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Media / Application stories / Application of Atlas Copco XD Heat of compression reactivated adsorption dryers for energy saving in the display industry

Application of Atlas Copco XD Heat of compression reactivated adsorption dryers for energy saving in the display industry

2011-10-10

Your Saving. My Saving. Let’s Share Energy-saving! -- A Case Study of Anhui Xinhao Plasma Display Devices Co., Ltd

Why we need to reduce energy consumption? The answer to this is very simple for factories, that is, to reduce production cost, improve product competitiveness, and eventually result in more sales and profits. However, many enterprises pay more attention to investment cost than to return on investment, and have no idea to purchase energy-saving equipment with a relatively higher price during initial investment. They usually attempt to realize energy saving by enhancing use of equipment and controling maintenance cost after the equipment is installed and debugged, or to reduce energy loss by restructuring new equipment. These measures, however, often require more labor and material resources, setting a limit to energy-saving effect. We think that energy-saving should be reasonablly assessed during the planning and design period. It is very important to find a professional supplier of energy-saving equipment.
 
Located in Hefei City, Anhui Xinhao Plasma Display Devices Co., Ltd (Anhui Xinhao) is a state-funded hi-tech enterprise that integrates manufacturing, sales and development of plasma displayer and other new type display products. The company introduced the advanced and mature plasma technology and 4 production lines from Hitachi, managed and operated by a technology and management team composed of elites with years of experience in manufacturing and developing plasma products in the industry in China. At present, Anhui Xinhao is the largest manufacturer of PDP full high-definition plasma displays in China, including series of standard high-definition and full high-definition plasma display modules from 42 inches to 85 inches.

XD 2400 in high-pressure system

A solution of ZH7000 centrifugal compressors combined with XD heat of compression reactivated adsorption dryers in the high-pressure system.


Phase I of the Xinhao Project planned to invest 0.3 billion US dollars (approximately RMB2 billion Yuan) and the construction was commenced in September 2009. In January 2011, the first display came off the production line. The planned production capacity of the project is 1.5 million displays (42 inches) annually. As the first manfuacturer using heat of compression reactivated adsorption dryers in the display industry, leaders of the Xinhao Project were brave enough to make such a selection because the cost in purchasing the hi-tech dryer is much higher. People believe that dryer plays not so important role as compressor does during the compressed air production. But the fact is dryer is actually as important as the compressor because operation effect of the dryer has direct impact on end products though the dryer, as post-treatment equipment in compressing air, seems to be less important. The dryer in the same air flow system that fails to process the compressed air at required air quality shall have serious impact on yield rate of the products. So performance and quality of heat of compression reactivated adsorption dryers are very important, because yield rate is an important indicator used in the electronic industry to measure the manufacturing level and decide the fate of a factory.

XD 3000 in low-pressure system

A solution of Z oil-free screw compressor combined with XD in the low-pressure system.


As a leading enterprise in the plasma industry, the Xinhao Project had enough reasons to select Atlas Copco XD compressed heat product. In similar projects, refrigerator dryer and blower adsorption dryers are often used in combination to treat the compressed air. However, more refrigerator dryers’ adding with relative valves and pipelines, and more power cables in such a solution not only lead to more investment, more difficulty in operation and management which cause operators’ more mistakes by carelessness with the increase of the equipments, but also result in obvious growth of operation cost, including remarkable cost on pressure drop produced by the dryer and filter added. In this case, the compressor has to consume more electricity to ensure air pressure at the rear. In addition, the pressure gap will cause difficulty to control at the central control system and sometimes lead to frequent start-stop of the compressor.
 
So the Xinhao Project finally selected Atlas Copco zero purge XD adsorption dryers with its sufficient research on applications of heat of compression reactivated adsorption dryers and visits to XD customers and comprehensive evaluation of other brands during the planning and designing period in advance. The project not only adopted a solution of ZH7000 centrifugal compressors combined with XD heat of compression reactivated adsorption dryers in the high-pressure system, but also adopted for the first time a solution of Z oil-free screw compressor combined with XD in the low-pressure system.

This was a right choice. As a unique product provided by Atlas Copco, zero purge heat of compression reactivated adsorption dryers is superior in performance and reliable in operation with patented control technology that can ensure stable dew-point. Compared with the blower dryers, its average energy consumption is reduced by almost over 50%. Such savings can help to basically balance the investment gap in about 1 year. For long term use, it will make more values than the cost. To evaluate the system’s energy-saving effect, Anhui Xinhao agreed to cooperate with Atlas Copco and Hefei General Machinery Research Institute to inspect the entire compressing system in order to get a reliable result. We wish that the system be promoted and used in other projects, helping customers realize their objectives on continuously reducing energy-consumption in practical use and improve product competitiveness to obtain more sales and economic benefits.

In this case, leaders of Anhui Xinhao gave a better interpretation to the true meaning of energy-saving, "At the very beginning we considered how to reduce unit energy consumption of the products, and looked for a reliable energy-saving solution. This cooperation enlightened us. Atlas Copco is not only a leading manufacturer of compressors, but also a supplier of various advanced energy-saving equipments for air compressing, enjoying obvious technological advantages in using compressed heat and providing more guarantees. We hope to realize mutual objectives through wider cooperation."
 
It can be seen that energy-saving is never a unilateral demand. The best way to save energy is to find a professional solution before making investment. For this kind of win-win energy-saving cooperation, our slogan is: Your saving. My saving. Let’s share energy-saving!

For further information, please contact:

  • Ming Xue
    Senior Product Specialist
    Compressor Technique Oil-free Air Division
    Phone: +86 21 6108 2436
    E-mail: Ming.Xue@cn.atlascopco.com

Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment systems, construction and mining equipment, power tools and assembly systems. With innovative products and services, Atlas Copco delivers solutions for sustainable productivity. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2010, Atlas Copco had 33 000 employees and revenues of BSEK 70 (BEUR 7.3). Learn more at www.atlascopco.com.

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 headquarter is located in Shanghai, China, and the production centers are in Antwerp, Belgium; Wuxi, China; Pune, India and São Paulo, Brazil.