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ComunicaçãoSocial / Histórias de aplicações / Atlas Copco oil-free compressors provide energy-efficient air at major aluminum plant

Atlas Copco oil-free compressors provide energy-efficient air at major aluminum plant


Henan Wanji Aluminum Co., Ltd. uses 10 Atlas Copco oil-free centrifugal compressors – five ZH 15000 and five ZH 10000 units – at its smelting plant. Designed for reliability and energy efficiency in the most demanding environments, Atlas Copco’s ZH compressors are used throughout the facility, providing optimum air quality for a variety of plant functions.

Atlas Copco China - Wanji Aluminum

ZH 15000 compressors produce 300 m3/min flow at 0.85 MPa and ZH 10000 compressors produce 200 m3/min flow at 0.85 MPa

Established in 2005, Henan Wanji Aluminum Co., Ltd. (Wanji Aluminum) is one of the largest aluminum smelters in China. The company uses the Hall-Heroult method to process the alumina, which is separated into components of aluminum metal and oxygen gas by electrolytic reduction. The facility has two electrolytic aluminum production lines with a total production capacity of 650,000 tons per year.

Compressed air is widely used throughout Wanji Aluminum’s plant for processes such as conveying alumina to the silo and from the silo into the pot lines, carbon anode production, air instrumentation and pneumatic conveying of recycled particulate. To meet their compressed air requirements, Wanji Aluminum employs five ZH 15000 and five ZH 10000 oil-free centrifugal compressors.

“Atlas Copco’s ZH centrifugal compressors are equipped to guarantee quality and reliability for such customer processes that demand large volumes of air,” commented by Mr. Sunghwan Kim, Product Manager of Atlas Copco Oil-free Air division.

ZH centrifugal compressors are designed to Maximum uptime-Minimum maintenance and energy savings. Milled impellers made from stainless steel 15-5 PH, spin tested at 115% of the nominal speed, ensure zero defects. Variable geometry flexible pad bearings, carbon ring air seals, labyrinth oil seal, AGMA Class A4 gears and stainless steel coolers contribute to trouble-free performance and long operating lives. The horizontally split gearbox makes access for inspection and preventive maintenance easy and quick.

Energy accounts for one-third of aluminum production expenses, so significant energy can be saved during the initial selection of a compressed air system. The majority of the components on the ZH compressor are specifically designed to optimize energy efficiency, and the entire unit is measured according to ASME PTC10. Oil-free turbo core unit provides the optimum combination of high flow with low energy consumption. Ample sized cooling, low pressure drops and an efficient drive drain result in high compressor package efficiency.

In the aluminum production industry, compressed air is used for pneumatic transport of raw aluminum powder. Oil contamination can cause quality defects and pipe clogging, as well as pose a fire hazard. ZH compressors provide 100% pure, clean air that complies with ISO 8573-1 CLASS 0 (2010) certification.

“In production, we use a large amount of compressed air for instruments and raw material conveying. To reduce production costs and improve end product quality, we chose the efficient and reliable compressors,” said Mr. Bai Xiao Jun, Process Manager at Wanji Aluminum. “Atlas Copco is a qualified supplier and its air compressor equipment has displayed excellent performance and super high stability since it was put into use, which is the key to our choice of Atlas Copco.”

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Atlas Copco is a world-leading provider of sustainable productivity solutions. The Group serves customers with innovative compressors, vacuum solutions and air treatment systems, construction and mining equipment, power tools and assembly systems. Atlas Copco develops products and service focused on productivity, energy efficiency, safety and ergonomics. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 180 countries. In 2013, Atlas Copco had revenues of BSEK 84 (BEUR 9.7) and more than 40 000 employees.

Oil-free Air is a division within Atlas Copco's Compressor Technique business area. It develops, manufactures, and markets worldwide oil-free and oil-injected air and gas compressors combined with air and gas treatment systems. The division focuses on sustainable solutions for all kind of industries where the gas quality is critical to the production processes. The divisional headquarters is located in Shanghai, China, and the production centers are in Antwerp, Belgium; Wuxi, China; Pune, India and São Paulo, Brazil.