GB Truly innovative oil-free compressed air technologies 02
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GB Truly innovative oil-free compressed air technologies 02
Truly innovative oil-free compressed air technologies GB 02 Why oil-free? Contaminant free… risk free When you choose an oil-free compressor from CompAir, you get a clean, reliable and costefficient air supply that benefits your business… and your bottom line! Air purity is critical for many applications where even the tiniest drop of oil can cause product spoilage or damage production equipment. We offer a wide range of oil-free compressor technologies, each one built to give you the peace of mind that comes with a high-quality air supply. Think of it as the best compressed air insurance money can buy! Guaranteed 100% air purity, that meets stringent quality standards… always. Reduced maintenance Our oil-free compressors are built to last, featuring robust designs and a simple construction, making them easier to maintain. We’ve also made them easy to operate, featuring a variety of control options to make sure that you are always in charge of your air supply. Lower energy costs Our speed regulated oil-free compressors only consume the energy you need, when you need it - whether under full or part load conditions, a CompAir oil-free compressor offers excellent energy performance. CompAir’s commitment to providing the purest, highest quality compressed air, through the development of innovative products, delivers world-class solutions. Truly innovative oil-free compressed air technologies 22 Think of it as the best compressed air insurance money can buy! Quality matters When it comes to compressed air, quality matters. That’s why every machine in our oil-free compressor range has been carefully engineered to deliver a totally clean and reliable source of air. Quality oil-free air… for legal compliance Quality oil-free air… for worry-free operation •• You may have no choice over the quality of the compressed •• Choosing oil-free means that you can spend less time and air used in your processes - it just has to be oil-free to eliminate any risk of product contamination. Quality oil-free air… for reliable productivity •• Your process equipment could be damaged by oil-laden compressed air, affecting sensitive electronic components and causing unnecessary downtime and expense. resource on your air treatment systems. Plus our waterlubricated and centrifugal compressed air technologies have no oil system to maintain at all – which means no oil to change or dispose of, helping you to do your bit for the planet too! Oil-free… stress-free •• And always, choosing oil free means that you get the peace of mind that comes with high-quality, contaminant free air. Smarter maintenance Lower your costs Our oil-free compressors are built to last, with a simpler construction that requires less overall maintenance. When you choose an oil-free compressor from CompAir, you get the benefits of a guaranteed, quality air supply plus much more. In our water-lubricated DH models, the traditional oil system is gone, replaced with simple water lubrication: Significant energy savings and environmental benefits to improve your carbon footprint and lower ownership costs. •• Purified water injected into the compression element •• Regulated speed technology available to help cut lubricates, seals and cools the compression process. •• No gearbox and the associated lubrication, significantly reducing compressor consumable costs. •• Significantly fewer moving parts means there’s less to go wrong, reducing lifetime compressor maintenance concerns and costs. Then there’s our groundbreaking Quantima compressor technology - just a single moving part spinning in a magnetic field means there is no performance degradation over the life of the compressor, significantly reducing your maintenance costs. energy consumption and lower compressor cost of ownership further. •• Range of control options available. These help you to manage your installation with greater efficiency, bringing compressors on and off line to suit plant demand and for more economical cost of ownership. •• Robust, easy-to-maintain designs, resulting in less downtime, improved cost of ownership and no damaged reputation. Our other tried and tested compressors, proven in applications all over the world, use a variety of methods to ensure that oil cannot contaminate the air. Whilst the technologies may differ, the benefits remain the same easy, low cost compressor maintenance, without the need for special tools, helping to keep downtime to a minimum. 