S-energy EES Energy Efficient Systems Rotary Screw Air ...

S-energy ®EES Energy Efficient SystemsRotary Screw Air Compressors30-75 kW ■ 40-100 Horsepower■ Superior energy savings■ Payback in less than 2 years■ 90% of wasted heat is recoverable■ Excellent source of comfort heat

Sullair CapabilitiesSullair LeadershipSince 1965, Sullair has beenrecognized around the world as aninnovator and a leader in rotaryscrew compression technology. Formore than 40 years, Sullair hasdesigned and manufactured its ownrotors and air end assemblies at thecorporate headquarters in MichiganCity, Indiana.The award-winning rotary screwdesign sets the industry standardsand delivers the quality and reliabilityone expects from a leader.Sullair TechnologyUtilizing the most moderntechnologies, equipment andadvanced manufacturing techniques.Sullair designs, manufactures,assembles, and tests the mostadvanced compressed air productsin the industry. Sullair products areknown around the world for theiruniversally applicable design,outstanding craftsmanship andsuperior quality.Sullair’s Statistical ProcessControlOur Statistical Process Control (SPC)system monitors rotor qualitystandards to assure consistentcompressor performance.Sullair’s Commitment toInnovationUnderlying Sullair’s leadership is adedication to excellence and acommitment to innovation. We areconstantly exploring new ideas andseeking new ways to meet industry’sneed for increasingly energy-efficientcompressed air solutions.2

Sullair Air System SolutionsSullair offers air system solutions—a total compressed air system—tohelp compressed air users reduceenergy costs and improve productivityby analyzing, managing andcontrolling total compressed airsystems. Sullair’s air system solutionsinclude: plant air system audits,energy efficient products, compressedair system controls, monitoring andmanagement systems, air distributionproducts, and after-purchase support.The Sullair System here includes: aSullair compressor, “wet” receiver,Sullair pre-filter, your choice of aSullair desiccant or refrigerated airdryer, Sullair after-filter, “dry” receiver,and Sullair Flow Controller. Monitoringand controlling the entire system isSullair’s PC-based eConnect.Sullair Reduces Your Life-Cycle CostsEquipmentMaintenanceElectricityAir Compressor Life Cycle CostsAccording to Best Practices forCompressed Air Systems,Compressed Air Challenge, SecondEdition, 2007, energy costs nowrepresent 82% of the total operatingexpenses. Energy savings fromSullair S-energy® compressors cansignificantly reduce life cycle costs.The Sullair S-energy® compressorssignificantly reduce operating andenergy costs over the entirecompressor life cycle. Contributingto the energy savings are:• Sullair’s proven air-end with the lowrestriction inlet valve• High efficiency fan• Low pressure drop air-fluidseparation system to preventenergy lossSullair designs deliver cost savingsfor the life of the product. Improvedair filtration translates into:• Extended separator life• Improved fluid filter life• Less lubricant contaminationTo reduce fluid disposal costs, weoffer our biodegradable Sullube 8000-hour fluid, or 24KT , a long-lifefluid that never needs changing.3

Why a Heat Recovery System?Energy from compressed airThe Sullair EES recovers energy thatis expended while producingcompressed air and converts it into ausable source of heat. The heat isstored in the compressor cooling airas it passes through the after-coolerand fluid cooler. This air can then beused as pre-heated make-up air orheating air for plants, warehouses andother buildings. Heat that is notneeded is rejected from the system.Primary function: make-up airThe EES is designed primarily torecover the heat of compression in theform of heated make-up air. When theEES is used for this purpose, energyis fully utilized, installation costs areminimized and return on investment ismaximized. For every cubic foot ofoutside air brought into a building bythe EES, another cubic foot of air thatwould have infiltrated into the buildingat outside temperature is eliminated.Fuel savings result because theplant’s primary heating system doesnot have to heat that cubic foot ofoutside air up to the temperature ofthe heated space.Supplementary heatingThe EES can also operate efficientlyas a heating system. In this type ofapplication, the air is drawn andheated to a higher temperature(90°F/32°C, for example), and thendistributed throughout the heatedspace. This kind of application usuallyrequires a larger ductwork system todistribute the heated air, and thereforea bigger capital investment.Process heatingThe EES can also utilize the wastedheat of compression for some processheating applications, such as dryingparts, boiler and process combustionair preheating. These kinds ofapplications provide an excellentreturn on investment because the heatcan be used year round.Types of heat lossA plant’s heat load is the amount ofheat required to overcome the sum oftwo types of losses: infiltrative andconductive.Infiltrative losses result when cold aircomes into the plant through cracks,open doors and other openings.Ventilation, processing and otheroperations utilize the building’s air,then exhaust it to the outside. As air isexhausted, it must be replaced bymake-up air. If the primary heatingsystem does not draw in outdoor air,there may be insufficientcompensation for the exhausted air.When this occurs, a negative pressureis created, causing infiltration.Conductive losses result when heatescapes through a building’s barriers,including wall, floors, roofs and glasswindows.Less infiltration, lower heating costsThe Sullair EES takes some of theburden off the primary heating system.It draws in cooling air for thecompressor from the outside, thenrecovers the compressor-heated airand delivers it into the building. Thiscan substantially reduce heatingcosts.4

