Why a Separator is Needed
In a flooded rotary screw compressor, intake air is compressed by rotors turning in a flood of
compressor fluid. The compressed air and fluid mixture is discharged into a receiver where most of the fluid falls, by gravity, to the bottom of the receiver, or sump. Fluid aerosols remaining in the compressed discharge air must be removed for the following reasons:
- To avoid discharging valuable fluid downstream
- To prevent damage or contamination to air-using equipment or processes by the entrained fluid
- To keep the compressor operating economically.
The function of the air/fluid separator is to retain fluid in the system for re-use in the compressor unit. The Sullair Optimizer agglomerates and separates fluid aerosols from the compressed air. The fluid aerosols impinge on a layer of Micro Glass fibers, where coalescing and separation occurs. The fluid drains to the bottom of the separator and is removed by a return line.
Why a Good Separator is Essential
The separator plays a key role in optimizing rotary screw compressor performance. By reducing fluid carryover, the separator reduces the amount of
compressor fluid that is carried into the service line. As a result, less fluid has to be added to maintain proper operating levels, and overall maintenance costs are reduced.
Less carryover also means that fewer fluid contaminants are passed into the airstream, so air quality is maintained. With reduced carryover, your compressor,
compressed air dryers and
filters, and air-using devices function better and last longer. Environmentally, fewer fluid contaminants, which are treated in thesame manner as hazardous waste, are passed to condensate drains.
The Optimizer separator has been designed for your compressor, built of quality materials, and can reduce power consumption by minimizing the differential pressure.
Why the Optimizer™ is the Best
To continuously improve our products to meet customer expectations, Sullair and its suppliers have thoroughly researched the design, materials and manufacturing assembly techniques of every component of its compressors, including separator elements.
The Optimizer™, standard on every
industrial Sullair compressor has been developed to provide optimum performance in your compressed air system. Fluid carryover in the discharge air is less than 2 PPM* (parts per million)—as much as 700% better than non-O.E.M. separators.
Less Pressure Drop
All separators have varying degrees of pressure drop. It is this pressure loss that determines relative power consumption over a period of time. For every additional psig of pressure required from the compressor, an additional 1/2% of power draw is required. The Optimizer is designed to reduce initial restriction, contributing to more efficient compressor performance.
The Optimizer™ Media
The media is the most important part of the separator. All other components simply support and protect it.
The thickness and density of the media fibers are closely controlled to maximize coalescing effect. The media is manufactured with small diameter fibers and formed by the “wet laid” process for more uniform distribution.
Pleated for Greater Surface Area
The Optimizer media is deeply pleated to provide maximum surface to the flow. The more surface area available, the longer the life of the separator and the lower the pressure drop across the separator. The Optimizer benefits include:
- More Surface Area
- Less Pressure Drop
- Unique sealing method used to insure a leak-tight seam
- Fiber thickness and density are closely controlled
- Surface of fibers is sealed to improve coalescing
- Designed to Sullair specifications
- Heavier guage metal withstands greater unbalanced pressure surges.