3 In capable hands We’ve been manufacturing and supplying oilfree compressors for over eighty years; each new decade bringing with it advanced technologies and engineering improvements. Today, we remain at the forefront of compressor technology. By understanding the challenges our customers face and by listening to their needs, we are continually developing technologies and driving innovation that are benefitting industry as a whole. This approach means that we engineer the right solutions to meet our customers’ objectives; whether that means improving air quality, lowering cost of ownership or simply achieving the peace of mind that comes with a reliable, durable source of air. In addition, we are committed to developing environmentally friendly solutions that are helping our customers meet the demands of climate change legislation, from cutting their energy bills and operating more efficiently to reducing their carbon footprint. Our oil-free solutions are proven in thousands of applications across the world, providing high quality, low cost air to manufacturers, processors and operators in a diverse range of industries including: •• Food and beverage •• Engineering and technology •• Pharmaceuticals •• Automotive •• Chemicals •• Electronics CompAir in action Mast-Jägermeister German bitter and liqueur producer, Mast-Jägermeister installed a new bottling line at its Linden facility capable of producing 20,000 bottles per hour. The purity of the compressed air used in the bottling process is critical to the finished product quality. After assessing several manufacturers’ systems, Jägermeister chose two CompAir DH 75 kW regulated speed models. 4 We are continually developing technologies and driving innovation that are benefitting industry as a whole. Engineering excellence When it comes to compressed air, it’s fair to say that we know a thing or two and we like to think that we’re experts at what we do! As with any expert in its field, we stick to what we know best; to engineer complete oil-free compressed air solutions for industries’ changing demands. With our DH series, we delivered new efficiencies with a 100% water-lubricated compressor and more recently, we’ve extended the concept of zero oil-lubrication with the introduction of our breakthrough Quantima compressor. Whilst the engineering expertise that goes in to our oilfree compressors is highly complex, we make sure that the finished product design is very simple, incorporating fewer parts and easier servicing. This means you get the benefits of over 200 years of compressed air industry experience, in a package that works for your business. Dedicated to improving performance and efficiency for our customers at the same time lowering the impact on our environment. At your service The real deal When you select an oil-free compressor it usually means that you need total control over the quality of your air. So it makes good sense to ensure that your compressor is operating correctly and economically at all times. Industry figures estimate that many systems can waste up to 30% of the compressed air through leaks, poor control or maintenance. In addition, the older the compressor the less energy efficient it is likely to be, so it is clear that implementing a compressed air maintenance programme can pay quick dividends. One way of ensuring maximum productivity is to implement a comprehensive service and maintenance routine – it’s one simple way you can keep a check on your compressor’s health and avoid any costly repairs or contamination issues. Through our global network of sales companies and authorised distributors, we offer a range of compressor maintenance options, using highly trained and skilled service engineers. From emergency call outs, to planned maintenance, to remote monitoring of compressed air operating parameters, we can tailor a service package to suit the needs of your business. Using genuine spare parts will also help improve compressed air efficiency. At CompAir, we only stock genuine spare parts, which are built to the highest specification and can help to avoid equipment breakdown at a later date. 5 DH Range delivering the highest quality, oil-free compressed air for all applications •• Single-stage, direct-driven compression element maximises efficiency and minimises maintenance. •• High quality water injection lubricates, cools and seals the compression process, maximising efficiency. •• Fully packaged and silenced enclosure reduces noise and simplifies