SECOTEC Refrigeration Dryers

Transcription

1 Refrigeration ryers SECOTEC Refrigeration ryers ir flow 0.6 to m /min

2 SECOTEC saves even more energy Separate condensate separator Operational reliability has hy do we need dry air? tmospheric air drawn into a compressor is a mixture of gases that always contains water vapour. owever, the amount of water vapour air can carry varies and is mostly dependent on temperature. If temperature rises as happens when air is compressed the capability of air to carry moisture rises as well. hen compressed air is cooled the excess moisture it can no longer carry condenses. This condensate is then removed in the centrifugal separator or the air receiver downstream of the compressor. Even then, the air is still saturated to 00 percent with water vapour. hich is why when air cools even further, significant amounts of condensate accumulate in the piping and at takeoff points. ithout additional drying, breaks in production, product downtime and expensive repair work are unavoidable. The innovative SECOTEC system The main goals during development of the SECOTEC dryer were further reductions of energy consumption and optimisation of reliability and userfriendliness. found the right answer with the innovative SECOTEC concept; in contrast to most refrigerant drying systems, s economic dryers use an extremely efficient cycling system called SECOTEC control. The dryer s refrigerant compressor cuts in and consumes power only when necessary. Variant If the air demand is largely constant, the SECOTEC dryer is located downstream of the compressor and air receiver. Variant If the air demand fluctuates heavily the SECOTEC dryer is located between the compressor, centrifugal separator and air receiver. been given top priority on SECOTEC dryers. That is why they are fitted with a separate, specially designed condensate separator made of stainless steel. Even under conditions of fluctuating air demand it reliably removes precipitating condensate from the air flow. ECO RIN SECOTEC refrigeration dryers are fitted with an ECO RIN as standard. This highly reliable device operates without loss of pressure, so contributing to energy savings. In contrast to time-controlled solenoid valves, it causes no air losses. This means that the ECO RIN saves further energy and contributes to the high operational reliability of the dryer. *) Model T 5 is fitted with a float drain as standard The SECOTEC dryer rying compressed air with the help of refrigeration is the most efficient answer to most air applications. rying air with the innovative SECOTEC system is even more cost-effective. The cost-saving effect of the SECOTEC system Comparing, for example, the T 9 dryer SECOTEC dryers save energy because with non-cycling dryers, the T 9 (. the refrigerant system is shut down. The m /min air flow) saves a total of # 67 per control system functions without the need year at a kh price of # 0.08 in single for preset run-on periods. The integrated shift operation (that is 8760 hours, of thermal storage mass guarantees constant which only 000 are under full load). operational readiness. This cost-saving is determined by the n added benefit is the low pressure drop following equation: across the SECOTEC dryer. (8760 h -000 h) x 0. k x 0.08 #/kh = # 67 The graph on the right shows a typical This low pressure drop allows the maximum pressure of the compressors to be profile of air consumption. uring breaks, periods of low demand and shutdown set lower, saving additional energy Early shift higher average air consumption Midday break ir consumption over a -hour period Late shift low average air consumption ir consumption SECOTEC energy-saving potential: s soon as there is little or no air demand the -SECOTEC dryer shuts down automatically. ir consumption = below the blue line Energy-saving potential = above the blue line Night shift very low average air consumption Uhr Lower differential pressure If the pressure differential (pressure drop or loss) across the dryer is 0.5 bar, for example, this means three percent more power requirement for the compressor upstream. Thanks to their generously-sized design, the differential pressure of SECOTEC dryers is reduced to a minimum; depending on model it is only 0.07 to 0. bar under reference conditions to ISO 78*. That means that as well as the energy savings achieved by SECOTEC cycling control there is a further, perceptible reduction of air costs because of the lower working pressure of the compressor. Even after years of operation the pressure differential remains comparatively low. *) see Technical specification

3 Technical specification ir dryers must be selected to suit actual operating conditions: The maximum possible flow rate through the refrigeration dryer rises with increasing working pressure. In contrast, the maximum possible flow rate through the dryer falls with increasing air inlet temperature. The maximum possible flow rate through the dryer also falls with increasing ambient temperature. Model T 5 T 8 T T 9 T 6 TC TC 6 TC T 5 T 6 T 76 TE 9 TE TE TF 7 TF 0 Flow rate in m /min at 7 bar working pressure ifferential pressure bar Max. working pressure bar 6 Effective power consumption k Power supply 0 V 50 z Ph 00 V 50 z Ph R a Refrigerant ir Condensate imensions in mm eight connection (female drain eight idth epth thread) mm kg N 6 70 G / G G / N G / G N 80 N Performance data for reference conditions to ISO 78, option ; ambient temperature 5 C, air inlet temperature 5 C, pressure dew point C. The flow rate changes for other operating conditions. Correction factors for other operating conditions (flow rates in m /min x c... ) eviating working pressure p at dryer inlet ir inlet temperature T i mbient temperature T a p (bar) T i ( C) T i ( C) c p c Ti c Ta Calculation of flow rate under deviating conditions: Selected dryer is a T 9 with. m /min (V reference ) Example: Max. possible flow rate under operating conditions: orking pressure: 0 bar Table c p =. V max, operational = V reference x c p x c Ti x c Ta ir inlet temperature: 0 C Table c Ti = 0.8 mbient temperature: 0 C Table V c Ta = max, operational =. m /min x. x 0.8 x =.89 m /min

