COMPRESSED AIR
and with hollow shaft achieving 97 per cent efficiency levels across the entire speed range. The motor is shaft mounted, reducing further losses in the system, increasing the overall efficiency of the compressor. Under the current European efficiency
regulations, electric motors must now reach the IE2, IE3 or IE4 efficiency level depending on their rated power and other characteristics. For instance, three-phase motors with a rated output between 0.75kW and equal to or below 1000kW must have reached the IE3 level by July 2021. Motors between 75kW and 200kW must also meet the IE4 level as of July 2023.
However, Lontra’s new compressor uses a
specially designed IE5 electric motor — the highest IE efficiency class — surpassing current requirements. The IE5 permanent magnet motor was chosen not only for its high-efficiency but because it generates less heat in the rotor and has a steadier temperature due to it being liquid-cooled, reducing the likelihood of overheating. Still, the industrial market is dominated by
However, the industry has been slow to
modernise. The first rotary compressor design can be traced back to Italian designer Ramelli’s water pump, from 1588. Despite having been designed as a water pump, its core design is used to this day, such as in vane and rolling piston compressors and in air conditioning systems. Another machine designed as a water pump,
originally made from wood, was repurposed as the lobe blower back in the 1860s. This made the Roots brothers wealthy and still accounts for most low-pressure air compressor sales. Arguably, the last big change was the screw compressor — invented by Swedish inventor Alf Lysholm in 1935, originally for a steam turbine. This currently dominates the mid-pressure market. Lontra, a world pioneer in advanced
engineering technologies, therefore decided to transform the industrial compressor landscape. In short, Lontra realised that compressors simply need to get gas efficiently, compress it without leakage and then let it out again without too much loss. Lontra designed a machine that is inspired by the piston and cylinder found in combustion engine-powered cars. Essentially, the Lontra machine uses the piston and cylinder, before wrapping the cylinder around into a doughnut shape, ensuring the two ends meet. The two ends then separate by a rotating disc, enabling the piston to become a blade.
Never seen before, Lontra now has a raft of patents for this new geometry, which does the aforementioned basics well. Early testing, in the water industry, has shown
electricity savings of over 21 per cent against competing machines. Usually, compressors are used in the water industry to blow air through wastewater, feeding natural bacteria and breaking down pollutants. This process alone accounts for one per cent of all UK electricity usage. A recent trial of Lontra’s latest machine for the
pneumatic conveying sector — blowing various solids through pipes — has also shown savings of up to 34 per cent against a market-leading competitor.
EXCEEDING ENERGY REQUIREMENTS To help achieve this, Lontra contacted WEG to be part of this wholly new compressor technology. Since most compressors are powered by electric motors, Lontra called upon WEG, a global manufacturer of industrial motors, to design a special motor for the LP2 Blade Compressor® — with maximum international energy (IE) efficiency class standard. This is Lontra’s first industrial blower, involving
WEG supplying and specifically manufacturing a WMagnet IE5 ultra-premium permanent magnet motor, rated at 80kW, 2500rpm, constant torque
induction motors. While these motors are reliable and have acceptable efficiency ratings, the emphasis on global warming has propelled the emergence of electric vehicles and has, therefore, led to research into permanent magnet motors. As a result, electric vehicles have already moved
from induction motors to permanent magnet motors, a switch that is lacking across the industrial landscape. But compressors do not have to absorb huge
amounts of energy, as proven with Lontra’s new compressor. In contrast to the historically slow developments in compressor design, WEG and Lontra have now revolutionised the industry — setting the standard for the rest to follow.
Founded in 1961, WEG is a global manufacturer of electrical and mechanical equipment for industrial sectors across all continents. With manufacturing units in 12 countries and present in more than 135 countries, the company has more than 33,000 employees worldwide with net revenue of over R$17.47 billion in 2020. Offering energy efficient solutions across all sectors including water, steel, pulp and paper, oil and gas, mining, among many others, WEG is constantly developing solutions to meet the major trends in energy efficiency, renewable energy, sustainability and electric mobility.
WEG
www.weg.net
FACTORY&HANDLINGSOLUTIONS | APRIL 2022 29
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