Distributor / authorized representative that deals with supply & delivery of rotor compressor (rotor compressor lines) to industrial enterprises of Russia
Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level.Contents:
We are interested in cooperation with the manufacturers of rotor compressor (rotor compressor lines), who are looking for an official and reliable distributor to supply their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your rotor compressors. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative for rotor compressor lines in Russia, our marketing staff will carry out a market research in order to check the demand for rotor compressor lines, will submit a market overview for rotor compressors that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your rotor compressor lines and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods or for various types of rotor compressors (rotor compressor lines) in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for rotor compressors as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your rotor compressor lines into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of rotor compressors. They will also provide necessary training and guidance for the customer’s personnel.
Overview: rotary compressors
Rotary compressors are equipped with a rotating compressing element. They include screw compressors. The market of screw compressors is diverse. However, the basic principles of design and operation of a screw compressor are practically the same for all manufacturers. In these compressors, pressure is reduced by the rotation of the screws.
The principle of operation of the screw compressor has been known for over 120 years; the design has been developed since the 30s of the XX century and was patented in 1934. The development of the screw compressor represents a success story of the 20th century. Initially, they were not in great demand, since the rotor production was expensive. However, following developments, this problem was solved. Screw compressors are used when you want to provide the plant with great amount of compressed air. Screw compressors are characterized by a low level of vibration and noise. The advantages of screw compressors include easy maintenance.
The air end - an important part of the compressor - is highly reliable with a lifetime of 15-20 years. The air end can work with a variable speed, wherein the speed reduction of the screws changes only the amount of compressed air.
The screw compressor has no parts causing noticeable vibration and noise. Therefore, the screw compressor can be installed directly at the place of operation - in the manufacturing workshop. The waste heat can be used for heating in winter.
General description of rotary compressors
Compressors are used to obtain a pressure higher than normal atmospheric pressure for various gases (including air, refrigerants, natural gas, and special gases: ammonia, oxygen, nitrogen, etc.)
Rotary compressors are positive displacement compressors. The displacement compressor creates a reduction in the volume of gas to increase its pressure.
Rotary compressors were named like this because of the rotating operating element. They compress gases by means of bump rotors, liquid, screws or vanes. In response to market demands owing to the efforts of many manufacturing companies compact and efficient compressor machines came into being.
Rotary compressors include compressors of the following types: screw, cam (Roots compressor), vane, scroll, and liquid-ring compressors.
Except for differences in the design, compressors of this type have several common features. The most important feature that distinguishes them from reciprocating compressors is the absence of a large number of valves. Rotary compressors have less weight than reciprocating ones, have a simple constructive solution, and may include one or more rotors. The design of the rotor distinguishes the types from each other, and also the size and mode of operation are unique to each type of compressors.
Rotary compressors are often single drive units. In addition, there are units with in-line arrangement, complete with or without an intermediate gearbox.
Most rotary type compressors are completed with electric motor; however, portable compressors can also be equipped with internal combustion engine.
Rotary screw compressor
Fig. 1 Screw compressor
The performance of screw compressors is close to that of reciprocating and centrifugal compressors. For example, a large screw unit designed for 40,000 cfm is a typical area of application of centrifugal compressors, and small units for automotive air conditioning is a typical field of application of reciprocating compressors.The screw compressor is a widely used equipment to compress air, process gases and refrigerant. Efficient operation of screw compressors is mainly dependent on the proper rotor design. This type of compressors is often used in industry. In recent decades, this type of compressors has become widely popular in the gas industry when working with low pressure and high efficiency. Suction pressure can be very low, and discharge pressure can reach 400psig.
The operating element of the compressor is two screw rotors, which rotate towards each other: when the left rotor turns clockwise, the right rotor rotates counter-clockwise. The rotors and the housing are separated by a small gap. Both rotors may be attached to the drive shaft that drives the compressor in operation. The compressor has an inlet and an outlet for the actuating medium. Screw compressors may have different material design. Thermal treatment of the rotors is normally not required.
Principle of operation
Rotary screw compressor shown in Figure 1 consists of two screws or rotors in engagement, which hold the gas between them and the compressor housing. The motor drives the male rotor, which in its turn drives the female rotor. Both rotors are located within the housing, which also has an inlet and an outlet. Gas enters the compressor through the inlet and fills the cavities between the rotors. When the rotors are in motion, they compress the gas, thereby reducing its volume. During operation of the compressor, there is no direct contact between the rotors, which in turn means no wear of the rotor surfaces, growth of the reliability of the whole equipment and uniform feed of gas.
