Two Stage Air Compressors
A two stage air compressor is a compressor which compresses the air in two separate stages. Two stage compression is vastly more efficient and provides many benefits. Sharing the compression process between two stages allows the air to be cooled at the interstage, bringing the efficiency curve of the compressor much closer to the ideal IsoThermal curve.
There is also less heat, less oil degradation and less moisture build-up, as cooler air has a lower moisture content.
These compressors are used for 7.5-10 bar pressure applications. The main difference between single stage and a two stage air compressor is that single stage compressors complete the compression in only one stage while 2-stage air compressors complete compression in 2 stages.
The L-Series from CompAir
Well known in the industry for quality and reliability, continuously develops the L-Series to achieve cutting edge performance and efficiency. The new high-power range L160e to L290e of lubricated screw compressors comprises of fixed speed and regulated speed (RS) models in air- and water-cooled variants. The design features brand new, innovative technology engineered to provide next level performance and efficiency for customers across a wide variety of industries.
Compressors are more than just a financial investment; they are a key component in ensuring that manufacturers, processors and operators receive consistent, high-quality low-cost air.
The screw compression element is the heart of the compressor and therefore CompAir keeps the design and manufacture in-house, using the latest CNC rotor grinding machinery, coupled with online laser technology. The resulting reliability and performance ensure that operating costs will remain low throughout the compressor’s life.
FourCore technology – the power of 4!
CompAir’s centre of excellence at its Simmern production site in Germany, home to the CompAir ranges of compressors, has designed and engineered a brand new, patented technology that offers best-in-class energy efficiency. Our application engineering team have developed a premium efficiency 2-stage model for fixed and regulated speed compressors using the new technology of the compact double stage airend. What’s unique about this design is that the airend has 1 motor and 4 rotors with 4 gears located in a single, semi-integrated casting. This differs from traditional 2-stage compressors, providing a compact package with high energy savings. In fact, these machines are the same size as a 1 stage machine due to new airend technology.
Premium efficiency airend
The new airend design features our highly efficient airend which delivers the highest quality compressed air at a low rotational speed to help minimise the unit’s energy consumption and achieve excellent performance and reliability. The semi-integrated airend design with integrated oil filter and oil regulation valve means fewer external components and pipework, taking less physical space, eliminating the risk of leakage and offering simplified maintenance. The innovative design of the failsafe shaft seal, ensures the highest levels of quality and reliability are achieved, minimising the down time of the compressor. Our top quality airends are covered by the new 10 year warranty and up to 44,000 hours.*
- Very compact & very low weight
- Highest efficiency
- Semi-Integration of the oil filter, oil stop valve, oil distribution system, and oil temperature valve:
- Less hoses and hydraulic pipes ➞ less costs
- No leakages
- High flexibility by a 2-step drive gear configuration ➞ UNIQUE to CompAir
- Constant interstage pressure ➞ better efficiency
- Compact design
- Designed to implement in current L-Range ➞ UNIQUE to CompAir
- Fixed and variable speed versions possible
- 10 years warranty
Improved efficiency by 8-10% compared to a conventional single stage
CompAir’s innovative new FourCore technology delivers greater efficiency in a low weight and compact size. The series comprises of best-in-class premium efficiency 2-stage oil lubricated
compressors across the range of 160-250kW. In some cases, payback times can be less than a year, delivering a fantastic return on investment and incredible energy savings to the user.
One of the smallest footprints in the market of 2 stage oil lubricated units
The core benefit of the new L160e to L290e range is that it delivers much greater efficiency than a 1 stage compressor but comes in a German engineered package that is the same size or smaller than most single stage units already in the marketplace! Users in a variety of industries benefit from an amazing, space-saving design that offers next-level efficiency and performance.
Advantages of using a CompAir two-stage compressor
- Large surface aftercooler
- High-performance separator filter
- High-efficiency electric motor
- Thermostatically controlled radial fans
- Automatic motor lubrication
- Viton Victaulic couplings
- Zero loss auto drain
- iConn Compressed Air Service 4.0
Total potential CO2 reduction of 1,500 tonnes in 10 years
FourCore Technology from CompAir offers a reduced environmental footprint, cutting tonnes of CO2 during manufacture, use and disposal, increasing your “green” credentials and market appeal.
Reduced greenhouse gas emissions*
CompAir’s L160e running 8,000 hours per year, compared to a conventional single stage 160kW compressor can reduce the amount of CO2 produced by 134 tonnes – equivalent to 29 family cars or 337,700 miles driven by a passenger car in 1 year! That’s the same as planting 165 acres of forest!
How to add further value
The heat generated during compression is paid for as part of the process, then paid for again during removal by way of cooling fans. Instead of simply removing the heat, it can be used to generate free hot process water or hot water heating systems by utilising a high efficiency, factory-fitted oil to water heat exchanger. Read more about heat recovery.
Upgrade your compressed air system with heat recovery
- Significant cost savings
- Lower CO2 emissions
- Low investment costs