Protecting installations Energy optimisation Improved profitability Flow rate of conditioned biogas: up to 6 000 Nm 3 /h Biogas efficient waste recovery Operating principle When produced, biogas contains many impurities and has a high moisture content. This vapour reduces energy efficiency and compromises the service life of the recovery systems, in particular the motor and any purification equipment. The system works in three steps: - Dehumidification of the biogas in an exchanger supplied by a cooled water loop via a chiller. - separation and draining of the condensed water vapour. This step allows the absolute humidity to be reduced. - Warming via a post-heater or economiser. This step (optional) allows the relative humidity to be reduced. Range The system is available in 3 versions: ONE comprises 8 predefined models configured to suit the most common ratings for agricultural installations. All components are assembled on a frame, ready to be connected. FLEX is an extension of ONE which offers an increased flow capacity combined with a range of options. FLEX can be fine-tuned to your requirements. Depending on the size, the components are supplied fully or partially assembled on a frame, ready to be connected. PLUS is an offer comprising components supplied separately, yet fully optimised to work together. Each component is selected in all available sizes for the CIAT exchanger and chiller ranges. Using CIAT's calculation tools, your system is guaranteed to be perfectly uniform and balanced. Description DPO 050 168-20C H05L n DPO: version: DPO ( ONE) or DPF ( FLEX) n 050: chiller size n 168: cooler diameter (mm) n 20: cooler length (dm) n C: cooler tubes: L = smooth, C = corrugated n H05L: Economiser (E) or Heater (H) option. 0000 if option not selected n 05: length of the economiser or heater (dm) n L: economiser or heater tubes: L = smooth, C = corrugated For the PLUS version, each component is designed according to its typology. heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A 1
Applicable standards and directives n 2006/42/EC - Machinery Directive. n 2004/108/EC - Electromagnetic Compatibility (EMC) Directive. n 2006/95/EC - Low Voltage (LV) Directive. n 97/23/EC - Pressure Equipment Directive (PED) (notified body 0060). n 90/396-93/68/EC - Gas Directive. n NF EN 1127-1 Explosion Prevention and Protection. The category under PED 97/23/EC for the ONE and FLEX depends on the size of the chiller. Chiller size 035 050 065 075 080 090 100 120 150 180 200 240 300 PED category 1 1 2 2 2 2 2 2 2 2 2 2 2 Limits of use Installation outdoors. Min/max temperature: -15/+45 C. Factory tests Each unit is tested before shipping: - Resistance test on the gas and liquid circuits - Sealing test on the gas circuit - LVD test (dielectric test, low voltage tests ) Each water chiller is subject to an operating test in the workshop before shipping. Recommendations - The ONE and FLEX systems are not designed to be installed in an ATEX zone. - Damage is possible if installed in harmful atmospheres or in the presence of H2S or NH3. These atmospheres may be present in landfills or WWTW (waste water treatment works) in particular. If there is a high concentration of H2S, it is recommended that adequate preventive measures are taken. - For further information, please contact your CIAT representative. INSTALLATION - ONE and FLEX systems must be installed outdoors, in a ventilated area. - Any air intakes must be more than 5 m from the system. - ensure there is sufficient free space around the device to facilitate service operations. To ensure easy cleaning of the tubes, we recommend a removable box is fitted perpendicular to the cooler axis (not provided). - A safety zone where only authorised personnel are allowed to enter must be set up around the unit. - the biogas circuit connections must be ISO PN10-01A NFEN 1092-1 type flanges with a tanged metal reinforced graphite gasket. RECOMMENDED INSTALLATION Biogas circuit By-pass for maintenance (recommended) Biogas connections using ISO PN10-01A NFEN 1092-1 flanges and tanged metal reinforced graphite gasket 1m Safety zone 1m 1m Elements not provided: : Removable box (recommended) : Coupling for inerting (recommended) : mist eliminator filter (recommended for landfill gas or WWTW) : Shut-off valves (mandatory) 2,2 m 1m Coupling for inerting (standard equipment) 2 heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A
