I

POWER UNDER PRESSURE

COMPANY OVERVIEW

Sullivan-Palatek Inc., a leader in innovation and design, offers the industry's widest range of user-friendly

electric and portable rotary screw air compressors that are built to last. In 1984 Sullivan-Palatek began by

provided engineering services to existing clients; now the privately-owned, Michigan City, Indiana company

manufactures the most rugged and reliable machinery available in the market.

OIL-FREE ROTARY SCREW

COMPRESSOR PACKAGES

by

It uses only WATER: the fundamental element of life

• NATURAL: Water is generated out of ambient air

• CLEAN: Using only water creates uncontaminated

compressed air

• COOL: Water creates cool discharge air with low heat

rejection

• EFFICIENT: A self-contained coolant system

generates make-up water and constantly refreshes

• SIMPLIFIED: Self-monitoring system with no waste

generated

• ECONOMICAL: Low operational costs

WHY AQUA AIR WORKS

OIL FREE INDUSTRIAL USE

• Automotive

• Aviation

• Beverages

• Breweries

• Chemicals

• Construction

• Electronics Manufacturing

• Food Processing

• Health Care

• Laboratories

• Metering Technology

• Oil & Gas

• Packaging Industry

• Pharmaceuticals

• Power Generation

• Pulp & Paper Industry

• Textiles Industry

BENEFITS OF OIL-FREE AQUA AIR

Cost-Effective High energy-efficiency

VFD and direct drive

optimization adaption of

volume flow to real

compressed air demand

No elaborate water

treatment

No disposal costs

Low maintenance costs: no

filters, absorbers needed to

remove oil

Reliable Environmental-oriented

technology made in

Germany

Marine-grade construction

to resist corrosion

Reduced mechanical load

due to slow speeds and

Hydro-bearings

Fewer mechanical parts

Patented self-healing rotor

design

Rotor profiles made of

proprietary polymer

material enhances

performance and efficiency

Environmentally

Sound No oil used; no hazardous

waste generated

Air quality meets ISO 8573-0

No water treatment needed

After-use water can be

drained to environment

No coatings applied to parts

that could contaminate the

oil-free air

Compressed air contains no

bacteria or microbes

4–11 kW PACKAGE (5–15hp)

• Low 70s dBA

• Robust Cooler

• Dual Voltage Motors

• Large Sound Enclosure

• Heavy-duty 3-Stage Air Filter

• VFD or Fixed Speed Packages

• High-efficient TEFC Motors

• Patented Rotor Profile and Design

• All Components are Marine-Grade

Aluminum, Stainless Steel and Copper

• Silicone-Free Design (continued)

• Condensate Recovered for Water

Make-up

• Refrigerated Dryers Clean and

Condition All Make-Up Water Needed

• Low Maintenance Package

• Single Stage Compression

• 16 Bar Capable

• Low Operating Temperatures

• Non Gear Driven Air Ends

4–11 kW PACKAGE (5–15hp)

REFRIGERATED DRYERS (Required)

• The downstream installed refrigeration dryer

will continuously generate condensate, which

is returned to the compressor system as

make-up water.

• A Zero Loss Drain is required. This constant

supply of fresh water assures the water

quality is refreshed.

• The filtration system generates water and

cleans the air in the compressed air system.

Standard Supply of AQUA AIR

75–110 kW PACKAGE (100–150hp)

• Low 70s dBA

• Robust Cooler

• Dual Voltage Motors

• Large Sound Enclosure

• Heavy-duty 3-Stage Air Filter

• VFD or Fixed Speed Packages

• High-efficient TEFC Motors

• Patented Rotor Profile and Design

• All Components are Marine-Grade

Aluminum, Stainless Steel and Copper

• Silicone-Free Design (continued)

• Larger Systems for Bigger Air Demands

up to 150hp

• Refrigerated Dryers Clean and

Condition All Make-Up Water Needed

• Single Stage Compression

• 16 Bar Capable

• Low Operating Temperatures

• Plate and Frame Cooler Options

Available for Chilled Water

• Complete Packages with External Air

Cooler Options

75–110 kW PACKAGE (100–150hp)

REFRIGERATED DRYERS (Required)

• The downstream installed refrigeration dryer

will continuously generate condensate, which

is returned to the compressor system as

make-up water.

• A Zero Loss Drain is required. This constant

supply of fresh water assures the water

quality is refreshed.

• The filtration system generates water and

cleans the air in the compressed air system.

Standard Supply of AQUA AIR

REFRIGERATED DRYERS (Required)

Sullivan-Palatek has a complete line of Dryers

and Zero Loss Drains that will be quoted with

each compressor package.

