At Intermat 2009, CompAir will exhibit models from its C Series of portable compressors, including machines from the TurboScrew range, which is proven to deliver up to 28% fuel savings compared to standard units, with no loss in pressure.

Manufactured at CompAir’s Simmern facility in Germany, CompAir’s TurboScrew compressors feature a lightweight and compact Cummins QSB6.7TTA engine, which is engineered with two turbochargers to deliver more air, at the same pressure. Taking the C210TS-12 as an example, this results in a 12.7-litre/hour reduction in fuel consumption at 100% load over previous models, but still with a sufficient-sized fuel tank for a 10-hour shift.

With a conventional design, an engine running at 100% efficiency would deliver just 36% power at the screw, but with the addition of the second turbocharger, CompAir has converted 5% of what would normally be wasted exhaust energy and converted it into motive power to create compressed air.

Companies that have benefitted from the energy-efficiency of these new TurboScrew models include engineering solutions provider Bechtel and Icelandic engineering specialist HRV, during the construction of one of the world’s largest aluminium smelting plants in Iceland; the Alcoa Fjarðaál Smelter.

Two C180TS-9 TurboScrew compressors were purchased and used to power 40 concrete vibrators to form a cylindrical concrete bauxite container in just 10 days.

Despite being located outside in freezing temperatures the C180TS-9s maintained consistent performance and enabled Bechtel to reduce environmental impact by up to 30%, saving more than 10 litres of fuel per hour of operation, without any difference in performance.

CompAir’s TurboScrew compressors have also helped hydraulic engineering firm, Hydrotechnik Lübeck GmbH (Hydrotechnik) to minimise its affect on the marine environment, in two separate applications in the North and Baltic Seas.

Both projects involved using the compressors to create a protective curtain of air bubbles around the site to absorb and reflect sound waves created during engineering work.

In the first application, nine portable compressors, including C210TS-12 and C190TS-12 models were hired from CompAir distributor, Peter Gay in Bremmen to help construct the foundations for Germany’s third marine research platform in the North Sea.

“It was a real challenge to complete a project of this scale in the time available,” says Cay Grunau from Hydrotechnik. “It took over six hours to drive the 315-tonne, 55-metre-long monopile around 30 metres down into the seabed. This meant that the CompAir compressors ran continuously for around 20 hours, but, because of their high fuel efficiency, we were still able to save about 2000 litres of fuel on this particular project compared with similar compressors.“

In the second application, Hydrotechnik hired a C210-TS NA TurboScrew compressor to create a bubble curtain during detonation of up to 100 large munitions off waters southeast of the Kiel Fjord in the Baltic Sea.

The TurboScrew design features electronic controls that are simple and intuitive. Grouped into three main display pages, the first control identifies the machine, the second enables the user to set the required operating parameters, such as engine speed and pressure via simple ‘up and down’ arrows and the final screen identifies faults taken from sensors located around the machine. In addition, the final screen enables the user to identify and take steps to rectify machine faults, helping to protect the life of the machine and avoid downtime.

All compressors in the range have wide opening doors that provide unrestricted access to all components for simpler and quicker maintenance. The system contains a series of engineer-accessed display screens that allow the technician to limit operating pressure to help protect the unit from misuse. An automatic de-rating system switches the unit to a slower speed when a fault is identified.

For further information about CompAir’s range of portable compressors, visit the CompAir stand 5a – E104 where technical experts will be available to discuss customer’s requirements and advise on the best equipment options.

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