installation. •• Variable speed technology available to reduce energy costs. •• Comprehensive control ensures safe and reliable operation and includes remote communication capability. CompAir in action Rohde & Schwarz Rohde & Schwarz GmbH & Co. KG has embarked on a programme to upgrade its compressed air supply to CompAir’s oil-free, DH compressors at its main production plant in Memmingen (Germany). The aim was to improve production reliability, while at the same time reducing compressed air costs and the company has already achieved these targets, with fast payback and improved efficiency. “The extra investment costs pay for themselves through lower energy consumption and reduced maintenance expenditure.” 6 Alfred Ahon, manufacturing technology projects, Rohde & Schwarz. CompAir are committed to quality and innovation and understanding the customers’ needs. A totally oil-free compressor means absolutely no possibility of oil contamination in your process guaranteed Our oil-free DH compressors are helping industries across the globe to meet and exceed quality and production objectives in food and beverage, pharmaceutical, electronic, healthcare and power generation applications to name but a few. The DH range from CompAir: Regulated Speed Technology Maximum efficiency at any level of demand cuts energy costs and saves money. •• Decreases energy costs. •• Decreases maintenance costs. •• High reliability. •• Decreases risk to businesses. •• High energy efficiency. •• Decreases impact on the environment. •• Low cost of ownership. ENERGY SAVINGS ANNUAL COST OF OWNERSHIP DH-Series water injected 8% 10% PRESSURE Energy Saving Two stage with intercooling 82% Maintenance and Service Costs 5% 12% Investment 58% Energy Cost 25% Isothermal Energy Saving A) A typical fixed speed compressor operating at 70% load. COMPRESSION DIAGRAM B) A variable speed compressor at 70% load. Water injection means lower temperatures, and lower temperatures mean more efficient compression. Your benefits: •• The assure warranty is totally free to the compressor owner 2). Assure warranty - to ensure your peace of mind! The compair assure warranty and service programs will assure you up to 44,000 hours/6 years1) peace of mind, and is one of the most generous warranties available in the industry. •• The compair authorised service provider will deliver a guaranteed quality of service. •• An assure service agreement underpinning the warranty will enable accurate maintenance budgeting and cost of ownership. •• The use of genuine compair parts will maximise compressor life and efficiency. 1) 2) whichever is the soonest subject to terms & conditions 7 Quantima unique innovation, outstanding efficiency CompAir Quantima - delivering a major breakthrough in oil-free compressor technology •• Outstanding efficiency. •• Premium reliability. •• Lower environmental impact. Quantima’s patented Q-drive compression and motor assembly has just one moving part and operates with the rotor spinning in a magnetic field at up to 60,000 rpm. Q-drive is special for what it doesn’t have: •• No gearbox. •• No oil. •• No contact. •• No wear. CompAir in action Murray Goulburn 8 Just five months after installing the Quantima air compressor, Australia’s largest milk processor, Murray Goulburn was on track to save over £70,000 in annual energy and maintenance costs and reduce CO2 by more than 1,908 tonnes over 12 months. CompAir Quantima advanced centrifugal compression technology delivering superb efficiency and high quality, quiet oil-free compressed air.” World class compressor offering outstanding efficiencies Quantima Centrifugal Air Compressors deliver significant benefits over traditional technology it’s easy to see how this innovative compressor is revolutionising energy savings and efficiencies. •• Outstanding efficiency due to no gearbox and no contact part. •• Energy savings of up to 25% and more are easily achievable. •• Lowest off-load power consumption – just 2.5% of full load power equal to 7kW for a 300kW compressor. •• Variable speed technology matches output to requirement minimising off-load running. •• Sophisticated compressor controls to maximise flexibility and provide additional power savings. •• Lowest physical foot print and 40-50% of the size and weight of an equivalent machine. Looking after the environment Quantima offers a reduced environmental footprint, cutting tonnes of CO2 during manufacture, use and disposal, increasing your ‘green’ credentials and market appeal. Quantima saves on power, which means lower carbon