Standard or optional equipment ONE FLEX PLUS Chiller range AQUALIS2+ AQUACIAT2 AQUALIS2+ AQUACIAT2 Cooler Mist eliminator separator Heater cable Condensate drainage by siphon Condensate drainage pump Heater Economiser - - Biogas kit (*) Phase controller kit - - - Potential-free (dry) contacts kit - - - Double pump - - - (from 180 to 300) Chiller coil Polyurethane precoated coils - - - Altena coated coils - - - See range of components Hydraulic module Buffer tank (integrated chiller) (integrated chiller) Pre-charged MEG30 circuit Electrical cabinet Thermal insulation (EPDM anti-uv foam) Aluminium insulation protection : Supplied as standard : Option -: Not available (*) The biogas kit includes: for AQUALIS 2+: crankcase heater - for AQUACIAT2: speed control and control valve. Shell and tube exchangers (description) COOLER HEATER ECONOMISER PRE-COOLER ranges ONE FLEX PLUS ONE FLEX PLUS FLEX PLUS PLUS Nominal diameter (DN) Operating position Support feet Thermal insulation (epdm anti-uv foam) 273 168 to 355 508 273 168 to 355 Horizontal - Vertical - - With - Without - - 355 168 to 355 508 - - - - 508 Tube type Material Connection Ped 97/23 ce Gas circuit Ped 97/23 ce Liquid line Smooth Structured Gas circuit 316L stainless steel 316L stainless steel 316L stainless steel 316L stainless steel Liquid line Carbon steel (1) Carbon steel (1) - Carbon steel (1) Gas circuit Flanges Flanges Flanges Flanges Liquid line Couplings (2) Couplings - Couplings (2) Category Not included in directive Not included in directive Not included in directive Not included in directive PS (bar) 0,5 0,5 0,5 0,5 PC (bar) 6 6 6 6 Category Article 3.3 Article 3.3 - Article 3.3 PS 6 6-6 : Supplied as standard (1) All stainless version as an option. (2) Flange connection larger than DN 273. The pre-cooler is supplied by a drycooler from the OPERA range (see corresponding manual). heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A 3
Mist eliminator separator (description) Material: 316L stainless steel - PED 97/23/CE : PS / PE : 0.5 / 2 bar, not classed within directive. C N2 ØD A N1 B M1"NPT F1/2"NPT 175 200 F1 F2 (4Ø15) = = = = E1 E2 SGMV E1 F1 E2 F2 A B C D N1-N2 L KG 200 298 268 364 344 979 517 350 219 DN100 34 29 250 428 278 514 480 1068 544 350 273 DN150 60 42 350 428 278 514 480 1200 570 350 355 DN200 115 72 400 428 278 514 480 1322 570 350 406 DN250 167 86 500 540 440 606 584 1499 638 350 508 DN350 300 135 600 668 500 734 710 1633 663 500 600 DN400 495 180 700 740 500 806 784 1790 688 500 700 DN450 700 230 800 840 500 906 880 1939 714 500 800 DN500 1000 285 L = capacity in litres - KG = Unladen weight in kg Mist eliminator separator N1-N2: ISO PN10 01A NFEN 1092-1 flanges Basic version Version with siphon Version with pump 8 models can be connected directly to DN DN508 exchangers. Depending on the version, they are comprised of the following elements: ONE FLEX PLUS Stainless steel casing with biogas intake and outlet tubes. High efficiency mist eliminator lagging: used to separate the gaseous flow droplets. High and low level detectors: these control the start and stop of the condensate drainage pump. These optical detectors have an anti-deposition surface treatment which prevents the need for frequent cleaning - checks. They can be easily