Oil Free Air Compressors: Best Choice for Pure Air

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. Investing in oil-free compressor technologies, such as the company’s Ultima, D-series or DX-series models, will help to mitigate the risks of contamination and, combined with intelligent heat recovery, can soon pay dividends.

Aside from a completely risk free operation, some of the core benefits of choosing an oil-free compressor are:

Low cost of ownershipSave on the costs of oil replacements as well as equipment used to clean and separate oil from air such as oil separators, filtration equipment and condensate treatment.

Environmentally friendlyOil free compressors are more compliant with international environmental regulations than lubricated systems, making for an environmentally conscious compressor choice.

Low maintenanceNo oil and less moving parts means less maintenance and fewer areas for problems to occur.

ISO Certified Air QualityAll of our air compressors meet either ISO Class 1 or ISO Class 0 air purity.

Quiet by designDue to the limited amount of moving parts, they produce less noise pollution and less vibration.

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.

Products in the CompAir range deliver 100 % oil-free performance, with fixed or regulated speed options alongside air and water-cooled models including:

• D15H (RS) to D37H (RS) single-stage, water-injected models, from 15 to 37 kW
• D37 (RS) to D160 (RS) two-stage models from 37 to 160 kW
• Ultima U75 to U160 two-stage, premium efficiency models, from 75 to 160 kW
• DX200 (RS) to DX355 (RS) two-stage models from 200 to 355 kW
• The D15H (RS) to D37H (RS range)

The range covers air and water-cooled models from 15 to 37 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.  

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 IE5 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.

An air-cooled variant is also available; the first ever air-cooled oil-free compressor to offer heat recovery for process water. Up to 98 per cent of heat generated during compression can be recovered to generate hot water at temperatures up to 85oC, achieving cost savings of approximately 80,000 Euros  when compared with the nearest rival models.

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 DX355 (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.

The range delivers up to eight per cent higher flow compared to industry standards, with up to seven per cent energy reduction on the fixed speed units and up to eight per cent on the regulated speed models.  The Xe-Series controllers deliver increased control and functionality through an intuitive user interface and provide remote access with any common, current web browser. Variable speed models can sequence up to four compressors without additional hardware to increase efficiency and stabilise pressure.

Seizing other opportunitiesWith 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.

To find out more, please visit  https://www.compair.com/en-gb/air-treatment-and-accessories/heat-recovery-oil-free

We offer a wide range of oil-free compressors such as two-stage, water-injected screw compressors and scroll as well as our highly efficient Ultima™ series.

Ultima™ is a ground-breaking PureAir compressor with revolutionary energy efficiency. Its unique design utilises both low-pressure and high-pressure compressor stages. Each compressor stage is individually driven by a speed-controlled permanent magnet synchronous motor, which offers exceptionally high efficiency compared to conventional technologies.

10 reasons why you can't ignore ULTIMA

1. Digital drive concept. The ULTIMATE economical way to generate compressed air. Calculate with 13 % savings potential.
2. The ULTIMATE way to generate compressed air. 37% smaller than the industry standard
3. Ultima air-cooled best in class. The most quiet pool among compressors
4. Greater planning security - upgradeable between 75 & 160kW
5. Optional heat recovery for both air-cooled and water-cooled models
6. Hybrid cooling - maximum flexibility with air and water cooling
7. Heat-of-compression - Lowest pressure dew points without additional energy consumption
8. Assure Service & Warranty
9. iConn proactive maintenance
10. ULTIMATE compressor stages made in Germany - high performance year after year!

Click here to find out more about Ulitma

With the DX series of oil-free screw compressors, CompAir has introduced a technology to the market that has an extremely low total cost of ownership. Customers get up to 8 % higher volume flow, up to 7 % energy savings and absolute air purity.

The new series is available with both fixed and variable speed. There are also models from 200 kW to 355 kW output and a choice of air-cooled or water-cooled versions. 

What makes our range of oil-free DX screw compressors so unique?

• State-of-the-art compressor stage
• Up to 8% higher volume flow compared to the industry standard
• Up to 7% (fixed speed) & 5% (variable speed) energy savings
• Premium variants with even higher efficiencies
• Models with variable speed and a turndown of up to 71%
• Large selection of pre-engineered and customised options
• Further savings through optional heat recovery
• Free iConn remote monitoring
• ASSURE service programme with various coverage options

Click here to find out more about the D-Series

The completely oil-free, single-stage, water-injected compressors in the DH series have a motor output of 15 to 37 kilowatts, a working pressure of 5 to 10 bar and operate at a flow rate of 0.3 to 5.9 cubic metres per minute.

As absolutely no oil is used in the process, contamination of the compressed air is ruled out.

The advantages of the DH series:

• No oil - No risks.
• Single-stage compressor element with direct drive maximises efficiency and minimises maintenance requirements
• High quality water lubricates, cools and seals the compression process, maximising efficiency
• No gearbox means no need for oil lubrication
• Low bearing load and low speeds mean that permanently sealed bearings can  used that do not require oil lubrication
• Variable speed models further reduce energy costs
• Extensive control options and remote monitoring capabilities ensure safe and reliable operation
• Fully enclosed and soundproofed housing
• Reduces noise pollution and simplifies installation

Click here to find out more about the DH series

The series includes air and water-cooled models from 37 to 75 kW and is available with both fixed and variable speed (RS). It delivers ISO 8573-1:2010 Class 0 certified, 100% oil-free air for the most critical applications.

Click here to find out more about the D-Series 37-75 kW