loading, plus we use less physical resources to build and maintain Quantima and don’t use a drop of oil anywhere in the compressor. •• Lowest noise levels of just 69 dB(A). Premium reliability & peak performance •• Sophisticated touch screen When it comes to delivering an environmentally friendly air compressor solution, Quantima offers outstanding energy savings, waste savings and reduced CO2 emissions. Over a ten-year period compared to traditional screw technologies, a 300kW Quantima unit can reduce the amount of CO2 produced by 1,920 tonnes. controller to maximise flexibility and power savings. •• Allows predictive That offsets the total emissions from 75 family cars or is equal to planting 16,000 trees*. maintenance via remote monitoring. •• Peace of mind and zero risk. * www.smmtco2.co.uk The Society of Motor Manufacturers and Traders Ltd www.unep.org United Nations Environment Programme Q-life service package delivers the risk-free peak performance, quality, efficiency and world-class reliability that you need, day after day The simplicity provided by Quantima’s innovative technology delivers minimum downtime and world-class reliability not only saving money on maintenance but also providing peace of mind and zero risk. Q-life is a predictive maintenance package where each unit is monitored constantly to deliver premium reliability and performance allowing us to service components before they create an issue. Unlike most other maintenance packages, Q-life covers all servicing under a single fixed cost ensuring an extremely cost effective solution. 9 D-series - oil-free rotary screw compressors CompAir‘s D-range of compressors generate the highest quality oil-free air in accordance with stringent quality standards making them the ideal choice for manufacturing processes where air is in direct contact with product or sensitive equipment. Industries such as Chemical, Food & Beverage, Pharmaceutical, Electronics and Power Generation already rely on CompAir for complete oil-free peace of mind. D-range compressors can be specially modified to meet specific applications and the individual demands and specifications of a wide range of industries. Examples of customer engineered products include alternative voltages, outdoor weather and freeze protection, non-standard motors and silicon free compressors to name but a few. CompAir in action AES Energia Cartagena Joaquin Sanchez, Plant Maintenance Manager said, “We considered compressed air solutions from several suppliers, but found that the CompAir system offered the best overall solution, with economic air production, a guaranteed oil-free supply and compressor sequencing to ensure equipment longevity.” 10 The CompAir compression element design sets the industry standard for energy efficiency. Outstanding reliability for demanding applications The new two stage oil-free screw compressor range has been designed with focus on operational safety in demanding applications. The innovative clear construction delivers a state-ofthe-art performance, in-depth control and outstanding reliability. The sophisticated Delcos XL controller protects your investment by continuously monitoring the operational parameters. CompAir’s own developed and manufactured airend works at constant low temperature levels and lowers the compressor’s lifecycle costs. With easy servicing and a full Assure warranty coverage, operators eliminate all possible risks to their business. Maximise your energy savings with regulated speed technology The D-Series regulated speed models perfectly cope with varying air demand and ensure that no energy gets wasted. Significant cost savings can be achieved by matching the output to the exact demand on the site. Compared to a fixed speed compressor the regulated speed technology can save up to 25% energy. Air purity that meets the most stringent hygienic standards CompAir’s D-Series offers the highest standard of air purity and has been certified ISO 8573-1 Class 0 (2010) and silicone free. Individual solutions for specific applications The D-Series compressors can be modified to meet the individual demands and specifications of a wide range of industries. ✓ Premium efficiency two stage airend design ✓ High quality IE 3 electric motor ✓ Efficient motor cooling ✓ High ambient temperatures of up to 45°C ✓D elcos XL touch screen controller with enhanced monitoring ✓ Closed cooling water circuit for airend cooling Simplified maintenance Servicing costs and downtime are kept to a minimum •• Hinged service access doors all around •• Up to 8000 