INSTALLATION–water

What type of water is used to fill the system at start-up?

When charging the system it is important to use distilled water

which has a neutral PH. Using distilled water in addition to the

make-up condensate from the dryer will maintain a neutral water

supply and greatly reduce any chance of corrosion.

CAUTION: Do not use standard tap water as it has a PH level that

may vary greatly. This allows for deposits of sediment and

corrosion, and will damage the internal components and bearings.

INSTALLATION–air line

What type of air line should be used?

A corrosion-resistant piping material should be used when installing

the compressor to the dryer. Options are:

• Aluminum air piping–it is nickel-clad so corrosion is usually not

a concern

• Copper Piping

• Galvanized pipe and fittings

What are the electrical requirements?

A certified electrician should be used to ensure the

electrical installation meets NEC (National Electrical

Code) as well as any state and local codes.

INSTALLATION–electrical

EASY ACCESS FOR MAINTENANCE

MAINTENANCE PARTS

With so few items to

service, the maintenance

costs for the AQUA AIR

are far less than any

other type of oil free

compressor package.

Oil injected compressor with downstream filtration = technically oil free

Water injected compressor

suction air oil injected

compression oil

separator

aftercooler coalescing

filters

compressed

air with no oil

content

suction air oilfree

compression

removal

of water

refrigeration dryer +

external cooler

clean

compressed air

any failure will cause contamination of downstream

costs for oil removal and disposal

pressure losses

trap

SYSTEM COMPARISONS

An oil free dry screw compressor has a

sensitive shaft sealing system that

prevents oil entry into the compression

chamber. It includes O-rings, labyrinth

sealing and retaining rings.

• Complicated design

• High investment costs

• High maintenance costs

Gears = decrease in efficiency

= costs

SYSTEM COMPARISONS (Oil Free Dry Screw Compressor)

Sophisticated rotor design with

Teflon coating, high RPMs, very high

discharge temperature and many oil

lubricated items.

• Complicated design

• High investment costs

• High operation & maintenance costs

• Clean compressed air questionable?

SYSTEM COMPARISONS (Oil Free Dry Screw Compressor)

Japanese patent, and still served by Japanese

company.

• Very slow technical support

• Very slow delivery time

• Water quality issues (tap water)

• Reverse Osmosis system necessary

• Not 100% reliable

• High maintenance costs

• Susceptible to downtime

SYSTEM COMPARISONS (Mono Screw Compressor)

Oil lubricated bearings with risk of oil

contamination into the compression process.

• Not 100% reliable

• High maintenance costs

• Susceptible to downtime

Star wheels, which are coated with carbon fiber,

are subjected to wear and tear, and will need

replacing at 7000 hours of operation.

• High maintenance costs

• Increased maintenance intervals

SYSTEM COMPARISONS (Mono Screw Compressor)

• Difficult maintenance due to complex design of crosshead piston

compressor.

• Long operation periods with discharge pressures from 9 bar & up

will cause early wear of the teflon sealing rings in the compressor

due to increased temperature load. Early failure most probable.

• Specific performance kW/m3/min of piston reduces with increasing

discharge pressure, also caused by the high discharge temperature.

• High pulsation rate of pistons.

SYSTEM COMPARISONS (Oil Free Piston Compressor)

• Difficult maintenance

• Operation with discharge pressures from 9 bar & up causes early

wear of the teflon coating in the scroll due to increased

temperature load. Tip and dust seals must be replaced after only 2,500 hours.

• Scroll suitable only for short-term running as long as inner

temperature level is limited.

• Specific performance kW/m3/min of scroll becomes substantially

bad with increasing discharge pressure, also caused by the high

discharge temperature.

• High investment costs for scroll multi-stages, which is necessary to

avoid temperature-related problems and early failure.

• Air end life is only 30,000 hours.

SYSTEM COMPARISONS (Scroll Compressor)

• Lower maintance costs with fewer parts to service

• Operation up to 15 bar available in single stage

• AQUA AIR performance improves with longer running time due to self-healing effects of rotor surfaces

• Cooler operation due to lower temperatures during compression process (~10°C) = less heat rejection and less ventilation needed

• No teflon or oil present in discharge air

• Discharge air has significantly less oil content than ambient• Air quality meets ISO 8573-0

• Bacteria and foreign particles are removed by water; water filter system constantly refreshes itself

• Very quiet operation–low 70s dBA

• AQUA AIR is ideal for use in all oil free applications

SYSTEM COMPARISONS (Aqua Air Oil Free Compressor)

MAINTENANCE PARTS

With so few items to

service, the maintenance

costs for the AQUA AIR

are far less than any

other type of oil free

compressor package.

IT SIMPLY MAKES SENSE

by