Oil-free units to save Merck Euro60k a year

Gernsheim, Germany – Merck KGaA, a paint manufacturer based in Gernsheim, is set to save Euro60,000 a year from its installation of oil-free compressor technology.

Merck’s performance material department develops and produces pigments for effect paints, for use on high-end luxury cars, including special glimmer and multi-colour effect paints. The process requires high-quality air to avoid any contamination issues, hence its requirement for oil-free technology.

Previously, Merck used standard turbo compressors but found that CompAir’s Quantima gearless driveline and compression technology made the system more cost-effective.

A speed-regulated, high-speed electric motor drives a rotor shaft that is directly connected to an impeller at each end. The rotor shaft is supported by magnetic bearings and is literally floating on air resulting in no mechanical contact and therefore reducing wear on components and helping to lower maintenance costs.

The first Quantima Q-52 package included a desiccant dryer that uses the waste compressor heat for full-flow, hot-gas regeneration. This, says CompAir, provides high-efficiency because the heat required to regenerate the adsorption material is provided with no additional energy outlay.

To make more use of the thermal energy, there is also no aftercooler installed, enabling the compressed air to be discharged into the full flow using a hot gas outlet.

Following the initial installation, when a large turbo compressor in the second compressed air station needed replacing due to old age, Merck opted to upgrade to the two smaller machines.

Demand in this compressed air station fluctuates dramatically in short intervals, so the new speed-regulated system provided an opportunity to match compressor output to varying factory demand.

With volume capacities of 2500 m3/h and 3100m3/h respectively, the compressors, said CompAir, are now able to operate in line with the actual air requirements at all times, providing further energy savings.