Compressors of this type can be oil-free or oil-flooded. In the oil-flooded screw compressor, lubricant is injected into the gas that is retained within the housing. In this case, lubricant is also used to cool the compressor. Gas is removed from the gas-lubricating mixture in the separator. Rotary screw compressors recirculate the mixture of gas with oil from 1 to 8 times per minute to cool the gas and their subsequent separation. Since screw compressors use a closed lubrication system, a small amount of oil is required. Oil viscosity is chosen according to the gas specific heat.
In the dry-type compressors, rotors move without lubrication (or refrigerant). Heat from compression is removed from the compressor, limiting the possibility of its operation to one stage.
Oil-free screw compressors are usually used for special conditions. Due to lack of oil, unlike in the oil-flooded compressors, there is no need in many stages to achieve the same high pressure. Some oil-free compressors use water as refrigerant. There are separate openings for oil and air.
Most industrial screw-type air compressors have motors with a capacity from 30 to 200 hp. These compressors use from one to three screw rotors that keep the medium within the chamber that is reduced in size to increase the pressure. The valves are opened when the compressor is stopped to release the internal pressure, and make the start smoother.
Industrial rotary screw compressors can operate around the clock, 7 days a week and usually work longer and more effectively if used this way. If the screw compressor is chosen correctly, it can be one of the energy-efficient types of compressors.
Typically, the oil-flooded compressor is equipped with a minimum pressure valve, which does not allow air to get into the air system, until a minimum pressure to lubricate the compressor is reached. The oil filter removes contaminants in the oil, and there is also the second oil filter which cleanses from coarse dirt. The bypass valve is mounted on the compressor to maintain the pressure when the compressor is idle.
The oil-free compressor has several other components. Typically, these are two screw pairs; the air is cooled in the intermediate radiator between them. Gears for both screw pairs are located in the gearbox housing and the gearbox is lubricated. Oil seal and high pressure keep oil from getting out of the gearbox on the screws.
In the rotary screw compressor, the lubricant is injected into the compressor housing. The rotating rotors are exposed to the mixture of gases and the lubricant. In addition to the fact that a thin lubricant film prevents metal-to-metal contact, the lubricant also carries a seal function to prevent gas recompression, which occurs when the hot gas at high pressure enters the seal between the rotors and is compressed again. Recompression could lead to the fact that gas discharge temperature exceeds the estimated one, which will ultimately lead to the loss of the unit reliability. The lubricant also acts as a refrigerant by removing heat during the gas compression process.
Main advantages of rotary compressors
- all working parts are moving and can operate at high speeds;
- there is almost no contact between the rotating parts, which makes them very reliable;
- easy maintenance;
- low cost of maintenance and operation;
- operation at low suction pressure;
- compact size and light weight;
- long service life.
Areas of use:
Screw compressors are commonly used for continuous operation in a variety of industries and can be both stationary and mobile. Their power may vary from 3hp (2.2kW) to 1200hp (890kW), and pressure from low to over 1,200psi (8.3MPa).
Screw compressors operate with a large number of media, which may include gases, vapors or multiphase mixtures given that phases may vary within the machine. Generally, compressors for refrigerant and process gases, which operate for a long time, are of high efficiency, while for air compressors, especially for mobile ones, efficiency may be less important than the size and cost.
Screw compressors are ideal for most applications that require compression:
- fuel gas boosting;
- boosting of gas from a borehole;
- vapor recovery;
- compression of gas from organic waste and digester gas;
- compression of corrosive and/or dirty process gases;
- refrigeration equipment
Rotary compressor with cam rotors
Fig. 2 Compressor with cam rotors
Type description and structural layout:
A schematic diagram of the rotary compressor with cam rotors is shown in fig. 2. Typically, this type of compressors is used where high volume is required. These machines are very reliable, as the rotating parts do not touch each other, the need for oil supply for their lubrication is eliminated and the need for maintenance is low. The supply air is 100% oil-free. The compressor consumption is largely dependent on the operating speed.
Large units (over 5000cfm) have a direct connection to its motors; smaller units have V-belt transmission. Electric motors usually act as drives. In addition, the compressors can be delivered with a bare shaft for connection to the drive of the Customer. The delivery set may include a sound absorber, valves, filters, pressure relief valve and compensators.