4 SECOTEC eight decisive advantages SECOTEC cycling control Non-cycling control. Save energy day after day with SECOTEC control SECOTEC control is a cycling control that cuts in the dryer s refrigerant compressor only when it is needed. The basic requirement for this type of control is a thermal mass of high capacity. It is cooled down to cut-out temperature and extracts the heat from the compressed air flowing through the heat exchanger. s soon as the temperature of the thermal mass rises to the cut-in temperature the refrigerant compressor starts and cools it down again. ecause of the thermal mass s high capacity, the refrigerant compressor can be shut down as soon as the lower temperature is reached. Compared with non-cycling controllers or controllers with a run-on period 5. Simple, cost-effective servicing ll the components in SECOTEC dryers such as heat exchangers, refrigerant circuit, condensate separator and drain are easily accessible from above when the panels are removed. Service valves are provided to check the refrigerant circuit. The condenser is located at the front of the dryer, allowing any accumulating dirt to be seen and quickly removed. The tower construction and component layout allow maintenance to be carried out easily. ll these features significantly reduce servicing effort and, therefore, cost. this reduces power consumption considerably.. Lower pressure drop means additional energy savings 6. Industrial quality control cabinet for increased safety The air/air and refrigerant/air heat exchangers are fitted with generously-sized copper tubing that cause a low pressure drop. The smooth inner walls of the tubes guard against deposits so that the pressure drop across the SECOTEC dryer remains low for years. nother advantage is that SECOTEC dryers need no prefilter. This means that costly pressure losses caused by an additional filter are avoided. Every SECOTEC dryer is designed to comply with EN 600- and checked for electromagnetic compatibility to EMC standards. In contrast to equipment conforming to VE 0700, SEC- OTEC dryers conform to a strict industrial standard, being fitted with a control cabinet to IP 5, cut-outs for the control and power circuits, and a control transformer. The control transformer galvanically isolates the control circuits from the mains, so that protection of personnel is guaranteed, even if a short-circuit occurs. The cut-outs in the equipment conform to EN 600-, as in an industrial environment fusing external to the dryer may not be reliably possible because of long supply cables, for example. delta P only 0.07 max. 0. bar This ensures maximum safety and reliability, factors that are not always a matter of course.. n efficient condensate separator of stainless steel 7. Easy to operate deflector plate forces the compressed air streaming into the separator into circular motion. The air then flows through a stainless steel wire mesh in which 99.9 percent of the water in the air is separated. ith perfect matching of components this degree of separation remains almost constant even if the air flow fluctuates. This allows the required pressure dew point of + C to be reliably maintained. The separator tank and the wire mesh are made of stainless steel so that no corrosion can occur. Solid particles are also washed out and separated together with the condensate. The tower construction of the SECOTEC dryer not only eases servicing but operating as well. The control panel is located within easy view on all models. dew point trend gauge integrated in the control panel monitors the dryer function. Further operating and monitoring elements are: Emergency Stop/main switch, LEs indicating ctive thermal mass and Refrigerant compressor ON ; optional from models TE 9 upwards and standard from TF models upwards are the LE indications of igh dew point and ECO rain alarm. This guarantees simple operating and increases operational reliability.. Sure and thrifty condensate drainage 8. Reliable functions The ECO-RIN is fitted with an intelligent level-sensing control that prevents loss of pressure through the condensate drain line. hen the collector tank is full, the level sensor opens a diaphragm valve and the condensate is drained off. The electronics keep the valve open until the container is empty and close it again before compressed air can escape. The operational functions of the SECOTEC can be divided into four stages: First stage: the hot compressed air () entering the dryer is initially cooled in the first part of the heat exchanger () by the cold compressed air leaving the dryer.* Second stage: the air is cooled down further to the dew point temperature in the second part of the heat exchanger () by a refrigerant circuit with a thermal mass (). Third stage: the condensate formed by the cooling action is separated from the compressed air by the multistage, maintenance-free separator (). The condensate is removed from the separator 5 by the automatic ECO RIN (). Fourth stage: The cold and dry air leaves the dryer (5) after passing through the first part of the heat exchanger () where it takes some of the heat* from the incoming air. *) Model T 5: without initial cooling and reheating, third stage uses float drain.

