Air compressor demand in the UAE
Demand has traditionally been influenced by the discovery of new oil fields and the installation of new refineries. However, energy producers are increasingly moving away from the sale of oil and dependency on oil. Gas production in the region is expected to be the key driver of the Middle East and Africa industrial air compressor market. The same can be said of the market for air compressors in the UAE, especially since the UAE is a key import/export hub for the entire region.
Where industrial air compressors are used
Apart from the oil & gas industry you will find air compressors also being used in food & beverage, chemical processing, pharmaceuticals, and manufacturing industries. For example, it is estimated that around 70% of manufacturing plants use air compressors to supply pneumatic energy to power their tools, machines, and essential processes.
Pneumatic energy has similarities with hydraulic energy as they both use fluids – hydraulic systems use relatively incompressible liquids like oil. Pneumatic systems on the other hand create energy from compressed (in other words pressurized) gas. The advantage of relying on pneumatic systems to generate power are:
- Low chance of liquid related safety hazards
- Relatively simple to design, operate and maintain
- Longer life cycle of the pneumatic system because gas causes less wear and tear on parts
The need for pneumatic energy (air compressors) becomes apparent when you consider that there are applications where high temperatures, the risk of explosion and fire hazards, or the inconvenience of the location itself restricts the source of energy that can be used.
The basic working principle of an air compressor
Air compressors are machines that convert electricity, or fuel, into potential energy that is stored in the form of compressed air. A bicycle pump for manually pumping air into tires is a simplistic air compressor. The pressure of compressed air is higher than atmospheric pressure, and it is an effective medium of energy transfer.
Air compressors exploit two laws of physics – Bernoulli’s principle and Boyle’s law. And by exploiting these principles we’ve established two fundamental air compression methods – dynamic compression and positive displacement compression. You can read in more detail about how dynamic compression and positive displacement compression work here.
Over the year’s engineers have developed 4 main air compressors types based on these compression methods:
- Axial compressors (dynamic)
- Centrifugal or radial flow compressors (dynamic)
- Rotary compressors (positive displacement)
- Reciprocating compressors (positive displacement)
Comparing air compressor types
Axial compressors VS centrifugal or radial flow compressors
The axial compressor’s advantage is that it produces higher flow rates of compressed air (large volume at high speed) compared to the centrifugal or radial flow design. They are comparatively smaller and slightly more energy efficient. They are an expensive design, but the cost per flow rate for large flow rates is lower than other compressor types. Multiple axial compressors can be stacked in a multi-stage arrangement to get much higher-pressure ratios.
Rotary compressors VS reciprocating compressors
The advantage with rotary compressors is that they produce a continuously high flow rate while maintaining relatively small exterior dimensions. They are more expensive than reciprocating compressors but are a better long-term investment. They allow for more up-time, better energy efficiency, higher air quality, longer lifespan and are cost-effective in the long-term.
The advantage a basic reciprocating compressor has over rotary compressors is that they are the most economical and relatively inexpensive type of air compressor, and relatively easy to maintain. They are the go-to choice for small projects, machine shops, body shops, tire shops and small manufacturing facilities.
For more detail about their design differences read this.
Portable air compressors
A 5th compressor type to consider is any portable air compressor variant of the four above. Portable air compressors are generally small and transportable, meaning that they can be placed on wheels. However bigger air compressors are sometimes loaded and hauled to sites as well.
While they lack the power of the Industrial air compressors, they offer attractive benefits. They are either diesel powered, or gas powered, and they are noticeably quieter. This is great for small working spaces or noise-sensitive environments. They take up less space with minimal installation requirements. Its portability means it is adaptable to a variety of outdoor and indoor scenarios. They are the most versatile type of air compressor overall.
Comparing air compressor seals: oil-injected vs oil-free
Deciding between the two depends on the standards and quality requirements of your specific application.
Oil-injected air compressors are very common since they are the more economical option. Compressor oil is not typical oil. It is a special compressor lubricant. The lubricant in air compressors is designed to provide the best lubrication, sealing, and cooling for the machinery. Oil-injected air compressors are the ideal choice for a lot of manufacturing, industrial and small workshops processes where oil-contamination isn’t a concern. These types of compressors are the more economical choice out of the two.
Oil-free air compressors could more accurately be called ‘Oil-less’ air compressors because there is always some small amount of lubricant used in the machinery. These machines are ideal for applications where oil-contamination is a critical concern, like in food & beverage processing for example. They are also suitable for applications like painting where the compressed air comes in contact with the product, and it must be oil-free or could ruin the process. Since these compressors don’t use oil or filters they require less spare parts and consumables. This means oil-free compressors require less frequent service intervention than oil-injected compressors.
This article will give you more insight into how compressor oil works and why buying the right oil matters.