Main parts of the compressor: rotors, housing, timing gears, bearings, seals. The profile of the rotor cams is usually involute, although it may be cycloidal. The gap between the rotors and the housing is usually minimal to prevent leaks. The rotor may have two or three cams. The housing is usually made of cast iron; the aluminum construction is delivered for special conditions. Commonly, spray lubrication is used, but in some units, there is an external lubrication system.
Principle of operation
The principle of operation is similar to the principle of the rotary screw compressor, other than that the cam rotors coming into contact are usually not lubricated. The feature of this type of compressors is that gas is not compressed inside. The rotors can be mounted on parallel shafts inside the cylinder. The set of gears synchronizes rotation of the rotors. The cams do not come into contact with each other. When the cam rotors rotate, the gas flows between them and the housing of the compressor, where it is compressed due to their rotation, and then flows into the discharge line. Whereby the bearings and timing gears are lubricated.
Areas of use:
This type of compressors is designed to compress air and neutral gas mixtures.
- civil engineering;
- chemical production;
- water supply systems;
- food industry;
- industrial ovens;
- pharmaceutical industry;
- central vacuum supply;
- storage locations of organic waste
Rotary compressors with cam rotors find their application where there is need for a relatively constant flow rate at varying supply pressure during transportation of materials, saturation of liquid with air, gas and vapor recovery, supply of low-pressure gas and air, waste water treatment, remediation of soil, in cement factories and so on.
Rotary vane compressor
Fig. 3 Vane compressor
Type description and structural layout:
The rotary vane compressor is shown schematically in figure 3. Rotary vane compressors are composed of a rotor with several sliding vanes that are mounted eccentrically in the housing.
Compressors of this type can be dry or oil-filled. Compressors with oil are most effective and may reach the efficiency of 90%. They also create a greater pressure than the dry compressor type.
Compressors of this type may be stationary or portable, have one or more stages, may be driven by electric motor or by internal combustion engine. The dry rotary vane compressor is used at a relatively low pressure (2bar), while the oil-filled compressors have sufficient efficiency to achieve a pressure of 13bar in one stage.
Electric motor is the most commonly used type of drive. V-belt transmission is used on smaller units (less than 100hp).
The cylinder is usually made of cast iron. Inlet and outlet openings have a flanged connection. For units with lubrication, the vanes are made from laminate asbestos interspersed with phenolic resins. Graphite is used in units without lubrication. The rotor is made of carbon steel. In large units, the rotor may be made of cast iron, and the shaft of carbon steel.
Principle of operation
Rotor blades protract and slide along the inner surface of the cylinder by centrifugal force. Because of the rotation, the volume of the chamber between the two blades constantly changes. As the rotor rotates, the actuating medium enters the area of higher volume, and then is supplied for the discharge already as compressed gas from the lower volume area.
The process of lubrication of the rotary vane compressor is carried out once per operation. The lubricant is sprayed into the compressor, leaves together with the compressible gas, and usually does not recycle. The lubricant forms a thin film between the compressor housing and the sliding vanes. The sliding of the vanes on the surface of the housing requires the lubricant to withstand high pressure in the compressor system.
Areas of use:
Rotary vane compressors are used to recover gas and increase gas pressure, competing with reciprocating compressors. They come short of efficiency, but they are quite compact, have lighter weight and do not require to prepare for them a special foundation. This type of compressors is also used for vapor recovery. Rotary vane compressors have proven their reliability as compression equipment for natural gas and methane.
Rotary vane compressors are used for:
- central vacuum supply
- solvent recovery
- impregnation (of the material surface under the impact of vacuum by the impregnant)
- drying (eg. of medical products)
- sealing of solar modules
- food packaging
- vacuum forming
- hermetic sealing of trays in the food industry
- packaging of non-food products
- printing and paper industry
Particular attention should be paid to control over the wear of the vanes, as their wear can cause damage to the cylinder.
Liquid-ring compressor layout
Type description and structural layout
The liquid-ring compressor is a unique kind of compressors, as it uses compression by liquid ring that acts as a piston. The single rotor is located eccentrically inside the housing. The inlet and outlet for gas are located on the rotor. The standard material design: cast iron for the cylinder and carbon steel for the shaft, steel for the rotor parts. Structurally, liquid-ring compressors can be both single-stage and multi-stage.