extracted without opening the separator. Condensate outlet valve. - Drain valve (1" NPT female): this is used to manually drain the condensates contained in the separator. - Siphon. - "Vane" type drainage pump driven by an electric motor: this enables condensates resulting from the separation to be drained under pressure and in complete safety, towards a remote collection point. It is controlled by the optical detectors. - Relief valve: this prevents the separator emptying when the pump stops. - Heater cable: protects the condensate drainage circuit from freezing. - : Supplied as standard : Option -: Not available 4 heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A
Skid-mounted versions (drypack one, drypack flex) ONE and FLEX are delivered as standard with the following components: - Free-standing painted steel frame for outdoor installation, - AQUALIS2+ or AQUACIAT2 water chiller, depending on the model, - Complete hydraulic module with storage tank, circulation pump, expansion vessel, safety valve, charged with MEG 30, - Shell and tube type exchangers (cooler and heater or economiser if applicable), - 316L stainless steel separator with PP mist eliminator and antifreeze tracing. Possible options: condensate drainage by pump or siphon, - Metal electrical cabinet centralising the water chiller, pump supply and antifreeze tracing controls; - Insulation of cold parts (cooler, separator, pipes, condensate drainage). DPO 035 114-20L 050 168-20C 075 219-20C 080 168-20C 090 219-20C 150 219-20C 150 273-20C 200 273-20C Type of biogas Methanisation (1) Biogas flow rate Nm 3 /h 100 150 300 250 400 500 600 750 Intake humidity % 100 Intake temperature C 40 Operating pressure Effective bar 0.02 Outlet dew point C 10 10 10 3 6 3 4 3 Condensates Kg/h 4.8 7.3 14.5 13.0 20.2 25.9 31.1 38.9 Outlet temperature C 10 10 10 3 6 3 4 3 Outlet humidity % 100 Pressure drop mbar 6.1 5.0 5.0 12.9 8.5 12.9 8.6 13.0 MACHINE CHARACTERISTICS Refrigerant R410A Power staging % 100-0 100-50-0 Ambient air C 35 Electrical supply 3-Ph / 400 V / 50 Hz + Neutral Protection IP 44 Average absorbed power (*) kw 2.1 2.9 5.9 6.0 8.3 12.2 14 16.9 Max absorbed power (*) kw 4.2 5.3 7.5 7.2 8.3 13.7 14 17.2 Starting current A 48 64 101 95 111 198 198 143 Max. rated current A 11.6 15.6 20.1 19.1 21.1 35.7 35.7 49.2 Sound level dba 47 45 50 75 75 78 78 79 Max capacity (MEG) dm 3 170 190 210 140 160 210 230 280 Length mm 2578 2578 2578 3300 3300 3300 3300 3300 Width mm 1334 1334 1334 2194 2194 2194 2194 2194 Height mm 1254 1254 1555 1469 1485 1719 1719 2067 Weight (in operation) kg 540 690 810 870 970 1140 1240 1610 H05L HEATER Engine fluid Water or MEG 30% Water flow rate m 3 /h 0.24 0.33 0.65 0.56 0.88 1.11 1.37 1.67 Intake/outlet temperature C 75 / 70 Water pressure drop mbar <5 Biogas outlet temperature C 38 36 36 30 32 30 31 30 Biogas outlet RH % 19 21 21 18 19 18 18 18 Biogas pressure drop mbar 1.7 0.6 0.6 1.7 1.1 1.6 1.1 1.7 WATER CHILLER Size 035 050 075 080 090 150 150 200 Refrigerant oil type Kow Polyolester POE 3MAF (32 cst) Quantity of refrigerant oil L 1.25 1.95 1.77 2.5 3.25 4.14 4.14 6.5 Refrigerant (GWP) R410A (2088) Refrigerant charge (kg) 2.2 2 2.8 3.7 3.9 5.2 5.2 10.5 CO 2 equivalent ton TCO 2 Eq 4.6 4 5.9 7.7 8.1 10.8 10.8 21.9 Chiller type refrigeration unit AQUALIS 2+ AQUACIAT2 (*) - average absorbed power: capacity for the operation conditions given (max data). These values decrease significantly according to the operating conditions (outdoor temperature, biogas temperature and flow rate ). - Max absorbed power: maximum instantaneous capacity of the water chiller during operation. (1) Other type of gas possible - Please contact us heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A 5