Picking the right air compressor
Start by determining the maximum pressure you need to operate your tools or machines, or to run your processes. Depending on the pressure you might need a single-stage (9 bar max) or multi-stage compressor (400 bar max).
Find out the flow rate you will require. The flow rate is the maximum volume of air that must move through your entire system per minute or per second. This will be measured in cubic feet per minute, liters per second, or cubic meters per hour. Include a safety margin of about 30%.
So for example for applications that require pressures of up to 10 bar with flow rates up to 4000 m3/h, screw compressors are the best fit. For larger flow rates requirements centrifugal compressors would be more economical. For high pressure requirements, say 14 bar to about 300 bar, reciprocating air compressors or piston compressors will be best because of their energy efficiency.
Intermittent duty-cycles require a compressor that is energy efficient in that scenario. You might even want a compressor that will adapt to an increased workload because you plan to expand your facility soon. Knowing if your compressed air demand is continuous or intermittent, or a mix between, will help you decide. You could benefit from a fixed speed or variable speed drive compressor. Identifying the correct compressor air regulation will save you a huge amount of energy over the lifetime of your compressor.
And finally consider the usage, configuration, and space limitations you might have. You might want something that is easily moveable, or fully portable. You might have ample room to spare and be fine with something that is stationary but prefer it to be as quiet as possible.
Once you’ve become clear on your requirements then it’s a matter of reviewing the spec sheets of air compressors and finding one that meets the criteria. This is where you will benefit from the knowledge of experts who can review your facility and guide your decision. Some air compressor manufacturers offer free audits to help customers make the right choice.
Air compressor maintenance tips
Air compressors have maintenance needs that vary depending on the amount that they’re being used every day. It also varies depending on the type of compressor – rotary screw, centrifugal, reciprocating and others. Auxiliary equipment and cooling systems are separate from the compressor but work in tandem with it. They will also require monitoring and maintenance.
The key to getting the best performance from your air compressor is to maintain a regular preventative maintenance schedule. You should stick to a compressor inspection routine and act immediately. The first 7 to 8 years of the air compressor’s life cycle are critical. After the 7-year mark you can start to see a decrease in energy efficiency or performance. With proper care your compressor can give you 10 to 15 years’ worth of high performance.
Anticipate an annual cost that’s between 5-10% of the compressor installation’s investment value. Compressor maintenance will be the smallest part of your installation’s total cost of ownership.
Here’s a list of things that influence your compressor maintenance budget.
- Type and size of compressors
- Auxiliary equipment (dryers, filters, control, and regulation equipment)
- Operating cycle load/unload and the degree of utilization
- Installation environment conditions
- Choice of safety level
- Energy recovery/cooling systems
Preventative compressor maintenance is how you minimize, and even avoid, downtime over the course of a machine’s life span. You will reduce the chances of having to spend on unexpected major repairs. You will also benefit from a higher average operational efficiency and lower energy cost over time.
All these things translate to cost savings. And we would advise you to seek out a service contract arrangement like this from your supplier or your manufacturer.
Conclusion
For more useful guidance about buying an air compressor in UAE read this article and feel free to contact us using the form.
Headquartered in Sweden and operating in over 180 countries, Atlas Copco has been providing industrial solutions since 1873.
Our vision has always been to be First in Mind—First in Choice as a supplier of compressed air and gas solutions worldwide. And over the years we’ve discovered that being interactive, committed, and innovative, is the key to offering them the best value.
To get in touch with a member of Atlas Copco’s UAE sales team click here.
And before speaking to our team, you might want to familiarize yourself with some of the compressors we have on offer by clicking these links:
Testimonials
The selection process was very strict and proposals were submitted by a number of different manufacturers. We considered reliability, durability and high performance as the priority factor to choose the compressors. Another reason we select Atlas Copco because of the VSD machines reducing the total energy consumption. More importantly after market service of Atlas Copco is always proactive, by utilizing the SMARTLINK feature we can keep track of running hours and service requirements of our compressors which improves the service efficiency and reduces the downtime.
Nestle believes in using the latest technology and innovations to bring value and improvement to our operations. Atlas Copco compressors are running in our plants across the region for many years mainly for medium pressure requirements. We are happy to be one of the first users of the new state-of-the-art oil free compressor combined with the high pressure booster that allows us to have a single supplier of both medium pressure and high pressure air. We trust Atlas Copco as a reliable partner who understands our environmental goals and works in ensuring we get the best systems that help us achieve these goals.
After having worked with the old standard 3-stage piston compressors, whenever I walk to the compressor house, I try and listen to see if the machines are working, as I hear almost no noise or vibrations that the standard piston units produced. The ZD concept is definitely a great concept and the fact that Atlas Copco has managed to listen to the customer concerns is worth appreciating.
