Mitigating compressed air risk with oil-free technologies

HYGIENIC APPLICATIONS, such as the pharmaceutical manufacturing environment, food and beverage sectors and sensitive electronic and automotive environments are demanding ever-increasing levels of air purity from their compressed air system.

In many of these processes, compressed air will come into direct contact with products and there can be severe consequences if air is contaminated with oil or other particulates. However, investing in oil-free compressor technologies, will help to mitigate the risks of contamination and, combined with intelligent heat recovery, can soon pay dividends.  

Oil-free for reduced contamination

There are many benefits to oil-free technology, which can help energy managers make valuable cost savings while improving operational efficiencies too. Whole life costs are reduced, with businesses able to save on the cost of air treatment and oil replacement. Unlike oil-lubricated systems there is no need to purchase equipment that would separate oil from air, such as oil separators, filtration equipment and condensate treatment.

• The D-series 37 to 75 kW range: The range covers air and water-cooled models from 37 to 75 kW and is available in both fixed and regulated speeds (RS) delivering reliability, dynamic efficiency, lower operating costs, and high-quality oil-free compressed air.  
• Ultima range: The CompAir Ultima compressor has been engineered with two highly efficient, permanent magnetic motors that replace the traditional gearbox design. These motors provide efficiencies greater than IE4 and directly drive the airends without the need for a gearbox. Ultima uses water in a closed-loop circuit for cooling all main components. This allows greater heat transfer and cooling efficiencies, as well as ensuring as little oil as possible is used in the system for assured air purity. 
• D37 (RS) to D160 (RS): Models in the D37 (RS) to D160 (RS) range offer 100% oil-free compression and robust performance thanks to a durable hard coating on the rotors and housing parts. 
• DX200 (RS) to DX255 (RS): Models in the DX200 (RS) to DX255 (RS) range feature a state-of-the-art airend that delivers significantly improved efficiency and best-in-class airflow. The premium e-variants with their water- cooled airend jackets enable even greater energy savings.

Seizing other opportunities

With many businesses faced with ambitious sustainability goals, deciding on an oil-free solution provides the most eco-conscious choice too, helping to contribute towards a facility’s green credentials.

For example, heat recovery offers further potential to save money and realise efficiency gains. Around 94 per cent of the energy required to run a compressor is converted to heat, but by using CompAir heat recovery options, this otherwise waste energy can be recovered easily. 

Companies consume a lot of energy and cost to generate hot process water, space heating or to preheat water for steam generation. Using CompAir’s heat recovery options, this waste heat can then be re-used to generate hot water of up to 85°C, to be used as process heat in manufacturing operations, for example. With a wide range of retrofit options and no impact on the compressed air supply, companies can often achieve payback on the investment in less than one year.

David Bruchof is product manager for oil free compressors at CompAir

For more information: 

www.compair.com/en-gb/oil-free-compressors

Tel: +44 113 - 8688139