hours standard service interval 11 V-Major & V-Compact significant energy savings with lower running costs. •• LOW POWER CONSUMPTION 75% of the running cost of an air compressor is energy cost. V-Major and V-Compact use less energy than rotary types, giving substantial cost savings every year - having three step regulation for full, part, or no load operation to reduce part load power consumption. •• LONG TERM RELIABILITY Hardwearing reliability under all conditions has been designed into CompAir reciprocating compressors, allowing for efficient operation in ambients of up to 55ºc. •• LOW COST MAINTENANCE Robust design with low running speeds, large bearing surfaces and frictionless valves ensure low maintenance. V-Major The V-Major compressor is a slow speed, double acting, water cooled free standing design. oil V-Compact The V-Compact is a free standing, single acting unit set on antivibration mounts and is suitable for air or water cooling. IN-BUILT RELIABILITY Discharge Pulsation Damper extends valve life. Intercooler ensures cool delivery air to the second stage. An Automatic Drain Valve opens when the compressor unloads. Comprehensive, clear instrumentation provides monitoring of machine condition to plan maintenance. SIMPLE INSTALLATION Compact direct coupled design incorporating integral, anti-vibration mounts, requires no special foundations. EFFICIENT REGULATION Automatic Valve Unloading matches output to system requirements to reduce power consumption costs. Typical Applications •• Power Stations •• Petrochemical Plants •• Bulk Powder and Fluid Handling 12 •• Steel Works and Foundries •• Biogas Recovery at Landfill Sites •• Desalination Plants •• Air Boosting •• Nitrogen and Natural Gas Compression •• Cement Manufacturing •• Instrument Air •• CO2 Recovery in Breweries •• Service/Utility Air •• Process Air: - Nitrogen Generation - Fermentation - Air Lifting - Spray Painting Champion R-series - designed to withstand extremely tough conditions Available in both open and soundproofed closed configurations, the R-series is designed for ease of use. The Champion R compressors can switch between full and half load depending on air demand, making them extremely efficient when compared with fixed speed alternatives. kW CONSUMPTION AT HALF LOAD = HALF VOLUME FLOW Thanks to the constructive assembly of the double affected Champion air end, there is a significant reduction of the power consumption at half load. IT PAYS OFF! Compared with other oil-free compressor systems, significant savings per year are possible using an oil-free R-series. These savings are a result of outstanding on-load efficiency and a power requirement of only 8% when off-load. Champion R-series - the last word in economic efficiency OPEN OR SUPER SOUND-PROOFED Technology is always at its most convincing when there is an optimum ratio between performance data and investment costs. This is exactly the case with the piston compressors in the R-series. UP-TO-DATE TECHNOLOGY! The R-Series convinces with clear verifiable facts: •• Generously dimensioned coolers. •• Low compressed air temperatures. •• Especially robust design. The simple robust construction reduces service and spare parts cost to a minimum. •• No separate components. •• System ready for connection. DELCOS 3100-R Compressor Controller •• Clear display in text form. •• Menu-assisted operation. •• Base load change for up to 5 machines. •• Switch clock. •• Monitored maintenance intervals. •• Half load/full load control. Typical Applications •• Aerospace •• Beverage •• Chemical •• Hospital •• Automotive •• Brewing •• Food •• Laboratory •• Electronics Manufacturing 13 CompAir Oil-free Product Range Technical Data DH-series - fixed speed water injected screw compressors Compressor Model Maximum Cooling FAD m³/min 1) Motor kW Noise level 2) dB(A) Dimensions Weight kg mm 8 bar 10 bar Length Width D15H Air 2.30 1.80 15 68 672 1345 880 Height 1612 D15H Water 2.30 1.80 15 65 624 1345 880 1612 D22H Air 3.50 2.89 22 68 691 1345 880 1612 D22H Water 3.50 2.89 22 65 643 1345 880 1612 D37H Air 5.86 5.04 37 71 960 1722 920 1659 D37H Water 5.86 5.04 37 61 860 1722 920 1659 DH-series - variable speed water injected screw compressors Pressure range 5 - 10 bar FAD1) m³/min Motor kW Noise level2) dB(A) 70% Load Weight kg Dimensions Compressor Model Cooling min. max. Length Width D15H RS Air 0.32 2.34 15 67 687 1345 880 1612 D15H RS Water 0.32 2.34 15 64 639 1345 880 1612 mm Height D22H RS Air 0.68 3.45 22 67 687 1345 880 1612 D22H RS Water 0.68 3.45 22 64 658 1345 880 1612 