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WATER LUBRICATED Air-Ends WL

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Water Lubricated Compressor Market

Oil free air market:

• Few suppliers / High entry barriers

• High margin applications

• Competition with dry screws/hook/claw/piston compressors.

(Better efficiency, lower air-end cost and noise/vibrations, no gear box oil mist)

• Atlas, IHI, Kobe, Hitachi, Mitsui-Seiki, Gardner Denver, SRM Oil injected air market

• High competition / Low entry barriers

• Increasing cost for separation/filtration of oil carry-over

• Increasing cost for condensate removal

(Similar high volume cost, similar efficiency, ”old vs new”)

• Low cost suppliers on ”their way”

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Development history of SRM Water-Lubricated-Air-ends

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Composite Rotor Manufacturing

Drivers: • Tribology• Cost

Applications: • Water lubricated• Oil lubricated compressors• Dry compressors

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Rotor molding process

• Mold and shaft preparation• Filling• Curing• Ejection• Post-curing• Quality control

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• Polymer rotors• Water lubricated bearings• Shaft seal has no pressure difference

1999: Water lubricated Air-end WL 37

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SRM profilesManufacturing Application

• Tool wear• Release• Lobe deformation• Tolerances• Measurability

• Lubrication• Clearances• Dynamics• Flow• Material

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G-profile

• Self limiting wear-in effect compensates for manufacturing errors

• Low contact stress

• Shorter sealing line

• Larger theoretical discharge port

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male drive sidefemale drive side

The G-radius

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Efficiency

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Efficiency comparison between GVM and SRM water lubricated airends

50

55

60

65

70

75

80

85

90

10 15 20 25 30 35 40

Tip-speed [rpm]

Eff

icie

ncy

K-376SRM

GVMDLWW22-10

vol eff

vol eff

adb eff

adb eff

Pressure ratio : 8.0Inlet pressure : 1 barInlet temperature : 25 deg CAir discharge temperature: 40 deg C

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2001: Prototype water lubricated Screw- Package

Water treatment

Water separation

Endurancetesting

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Reliability Issues

Separator test no 14, Fine filter

00.5

11.5

22.5

33.5

4

2000 3000 4000 5000 6000 7000

Speed [rpm]

delta

X [g

wat

er p

er k

g dr

y ai

r]

100

105

110

115

120

125

130

Rel

ativ

e hu

mid

ity

afte

r sep

arat

or

[%]

Disch pressure: 8 bar aDisch temperature: 40 deg CWater injection: 43 lpm

Corrosion/wear Water Circulation System

LubricationProduct designs

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2004: New Generation WL, direct- and belt drive

WL 37 (axial air-intake) WL 38 (radial air-intake)

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Development history of Package Design from 1996 to the finished product 2006

2006: First Water Lubricated Screw Compressor WLC 38 by GCI Consulting GmbH, Germany

1996: SRM first Prototype for testing

2001: SRM Prototype for endurance test

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July 2004:Exclusive Sales Agreement of SRM WL Air-ends between SRM and GCI Consulting:

GCI distributes WL Air-ends and support OEM Customers re Water Screw Packaging due to GCI expertise in order to build their own Water Lubricated Compressor Range fast and with low cost.

April 2005, Hannover Fair :

SRM presented their Market-Ready oil-less WL 37/38 Air-ends and GCI their Package-Design know how

Marketing of SRM WL Air-ends to OEM Customers

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www.rotor.se© Copyright GCI Consulting GmbH

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2006: GCI supplied several oil-less WLC 38-Packages to OEM-Manufacturers in Europe, Asia and USA.

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