Dimensions (drypack ONE and FLEX dpo/dpf 035, 050, 075) HEATER OPTION Biogas intake PN 10/16 flange C A AQUALIS 2+ 2351 110 280 B 500 Transport chocks 125 1500 mini Water chiller air discharge 1284 (4 Ø 14.5) Water chiller air intake 250 Filling 3/4"GAS coupling 2578 1334 2070 580 1416 Water chiller air discharge Condensate drainage pump (option) PVC DN10 «union» connection AQUALIS 2+ Biogas intake PN 10/16 flange Water chiller air intake 851 Filling 3/4"GAS coupling 1183 Condensate drainage 1" NPT sleeve (male) Refrigerant fluid: R410A. Electrical supply: 3-Ph / 400 V / 50 Hz + Neutral. Connections: Biogas intake/outlet: ISO PN10 flanges type 01A NFEN 1092-1. Always use the gaskets provided with your equipment. Post-heater intake/outlet: gas couplings NF NF EN 10226 Condensate drainage (pump option): NPT NF ANSI/ASME B1.20.1 couplings Data for outdoor air 35 C, biogas 40/10 C DPO 035 114-20L DPO 050 168-20C DPO 075 219-20C A mm 667 694 720 B mm 1129 1218 1359 C mm 830 1430 1430 : Cooler intake/outlet : Post-heater intake/outlet DN100 DN150 DN200 1" GAS 1"1/2 GAS 2" GAS Weight (in operation) without heater kg 540 690 810 Biogas flow rate Nm 3 /h 100 150 300 Condensate flow rate kg/h 4.9 7.4 14.8 Pressure drop mbar 6.2 5.1 5.2 Average absorbed power (*) kw 2.1 3.9 5.9 (*) Average absorbed power: capacity for the operation conditions given (max data). These values decrease significantly according to the operating conditions (outdoor temperature, biogas temperature and flow rate ). 6 heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A
Dimensions (drypack ONE and FLEX dpo/dpf 080, 090, 150, 200) C A Face de joint bride entrée refroidisseur AQUACIAT2 Transport chocks 2351 3300 HEATER OPTION Biogas intake PN 10/16 flange 280 110 282 500 B 125 1000 mini Water chiller air intake Water chiller air discharge 2029 (4 Ø 14.5) 2079 209 Water chiller air intake 556 96 484 2138 AQUACIAT2 Condensate drainage pump (option) PVC DN10 "union" connection Biogas intake PN 10/16 flange 525 Face de joint bride entrée refroidisseur Filling 3/4" coupling 1450 2040 Condensate drainage 1" NPT sleeve (male) Refrigerant fluid: R410A. Electrical supply: 3-Ph / 400 V / 50 Hz + Neutral. Connections: Biogas intake/outlet: ISO PN10 flanges type 01A NFEN 1092-1. Always use the gaskets provided with your equipment. Post-heater intake/outlet: gas couplings NF NF EN 10226 Condensate drainage (pump option): NPT NF ANSI/ASME B1.20.1 couplings Data for outdoor air 35 C, biogas 40/3 C DPO 080 168-20C 090 219-20C 150 219-20C 150 273-20C 200 273-20C A mm 694 720 720 747 747 B mm 1218 1360 1360 1472 1472 C mm 1344 1344 1594 1594 1942 : Cooler intake/outlet DN150 DN200 DN200 DN250 DN250 : Post-heater intake/outlet 1"1/2 GAS 2"GAS 2"GAS 2"1/2 GAS 2"1/2 GAS Weight (in operation) without heater kg 870 970 1140 1240 1610 Biogas flow rate Nm 3 /h 250 400 500 600 750 Condensate flow rate kg/h 13.2 21.1 26.5 31.7 39.6 Pressure drop mbar 13.1 8.6 13.1 8.7 13.3 Average absorbed power (*) kw 6.0 8.3 12.2 14 16.9 (*) Average absorbed power: capacity for the operation conditions given (max data). These values decrease significantly according to the operating conditions (outdoor temperature, biogas temperature and flow rate ). heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A 7
This document is non-contractual. As part of its policy of continual product improvement, CIAT reserves the right to make any technical modification it feels appropriate without prior notification. Head office avenue Jean Falconnier - B.p. 14 01350 - Culoz - France tel.: +33 (0)4 79 42 42 42 Fax: +33 (0)4 79 42 42 10 info@ciat.fr - www.ciat.com CIAT Service tel. : 08 11 65 98 98 (0,15 / mn) Fax : 08 26 10 13 63 (0,15 / mn) Compagnie Industrielle d Applications Thermiques - S.A. with a registered capital of 26 728 480 - R.C.S. Bourg-en-Bresse B 545 620 114 Certified Management System 8 heat pumps - AIR CONDITIONING - REFRIGERATION - AIR HANDLING - HEAT EXCHANGE - NA 14.704 A