Why a Sullair Energy Efficiency System?Figure 1.Conventional Recirculating System40° ■ 65° ■ 90° ■Figure 2.Sullair Energy Efficiency System40° ■ 65° ■ 90° ■Figure 1. shows a conventional compressor recirculating system. Forcompressor cooling, it uses inside air rather than outside air. The warmed air isthen distributed to the building through a costly ductwork system. While thissystem adds heat to the building, it fails to offset some of the negative pressurethat causes infiltration.Figure 2. shows the EES drawing in 40°F outside air, then discharging it into theplant at a comfortable 65°F. Note the reduced infiltration.Why it’s bestPositive pressure make-up air■ May eliminate the need foradditional or alternative make-upsystems.Pre-engineered factory package■ Assures system reliability andresponsibility through one source.■ High static fans optimize systemperformance.Sound reduction■ EES enclosure provides additionalsound reduction.Thermostatic damper package■ No manual damper adjustmentsnecessary.■ Adjustable make-up airtemperature settings.■ Consistent temperature inpackageand make-up air to plant.Constant clean inlet air■ Minimizes compressormaintenance.5

Outstanding Energy SavingsAnnual energy savings up to$16,700With Sullair’s EES, you can achievesignificant savings on fuel heatingbills. For example, a 300 hpcompressor can generate 13,610BTU/minute. This represents 8.16therms/hour of usable heat worth$4080.00 per 1000 hours ofcompressor operation at $0.50/therm.And the EES does not impaircompressor cooling efficiency.CFM Make-up Air vs. OutdoorTemperature for typical 50 hpcompressorThe Make-up Air Versus Outdoor AirTemperature curve (right) indicatesthe quantity of make-up air providedby a Sullair EES under commonoutdoor and recovered airtemperature conditions. The curveshown applies to Sullair 50 hpcompressors.For example, for a 20°F outsidetemperature and a desired deliveredair temperature of 70°F, follow the20°F horizontal line to its point ofintersection on the 70°F curve. Readdown to find a make-up flow of 2700cfm make-up air at full load on thecompressor.CFM Make-up Air vs. Outdoor Temperature for typical 50 hp compressorOutdoor Temperature °F70°F60°F50°F40°F30°F20°F10°F0°F90°F80°F70°F60°F-10°F0 2 4 6Make-up Air (cfm) X 1000Actuators:• Easy set-up• No linkagesConnectionpointQuick connectwiring6

How They WorkWarm Weather OperationThe temperature controller signals damper C to open anddischarge the compressor-heated air to the outside.Simultaneously, damper A opens fully while dampers B and Dclose. The compressor takes in all cooling air from theoutdoors and the heat recovery module discharges all of theheated cooling air to the outdoors, thus isolating thecompressor cooling system from the indoor plant environment.Cold Weather OperationWhen the compressor isn’t operating, dampers A, C, D arefully closed to prevent heat loss and damper B is open. Whenthe compressor starts, damper A opens; and either damper Cor D also opens, depending on the signal received from theroom thermostat or the outside air changeover control.To OutdoorsCTo OutdoorsCBDTo PlantBDTo PlantExhaust PlenumExhaust PlenumFrom OutdoorsAFrom OutdoorsAWarm Weather OperationCold Weather OperationSpecifications:Dimensions and WeightsMotor Length Width Height Weight*Models HP inches inches inches lbs3000 40 67.1 34.5 98.3 20973000V 40 70.9 34.5 98.3 21733000P 40 67.1 34.5 98.3 22723000PV 40 70.9 34.5 98.3 23483700 50 67.1 34.5 98.3 23223700V 50 70.9 34.5 98.3 23984500 60 67.1 34.5 98.3 27724500V 60 70.9 34.5 98.3 26404500P 60 84 43.3 111.7 31894500PV 60 88 43.3 111.7 34604500PS 60 84 43.3 111.7 3465*Weight based on 460V ODP.Dimensions and WeightsMotor Length Width Height Weight*Models HP inches inches inches lbs5500 75 84 43.3 111.7 32605500V 75 88 43.3 111.7 35865500PS 75 84 43.3 111.7 36517500 100 84 43.3 111.7 35877500V 100 88 43.3 111.7 37797500P 100 84 43.3 111.7 37187500PV 100 84 43.3 111.7 39217500PS 100 84 43.3 111.7 3793*Weight based on 460V ODP.7

Global Support. Local Solutions.SULLAIR CORPORATION SULLAIR ASIA SULLAIR ASIA, LTD. SULLAIR AUSTRALIA SULLAIR EUROPE SULLAIR TAIWAN, LTDMichigan City, Indiana USA Shenzhen, China Jurong, Singapore Hallam, Victoria Australia Montbrison, France Taipei Hsien, TaiwanSullair offers air system solutions to help compressed air users reduce their energy costs and improve their productivity by analyzing, managing andcontrolling total compressed air systems. Information on the compressed air system tailored to your specific needs can be obtained by contactingyour local Sullair Distributor. To acquire local distributor contact information visit us online at www.Sullair.com or call 1-800-SULLAIR.Sullair Corporation3700 East Michigan Boulevard, Michigan City, IN 46360Telephone: 1-800-SULLAIR or 1-219-879-5451www.sullair.comSullair Corporation, a Business Unit of Hamilton Sundstrand,a United Technologies Company.© Copyright 2008 Sullair Corporation. All rights reserved.The color green is a registered trademark of Sullair Corporation.Specifications subject to change without notice.EE01E 0809R5The paper used in printing this literature was manufactured using recycled fiber, eitherpre-consumer or post-consumer waste, therefore less harmful to the environment because lessvirgin fiber is used, thereby reducing tree harvesting, water usage, energy consumption,emission of greenhouse gases and pollution.