): Suitable for areas with water shortage or poor water quality, it is necessary to ensure good ventilation in the computer room and reserve sufficient heat dissipation spacing (the document size table provides length, width, and height data).

6.3 Installation and Environmental Requirements

Standard models can adapt to environmental temperatures up to 40 ℃; Optional HAT (High Environmental Temperature) version, up to 50 ℃.

The ground foundation needs to meet the weight of the unit (as low as about 2500 kg, as high as about 6500 kg, depending on the model), and it is recommended to install vibration damping pads.

The intake and exhaust ducts can be designed separately according to the site conditions to allow for the intake or exhaust of hot air to the outside.

6.4 Optional Item Reference

The options listed in the document include:

Anti condensation heater (used for high humidity shutdown state).

Energy recovery device (recovers compressed heat for preheating boiler water or workshop heating).

Various flange standards (ANSI, etc.) facilitate the connection of specific pipelines.

Material certificates and witness performance tests are applicable for engineering project acceptance.

TT/TN and IT network adaptation to meet different distribution systems.

Application scenarios and customer value

7.1 Food and Beverage Industry

Pure air is required for fermentation gas, packaging blowing, and material transportation. CLASS 0 certification ensures no chemical contamination risk, while Full Feature provides stable low dew point to prevent pipeline icing and bacterial growth.

7.2 Automobiles and Painting

If there is a trace of oil mist in the gas used for painting, it can cause defects in the paint surface (shrinkage, fish eyes). ZR/ZT provides absolutely clean compressed air, improving the first pass rate.