D37H RS Air 1.09 6.87 37 71 995 1722 920 1659 D37H RS Water 1.09 6.87 37 60 895 1722 920 1659 D50H RS Air 1.17 7.64 50 73 1570 2158 1412 1971 D50H RS Water 1.17 7.64 50 73 1490 2158 1412 1971 D75H RS Air 1.72 11.39 75 75 1890 2158 1412 1971 D75H RS Water 1.72 11.39 75 75 1810 2158 1412 1971 D110H RS Water 3.04 18.55 110 72 2200 2158 1412 1971 Quantima - variable speed centrifugal compressors 14 Pressure range 5 - 8 bar FAD1) m³/min @ 7 bar g Dimensions mm Motor kW Noise level2) dB(A) Weight kg Length Width 26.7 150 69 2400 2400 1600 1850 33.8 190 69 2400 2400 1600 1850 Compressor Model Cooling min. max. Q-26 Water 21.0 Q-34 Water 25.8 Height Q-43 Water 32.5 44.4 240 69 2600 2400 1600 1850 Q-52 Water 38.7 52.7 300 69 2600 2400 1600 1850 Motor kW Noise level2) dB(A) Weight kg 300 69 3800 Compressor Model Cooling Q-70L Water Pressure range 3 - 5 bar FAD1) m³/min @ 3 bar g min. max. 44.6 70.9 Dimensions mm Length Width Height 2950 2000 1950 Data measured and stated in accordance with ISO 1217 Edition 4, Annex C & E at the following conditions: Air Intake Pressure 1 bar a / 14.5 psi; Air Intake Temperature 20° C / 68° F 1) D-series - oil-free screw compressors air cooled Compressor Model Maximum FAD1) Motor kW Noise level2) dB(A) Weight kg Dimensions mm bar m³/min Length Width Height D75 8 12.89 75 75 3023 2597 1744 2001 D75 10 10.61 75 74 3023 2597 1744 2001 D90 8 15.60 90 76 3223 2597 1744 2001 D90 10 13.90 90 75 3223 2597 1744 2001 D110 8 19.43 110 77 3265 2597 1744 2001 D110 10 17.33 110 77 3265 2597 1744 2001 D132 8 22.26 132 78 3432 2597 1744 2001 D132 10 20.41 132 78 3432 2597 1744 2001 D160 10 22.21 160 78 3644 2597 1744 2001 D-series - oil-free screw compressors water cooled Compressor Model Maximum FAD1) Motor kW Noise level2) dB(A) Weight kg Dimensions mm bar m³/min Length Width Height D75 8 11.25 75 75 2193 2300 1500 1500 D90 8 14.61 90 76 2323 2300 1500 1500 D90 10.5 11.17 90 75 2323 2300 1500 1500 D110 8 17.62 110 77 2423 2300 1500 1500 D110 10.5 14.45 110 76 2423 2300 1500 1500 D132 8 20.59 132 78 2633 2300 1500 1500 D132 10.5 17.53 132 77 2633 2300 1500 1500 D150 8 22.78 150 79 2843 2300 1500 1500 D150 10.5 20.40 150 78 2843 2300 1500 1500 D155 10.5 22.61 185 79 2855 2300 1500 1500 D160 8 24.21 150 77 4243 3200 1900 1841 D185 9 28.95 185 78 4253 3200 1900 1841 D185 10 23.96 185 77 4253 3200 1900 1841 D200 9 34.34 200 79 4743 3200 1900 1841 D200 10 28.74 200 78 4743 3200 1900 1841 D250 8 42.42 260 80 4894 3200 1900 1841 D250 10 34.18 260 79 4894 3200 1900 1841 D275 9 42.30 300 80 5244 3200 1900 1841 Motor kW Noise level2) dB(A) 70% Load Weight kg D-series - variable speed Compressor Model Pressure range 4 - 10 bar FAD1) m³/min min. F ; Humidity 0 % (dry) Width Height 8.88 19.59 110 76 3278 2597 1744 2001 D110RS-10A 10.50 17.71 110 76 3278 2597 1744 2001 D132RS-08A 9.12 22.82 132 77 3476 2597 1744 2001 D132RS-10A 10.50 21.00 132 77 3476 2597 1744 2001 D160RS-10A 10.39 23.56 160 77 3688 2597 1744 2001 D110RS-10W 7.05 14.20 110 77 2423 2300 1500 1500 D155RS-10W 12.05 22.89 160 80 2855 2300 1500 1500 D275RS-10W 21.20 42.60 300 81 5100 3200 1900 1841 V-Major Piston Compressors V-Compact Piston Compressors R-series Champion Standard Piston Compressors 1.5 - 20.5 bar 1.5 - 10.5 bar 4 - 12 bar 15.1 - 92.7 m³/min 2.76 - 12.3 m³/min 7.5 - 18.1 m³/min 81 - 243 kW 18.5 kW - 59 kW 45 kW - 110 kW Measured in free field conditions in accordance with ISO 2151, tolerance ± 3 dB (A) 2) Length D110RS-08A Piston compressor range Pressure Range Volume Flow Power max. Dimensions mm 15 Truly innovative oil-free compressed air technologies CompAir for your industry CompAir is a leading global manufacturer of compressed air and gas solutions, providing high performance and low operating cost compressors including rotary screw, oil-free, centrifugal, piston and portable units, as well as ancillary products, for a broad range of industries. Contact Us With a network of sales companies and distributors across all continents, the company offers global expertise with a local service capability. For more information email sales@compair.com or visit www.oilfreecompressors.net CompAir is part of the Gardner Denver Group, a worldwide manufacturer of compressors, pumps and blowers and other fluid transfer equipment. CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications and prices without prior notice. All products are sold subject to the company’s conditions of sale. CompAir is a brand of Gardner Denver www.compair.com Brochure re-order. 91005-610GB 02/13 CI Your Ultimate Source for Vacuum and Pressure