Atlas Copco’s Hybrid Compressor Room Delivers Energy Efficiency Gain
26 October 2025
Overview (at-a-glance)
- Customer: BlueScope Steel Hastings, Victoria
- Challenge: Replace ageing centrifugal compressors with a new multi-compressor installation
- Recommendation: Hybrid compressor solution
- Advantages: Unique mix of high-capacity oil-free screw + turbo technology delivering unparelleled energy efficiency
Challenge
BlueScope Steel Hastings had long depended on externally supplied compressed air, relying on ageing centifugal compressors. These large, centrifugal compressors struggled to meet the site's varying air demand efficiently.
With reliability and energy cost becoming increasing concerns, BlueScope sought a long-term solution to have a new compressor facility constructed on site. Their goal was to gain control of compressor operation, service and overall performance - all while meeting low voltage constraints (400V) and ensuring both capacity and compressor redundancy.
Solution
Atlas Copco provided the equipment selection, pipework and vessel design, and control system for a turnkey hybrid compressor facility tailored to meet BlueScope's operational requirements.
What 'hybrid' means in this project
Hybrid: A compressor room that combines oil-free VSD screw compressors for variable demand with oil-free turbo compressors for base load - all coordinated by a central controller.
Hybrid compressor room
Smart air management
- Atlas Copco Optimizer 4.0 central controller maximises efficiency by intelligently selecting the right mix of compressors based on absolute demand and fluctuations.
- This ensures maximum efficiency across varying production loads.
High-quality air treatment
- 5 x FD2000 VSD+ premium air dryers, combined with
- 5 x DDP22000+ filters.
- Delivering high-quality, dry, oil-free air with PDP of 3–5°C.
We followed a process of continuous optimisation of the installation via regular meetings with the main client stakeholders. After commissioning, we spent a week on site to fine tune the Optimizer 4.0; the months after that, we further assisted the client both on site and as well as off site, to have the compressor room fine tuned in the best possible way.
Results
Following commissioning in April 2024, BlueScope confirmed a more than 30% improvement in energy efficiency compared to its previous system - a significant gain for a facility of this size and air demand.
Atlas Copco’s hybrid compressor installation at BlueScope Steel Hastings (VIC)
Why Atlas Copco?
From initial inquiry to commissioning, Atlas Copco provided end-to-end technical support and project continuity, ensuring reliable delivery at every stage.
- Turnkey delivery including design and installation
- Continuous optimisation during the pre- and post-award phases
- On-site fine tuning of compressors and Optimizer 4.0
- Ongoing support - remote and on-site - to enhance system performance
Ready to optimise your compressed-air system?
Wondering what hybrid compressed air solutions mean?
A compressor room that combines two distinct compressor technologies to achieve the best balance of energy efficiency, reliability, and flexibility in compressed air systems.