Principle of operation
The compressing fluid medium partially fills the rotor and the cylinder, and forms a ring when the piston moves. When the piston moves, a gas pocket forms in the housing. The gas is compressed in the cavities, which form the surfaces of the liquid ring and the rotor. At the suction side, the volume of the cavities is increased and it is filled with the gas, at the discharge the volume decreases, the gas is compressed and supplied into the discharge line. Water is usually used as the service liquid.
- ability to operate in sub-zero temperatures;
- effective heat transfer;
- easy maintenance;
- low noise level and almost absence of vibrations;
- compressors can work with almost all gases and vapors;
- no metal contact between the rotating parts.
Areas of use:
This type of compressors is used for compressing vapors, hazardous and toxic gases as well as hot gases including those with dust or liquid content. After the interaction of gas and actuating fluid, the gas temperature rises insignificantly, which gives almost isometric seal. Liquid ring compressors are used where there is need for reliable, safe operation and special technological conditions.
- plastics industry - regeneration of process gases
- petrochemical industry - sealing of combustible gases (vapors of gasoline, hydrogen)
- overall gas transfer
- clay deairing
- removal of oil residues
- corrosion protection of water pipes
- dust removal in the mining industry
- biogas production
- compression of anaerobic gases
- treatment and disposal of sewage
- filling of product in breweries
- loading and unloading operations
- systems of cleaning and removal of fat from hydrocarbon particles
Scroll compressor layout
Type description and structural layout
The scroll compressor is a massive machine with motion in orbit, in which compression takes place by means of two scroll elements put one into the other.
Although the idea of a scroll compressor has long been known, the scroll compressor is a rather new technology. The first patent for a scroll compressor was issued in 1905 by French engineer Leon Croix, but only in 1970 with the development of high-precision machining it was possible to create a working prototype. To date, scroll compressors find their application both in commercial and residential areas.
Scroll compressors are fully sealed. Scroll unit, counterweights, motor, and bearings are mounted in the welded stainless steel housing. Most scroll compressors for air conditioning have a vertical design. The housing is a cylindrical container positioned vertically and divided into a low-pressure part and a high-pressure part. The lower part of the housing serves as a reservoir for fluid and oil. Scrolls are typically made from carbon steel workpieces. Particular attention is paid to the production of scrolls, as they should be perfectly adjusted.
Principle of operation
The scroll compressor uses two spirals, one fixed and the other one moving, coupled with the motor. The scrolls are put one into the other, so that cavities for the actuating medium are formed during movement as they interact. The medium is subjected to compression while moving in orbit of the moving scroll around the fixed scroll and is gradually forced to the center. When the cavities shift, they decrease in volume and compress gas.
The scroll technology offers advantages for a number of reasons. Large suction and discharge openings reduce the pressure loss occurring during the suction and discharge. Also, the physical separation of these processes reduces the transfer of heat to the suction gas. The advantages of scroll compressors are their small size and less weight than that of reciprocating compressors of the middle class. These are effective devices operating at different compression ratios. In addition, the advantages include the relatively low level of noise and vibrations, high reliability and long service life thanks to the fact that the compression involves a small number of parts and no valves.
Areas of use:
Scroll compressors are manufactured in different sizes up to 25t. They are widely used in residential and commercial heating, ventilation and air-conditioning. They are successfully used for cooling bulk milk, in container transportation, in sea containers and food display cabinets, in water coolers. Scroll compressors are used for the production of compressed air and oil-free compressed air.
Horizontal sealed scroll compressors can operate with natural gas, air and helium, and are oil-cooled. Another area of application for such compressor is recovery of gas vapors in the oil fields.
Basics of the design and principle of operation of the rotary compressor (by the example of the screw compressor)
Most screw compressors have the following principle of operation
Main parts of the screw compressor
The air end is a pair of worm-geared rotors, male and female, in the housing that fits tightly to them. The housing and the rotors are separated by a very small space between them. The rotors engage like gears, so that when they rotate, the space, which is formed between them and the housing, is reduced gradually. Any gas, which enters into this space, is compressed.
The volume of the compressor is determined by the profile of the rotors, their shape and size.
Review of modern screw compressor rotor profiles
Types of profiles
The air end can operate only when all the parts of the housing and 2 rotors are perfectly adjusted and properly lubricated. Compressor oil is of great importance.
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Upon becoming the official distributer of rotor compressors (rotor compressor lines), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (rotor compressors) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!