New Technology Air Compressor

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• NCI Information Systems, Inc.
• 811 Park Drive
• Warner Robins, GA 31088

• rmiles_at_nciinc.com
• Phone [phone]
• Fax [phone]

New Technology Air Compressor
Rick Miles, Ph.D. David Ellicks, Materials
Engineer Air Force Corrosion Prevention Control
Office

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Purpose

• Develop Field Test More Efficient Air
  Compressors That Can Be Used In Military
  Applications

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Outline

• Advantages of New Technology
• Phase I Compressor
• Phase II Compressor
• Applications of Future Technology
• Phase III Performance Parameters
• Summary

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Traditional Compressor

• Large footprints and extremely heavy
• Must be oriented in a particular direction
• Usually requires a surge tank
• Requires lubrication
• Requires significant filtration to provide
  breathable air

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Resonance Compressor

• Linear Simplicity and Reliability
• High Force for Low Cost
• Control and Variable Capacity
• Smooth Start-Up and Low In-Rush Current
• Clean and Contamination Free
• Oil-free and Flexible Orientation

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Advantages

• Reliability and Maintainability
• Performance
• Environmental/Safety Aspects
• Applications

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Reliability Maintainability

• Doesnt experience total system failure
• Modular replacement
• Capability degrades but total loss of use avoided
• Ease of maintenance
• Filter replacement
• Minimum repair time for modules
• No maintenance checks
• Doesnt require back up compressors

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Reliability Maintainability

• No extensive filtration requiring maintenance
  upkeep
• Typical filter system cost to produce breathable
  air
• When CO is a concern 11,000
• When water vapor particulate but not CO is a
  concern 2,900
• Filter change frequency can vary. Typical is 30
  and 180 days
• 1 Filter changed at 30 days costs 50
• 2 Filters changed at 180 days costs 320
• Annual cost is 1240

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Reliability Maintainability

• No special facility requirements
• Requires only a covered facility
• No external refrigeration units required
• An additional system that wont be required and
  have to be maintained

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Performance

• Variable Output
• Most compressors in the military are used at 40
  capacity 80 of the time
• Dual Capability
• Breathable air source
• Shop air
• Energy Consumption

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Environmental/Safety Aspects

• Eliminates need for refrigeration unit
• No CFC utilization
• OSHA requirements and certification

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Compressor Development History
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Prototype Development

• 1st Generation Prototype (9 CFM, 15 PSI)
  Delivered December 2001
• 2nd Generation Prototype (25 CFM, 90 PSI) To Be
  Delivered March 2003
• 3rd Generation Prototype (100 CFM, 125 PSI), To
  Be Delivered April 2004

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Compressor Modules
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Compressor Modules

• AG-1250-475 (x3)
• 1.25 center lamination width
• 4.75 piston diameter
• 18 lbs
• 7.25 overall diameter
• 6 overall length
• Max pressure of 30 psig
• Max flow of 6 cfm
• Flow of 3.5 cfm _at_ 15 psig

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Final 1st Generation Status
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ModAir Compressor
Handle
Cooling fan
Inlet filter
Set Pressure Knob
Power switch
Controller
27.25
Compressor module
Display
Pressure transducer
Service Hose
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2nd Generation Targets

• Tank not included
• Compressors and controller only, does not include
  approx 1/2HP for fans and pump
• As requested in July 2002

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2nd Generation Work Plan
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ShopAir System Requirements

• Controller with LCD display screen that displays
  pressure reading
• Oil free pump assembly with no lubrication or
  rotating parts
• Variable output operation
• Field serviceable
• 3/8 diameter 5 hose between quick disconnect
  connections
• 3/8 quick disconnect connections to hook up
  paint gun to compressor
• Ability to work with a surge tank of at least 80
  gallons capacity
• User adjustable pressure from 60 to 90 psi

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Breathable Air Source

• Must follow guidelines of T.O. 42B-1-22
• Satisfies guidelines for OSHA Grade D Breathable
  Air Source
• CGA D, NFPA 1500 (G-7.1, 1997)
• Air from compressor must be recertified every 90
  days
• Air checked at point of use

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Breathable Air Source
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Shop Air Schematic
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Concept Model

• 80 gal surge tank
• Compressor Compartment
• 3-stage modules (12)
• Coolant and air lines
• Control Module
• Controller boards (12)
• Inlet filter and muffler
• Heat exchanger and cooling fans
• Coolant pump and tank

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25
Shop Air Compressor

• To be installed in Robins AFB Radome Repair Shop
  end of March 2003

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Shop Air Compressor
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Phase III Compressor Utilization

• Air Force uses significant industrial compressors
  for breathable and clean air
• Project target capability is 100 cfm at 125 psi
• 19 compressors of this category are in use at
  Robins AFB
• 8 would be perfect drop-in replacements
• 1100 military sites
• Air Force, Army, Marines, Navy, Coast Guard,
  National Guard, Reserve

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New Compressor Utilization

• Applications
• Paint Shops
• At least 2 per base and depot
• Fuel Cell Hangar
• 1 per base and depot
• Gyro Shop
• 1 per depot
• Other Military Applications

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Applications for Future Technology (100 SCFM at
125 PSI)

• Military
• Breathable (Masks)
• Air Pumps (Hoods)
• Compressed Air
• Clean, dry air desirable for use with tooling
• Navy (on board ships)
• Commercial
• Clean Rooms
• Paint Facilities
• Space
• Electronics

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Phase III Performance Parameters

• Capacity
• 100 CFM _at_ 125 PSI
• T30 Ingersoll Rand with applicable filtration
• 101 cfm _at_ 125 psi
• 240 gallon surge tank
• 8 in use at Robins AFB
• Cost 18,400
• Compressor and after cooler 7,400
• Filtration 11,000
• Size
• Existing T30 Ingersoll Rand footprint
• Weight 1800 lbs
• Dimensions 71 L X 33 W X 61 H
• Does not include aftercooler and filtration
  footprints

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Summary

• Significant advantages over current technology
  compressors at this capacity
• This capacity compressor has broad use
  applications throughout the military
• At least 1100 potential sites DOD wide

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Other Potential Applications of the Technology

• Powder Coating Application
• Chemical Mixing
• Crushing Material
• Refrigeration
• Purification of Gases

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Qualified Plastic Media (PMB) Vendors (TO 1-1-8)

• rmiles_at_nciinc.com
• Phone [phone]
• Fax [phone]

• NCI Information Systems, Inc.
• 811 Park Drive
• Warner Robins, GA 31088

• Rick Miles, Ph.D.
• David Ellicks
• Air Force Corrosion Prevention Control Office

34
Mil-P-85891A QPL (As of 26 Dec 02)

• Type V
• Composition Materials Co., Inc.
• MPC, Inc./Patent Plastics, Inc.
• Opti-Blast, Inc.
• Poly-Pacific International, Inc.
• Solidstrip, Inc.
• U.S. Technology Corporation
• Type VII
• Archer Daniels Midland
• e-Strip GP (Type VII)

• Type II
• BIP Plastics, Inc.
• Composition Materials Co., Inc.
• MPC, Inc./Patent Plastics, Inc.
• Opti-Blast, Inc.
• Poly-Pacific International, Inc.
• Solidstrip, Inc.
• U.S. Technology Corporation
• Type III
• MPC, Inc./Patent Plastics, Inc.
• Solidstrip, Inc.

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QUESTIONS?