Go Green with Energy Efficient Air Compressors
November 8, 2022
Proper Air Compressor Maintenance
November 16, 2022Improve Efficiency with a Belt-Drive Air Compressor
Kaishan USA | November 10, 2022 | Uncategorized
Belt-drive air compressors are a staple in the industrial world of work. They’re solid workhorses used everywhere from auto body shops to major manufacturing plants, known for their versatility and low price tag.
Plus, they’re easy to install and maintenance is relatively straightforward. They’re also relatively cool and quiet. And you can adjust the output pressure easily, replacing a pulley, for instance, to go from 90 to 175 PSIG.
Belt-drive air compressors are a frequent choice for auto body shops.
They’re perfect for light- to heavy-duty industrial applications with limited space. They range in size from 5 to 50 horsepower.
What follows is some insight into how they work and how you can optimize the performance of your belt-drive air compressor to improve energy efficiency.
How a Belt-drive Air Compressor Works
Belt-drive air compressors have a circular belt, usually rubber, running from a pulley on a motor, which is normally electric, but could be diesel. The belt then connects on the other end to another pulley mounted on a rotor shaft that drives the compressor. By comparison, the rotor shaft is connected directly to the compressor's motor in a direct-drive air compressor.
A large number of general manufacturing operations use belt-drive compressors.
Direct-drive vs. Belt-drive Air Compressors
- “Belt drop” or slippage. As the rubber belts age, they stretch and loosen, resulting in less friction with the pulley and a loss of tension overall.
- Lower power efficiency, as a result. Direct-drive machines also have fewer drive losses saving on energy costs.
- Weather hazards. Especially in extreme weather, with belts becoming stiff and brittle in cold weather and looser when it’s hot. Airborne debris can also shorten belt life.
- More routine maintenance. You will have to repair and replace belts on a regular basis. Because direct-drive options need fewer wear parts like belts and pulleys to transmit power, they require much less routine care.
- More downtime, as a result.
Belt-drive air compressors are not without their disadvantages, however, especially when compared to direct-drive alternatives:
While the disadvantages outweigh the advantages in many applications, belt-drive air compressors are here to stay, largely because of their simplicity and low cost. And while many of you out there would like to trade up to more efficient models, the reality is that a replacement may simply not be in the budget.
Improving Efficiency of Belt-drive Air Compressors
The good news? There are a number of ways to make sure your belt-drive air compressor is operating as effectively as possible.
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- Maintain belt tension. If you fail to maintain belt tension, both the belts and the compressor will experience premature wear. The belts eventually will break, causing damage to the belt guard and the compressor. And you’ll even risk injury to operators or nearby workers.
- Replace belts as needed, with manufacturer-approved replacements. Cheap belts are not cost-effective, especially considering the risk of failure.
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If you are in the market for a belt-drive air compressor you may consider purchasing a single-stage rotary screw compressor with a premium-efficiency electric motor like the Kaishan KRSB that improves efficiency significantly. It has automatic belt tensioning to avoid slippage and is available with a tank-mounted model with integrated dryer and filter.
Key Takeaways
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- Belt-drive air compressors are a staple in the industrial world of work.
- They’re solid workhorses used everywhere from auto body shops to major manufacturing plants.
- They’re not without their disadvantages, but they’re here to stay because of their simplicity and low cost.
- They’re perfect for light- to heavy-duty industrial applications with limited space.
Kaishan KRSB
We designed the KRSB series to deliver reliable performance at an affordable price. You’ll find it gives you a low operating cost, high productivity, and reduced downtime, and helps ensure the safety of your workers.
The Kaishan KRSB belt-drive compressor provides great performance at an affordable price.
Affordability
Kaishan manufactures 85% of the components of the compressor in-house, keeping your costs low and protecting us against the supply chain issues that plague so many companies today. From stamping sheet metal for the enclosures to pouring castings for the airend in our own foundry, we provide more cost-effective and higher quality products to our customers.
Outstanding Productivity
The performance of the KRSB helps you improve productivity throughout your plant:
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- Maximum output. The rotor of the KRSB and its housing are precision-machined for tighter clearances and improved performance. KAPP grinder rotor technology for tighter clearances and improved lubrication. Precision machined rotor housing to optimize performance.
- Increased cooling efficiency. Our integrated after-cooler and fans provide keep the KRSB from over-heating, even when there are high ambient temperatures. The fans have a dedicated motor to ensure continuous operation.
- Dust removal. Premium-efficiency air intake filters offer excellent dust capture without impeding airflow, making the system more efficient overall.
- Removal of contaminants. A large cyclonic air intake filtration system removes contaminants, ensuring longer element life and long-term protection of your investment.
Lower Operating Cost
You’ll find it hard to beat the KRSB on operating costs, because of the following factors:
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- Lower energy use. Our premium-efficiency electric motors are known for their lower power use. And our SKK series airend and a laminar flow inlet valve maximize output while minimizing energy cost.
- Less energy loss. Our advanced belt-drive system and automatic belt tensioning keep belts tight, reducing slippage and cutting energy loss.
- Longer life. Because belts are properly tensioned, both the belts and the bearings will last longer, reducing maintenance hours and replacement costs.
- No loss of pressure. Key elements of our system, including our laminar flow inlet valve, large cyclonic air intake filtration and the spin on air/oil separator element are designed to reduce or eliminate pressure drop.
The Kaishan KRSB is equipped with an SKK series airend and a laminar flow inlet valve, maximizing output and minimizing energy cost.
Reduced Downtime
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- Longer component life. As mentioned above, both the belts and the bearings will last longer because belts are properly tensioned. In addition, the SKF bearings in the SKK airend absorb radial and axial load, increasing load capacity and prolonging bearing life.
- Easier maintenance. Your maintenance crew will have fewer belt and bearing replacements to perform. And the spin on air/oil separator element is also easy to maintain.
- Corrosion-resistant. Rather than use nylon, copper or mild steel, which all ultimately fail, we chose premium 316 stainless steel for our control tubing, giving our unit longer life, and leading to lower service costs, increased reliability and less downtime.
- Advanced controls with built-in alarms. The MAM-200 digital control panel monitors and controls key compressor functions, protecting the compressor in the event of a fault. In addition, it allows sequencing of up to 16 compressors and external monitoring via an RS 485 interface.
Enhanced Safety
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- Safety features. KRSB air compressors incorporate advanced safety features such as diagnostic controls, safety relief valves, and comprehensive belt guards to prevent on-the-job accidents.
- Noise. We’ve designed in world-class SKF discharge bearings and sound-deadening enclosures for quiet operation.
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Key trade-up options include:
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- A 120-gallon air receiver tank can help reduce load cycles to minimize energy consumption and cut wear and tear. It also provides peak demand coverage and increased condensate removal.
- An integrated dryer and air filter can be matched to your compressor, minimizing the footprint in your plant. With options for an oversized dryer for warmer environments.
An optional air receiver tank and an integrated dryer and air filter are available for the Kaishan KRSB belt-drive compressor.
Need Help?
Every situation is unique. So picking the right equipment for your air compressor system can be quite a challenge. But the experts at Kaishan are happy to help. Talk to us by visiting our contact page today.
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Belt-drive air compressors are a staple in the industrial world of work. They’re solid workhorses used everywhere from auto body shops to major manufacturing plants.