5 SECOTEC Equipment Construction Tower construction with removable side panels, sheet steel panelling powdercoated outside and galvanised inside; all cold components are insulated; all materials used are free of CFC; the built-in control cabinet is enclosureprotected to IP 5; air to air heat exchanger (model T 8 upwards); condensate separating system, automatic condensate drain; scope of delivery includes refrigerant and oil charge. Fitted with dew point trend gauge, Emergency Stop/Main Switch, LEs for ctive Thermal Mass and Refrigerant Compressor ON. Volt-free relay contacts for igh ew Point and Refrigerant Compressor ON are fitted as standard on models TC and upwards. LEs for igh ew Point and ECO rain larm are optional on the TE series and standard on the TF series. Refrigerant circuit The refrigerant circuit is fitted with service valves, SECOTEC cycling control of a thermal mass store, automatic dew point control and a generously sized refrigerant compressor. Optional accessories ypass piping. This option ensures air supplies when the refrigeration dryer is being serviced. Comprehensive design know-how KESS, Kaeser s Energy Saving Service, is available to you as a comprehensive service concept that determines the optimum means of supplying the compressed air needed in your production facility. This service combines elements such as air components, user advice and services with new ideas made possible by the optimised use of data processing. ir systems planned and designed by are characterised by their efficient use of energy. uty cycle factors for the compressors of 95 percent and more are possible. ir quality tailored to the application at lowest cost and with high operational reliability is a further characteristic typical of Kaeser air systems. Take advantage of this expertise. ave your compressed air supply system designed by.

6 imensions T inlet Electrical Compressed air Condensate drain (N 9) View from right Front view View from left Cable inlets inlet T, TC, T View from right Front view Rear view Condensate drain Compressed air Electrical cable inlets Compressed air inlet Cooling air TE View from right Front view Rear view Condensate drain Compressed air Cooling air inlet Electrical Condensate drain TF View from right Front view Rear view

7 ifferent applications need different grades of treatment Choose the required grade of treatment according to your field of application: ir treatment using a refrigeration dryer (+ C pressure dew point) Examples: selection of treatment classes to ISO 857- Solids ater Oil acteria airies, breweries FST Food and semi-luxury food production Very clean conveying air, chemical plant Pharmaceuticals eaving machines, photo labs Paint spraying, powder coating Packaging, control and instrument air General works air, quality sandblasting Shotblasting Low quality shotblasting Conveying air for waste water systems No quality requirements For air mains subject to sub-zero temperatures: treatment systems with desiccant dryers (pressure dew point to -70 C) Pharmaceuticals, dairies, breweries Microchip production, optics, food and semi-luxury food production Paint spraying Process air, pharmaceuticals Photo labs pplications subject to subzero temperatures, especially dry conveying air, paint spraying, fine pressure controllers C C E G G 7 7 I 7 J 6 7 C F Solids ater Oil acteria - FST - Oil vapour content 0.00 mg/m, particle retention > 0.0 µm, sterile, odourless and tasteless Oil vapour content 0.00 mg/m, particle retention > 0.0 µm Oil vapour content 0.00 mg/m, particle retention > µm FST FST F F CT CT F FF rotary screw compressors other machines FG FFG FF F KOMPRESSOREN Gmb 960 Coburg Postfach GERMNY Phone Fax productinfo@kaeser.com FC R E Compressor Filter ir receiver E Installation for heavily fluctuating air demand Filter ir receiver R quamat Compressor ZK Installation for heavily fluctuating air demand T ZK TNF TNF quamat Explanation: TNF=bag filter Cleans dusty intake air ZK=centrifugal separator separates accumulating condensate E=ECO rain electronic level-controlled condensate drain F=prefilter µm separates liquid droplets and solid particles > µm, oil content 5 mg/m³ FC=prefilter µm separates oil droplets and solid particles > µm, oil content mg/m³ F=particulate filter µm separates dust particles (attrition) > µm =microfilter 0.0 µm separates oil aerosols and solid particles > 0.0µm, aerosol content 0.0 mg/m³ FF=microfilter 0.00 ppm separates aerosols and solid particles > 0.0µm, aerosol content 0.00 mg/m³ FG=activated carbon filter for adsorption of oil vapours, oil vapour content 0.00 mg/m³ FFG=combination filter comprising FF and FG R=refrigeration dryer pressure dew point to + C =desiccant dryer C series: heatless regeneration, pressure dew point to -70 C,, N, TL, T series: heat regeneration, pressure dew point to -0 C CT=activated carbon adsorber for adsorption of oil vapours, oil vapour content 0.00 mg/m³ FST=sterile filter provides bacteria-free compressed air quamat=condensate treatment system Contaminants: + solids - + water - + oil - + bacteria - egree of filtration: ISO 857- Class Solid particles Max. no. of particles per m with size d (µm) 0. 0.d d.0.0d5.0 µm mg/m umidity Pressure dew point (x=liquid water in mg/m ) Overall oil content mg/m 0 as specified by user C C C + C +7 C C x x x 0.0 E F G erosol oil 0.00 mg/m, particle retention > 0.0 µm erosol oil 0.0 mg/m, particle retention > 0.0 µm erosol oil 0.0 mg/m, particle retention > µm erosol oil mg/m, particle retention > µm I J erosol oil 5 mg/m, particle retention > µm erosol oil 5 mg/m, particle retention > µm Untreated P-0E.9/0 Specifications are subject to change without notice