High-Capacity Cycling Refrigerated Compressed Air Dryer RTM Series
ié~çáåö íüé t~ó áå ^áê mìêáñáå~íáçå As one of the world s leading manufacturers of compressed air purification equipment, Aircel has built a comprehensive engineering, manufacturing, and customer support network to meet the most demanding applications. With over 30 years of expertise in compressed air filtration and separation technologies, Aircel manufactures a complete line of drying and filtration equipment using innovative designs that focus on energy efficient operation and reliable performance. Our refrigerated dryer offering is split into two distinct ranges: Aircel offers a cycling and a non-cycling range of refrigerated dryers to meet all application requirements. Cycling range* RFC Series (200-650 scfm) DVF Series (800-2,000 scfm) RTM Series (2,500-30,000 scfm) Non-cycling range* SD Series (10-40 scfm) VF Series (50-2,000 scfm) AR Series (2,500-10,000 scfm) Aircel RTM Series utilizes high efficiency compressors with defined loading and unloading capacities and a thermal mass medium for storage. The refrigeration system cools the thermal mass medium to a predetermined lower temperature. Once that temperature is reached, the system goes into standby mode until the temperature rises to another predetermined set point. Only then does the system come out of standby mode and once again cools the thermal mass medium. No energy is wasted when demand on the dryer is low. The RTM dryers are ideally suited when large air volumes need to be dried to a reliable and constant dew point. RTM-6000 with optional shell and tube heat exchanger All Aircel dryers are designed to give our customers the best value available in the industry reliable performance to CAGI ADF 100 specification while consuming the lowest amount of energy possible. * For more information on other Aircel cycling and non-cycling dryers, please refer to respective brochures.
qüé fåíéääáöéåí `ÜçáÅÉ Ñçê båéêöó bññáåáéååó Every compressed air system needs an air dryer. Compressed air is one of the most important sources of energy that is widely used throughout the industry. As atmospheric air is drawn into a compressor, water vapor, dirt, particles and lubricants are introduced. During compression, air heats up and is able to hold more moisture. Normally, the aftercooler and moisture separator are used to remove liquid water; however, air remains saturated with water vapor and oil. As air travels through the piping, the vapor condenses and creates corrosion inside the piping. This leads to expensive downtime and failure of equipment. A Aircel high capacity air dryer will always pay for itself by reducing air distribution system costs, lengthening tool life, reducing maintenance downtime and system damage. Most manufacturing facilities have widely varying compressed air demands, depending on production schedules, multiple shifts, break times, holidays and weekends. While air compressors are cycled and loaded/unloaded to match compressed air demand, thermal mass cycling refrigerated dryers also can match the compressed air demands, saving energy and maintenance costs. For high-capacity dryers, cycling, loading/unloading is done by using multiple compressors with specific loading/unloading capacities and using a thermal mass medium for storage. This is achieved by using the refrigeration system to cool the thermal mass medium to a predetermined lower temperature. Once the lower temperature is reached, the system cuts off until the temperature rises to a predetermined upper level before starting again. Therefore, the dryer is not wasting energy when the demand is low, compared to a non-cycling dryer which continues to operate even during lowdemand periods. jééíáåö aéã~åçáåö ^ééäáå~íáçåë 1
How the RTM Series Works Hot saturated air from the aftercooler enters the air/air heat exchanger, where the air is pre-cooled by the cold dry air leaving the heat exchanger. The pre-cooled air then enters the air/glycol heat exchanger, where is it cooled to its final dew point by chilled water/glycol, flowing in the counter-current through the shell. The chilled air passes through the moisture separator, which has a high efficiency of separation at varying flow rates. Condensate is removed from the system without any loss of air via a zero purge drain valve. Finally the cold, dry air is reheated in the air/air heat exchanger by the incoming hot air for maximum volumetric efficiency before exiting the dryer. The water/glycol is chilled by a cycling refrigeration system, and continuously pumped through the shell side of the air/glycol heat exchanger. The glycol flow rate remains constant, regardless of compressed air load. The refrigeration compressor unloads, and/or cycles OFF, when a pre-set temperature is reached for the water/glycol, thus minimizing electrical power consumption. Air Outlet Pre-Cooler/Reheater Air Inlet Moisture Separator Air-to-Water/Glycol Heat Exchanger Defroster Solenoid Valve Evaporator Condenser Compressor Suction Accumulator Isolation Valves Standard Features Condenser automatic water regulating valve Inlet temperature indicator Outlet temperature indicator Refrigeration discharge pressure gauge Refrigeration suction pressure gauge Compressor sequencer (for units with multiple compressors) Equipment Options Duplex pumps Multiplex compressor Air-cooled condenser Compressor ON/light indicator Air inlet pressure gauge Air inlet temperature gauge NEMA 12 electrical Zero-purge drain system Pump pressure gauge Thermal storage temperature gauge Remote condenser Compressor sequencer Three-valve by-pass Pump Cold Bank Storage Phase protection module High-temperature module Pump failure indicator No flow indicator Compressor starter with overload protection Mounted pre- and afterfilter Digital dew point monitor NEMA 4, 7 2
nì~äáíó `çãéçåéåíë Ñçê aéééåç~äáäáíó Compressor As an industry leader in compressed air drying technology, Aircel uses high efficiency scroll compressors, semi-hermetic compressors, and rotary screws for all high-capacity dryers providing extra reliability and more energy savings Heat Exchangers Aircel s high thermal efficiency stainless steel plant heat exchanger and ASME-stamped shell and tubetype pre-cooler/reheater and air-to-water/glycol heat exchangers are designed for low pressure drop and maximum performance. Separator High efficiency centrifugal separators and integrated stainless steel separators eliminate moisture from the air system. The unique design of the separator removes 99% of the water droplets with no mechanical movement and maintenance. Condensers Aircel s high-capacity dryers are built standard with air-cooled (2500-5000 scfm) or water-cooled (6000 and up scfm) condenser and automatic water regulating valve (remote air-cooled condenser option). Demand-Activated, Zero-Purge Condensate Drain One of the important components of the dryer is the discharge of the condensate, which has been removed from the compressed air supply. Aircel s zero-purge drain system automatically discharges contaminated condensate from compressed air systems. Centrifugal Pump High efficiency close-coupled centrifugal pump with back flow preventer and no flow shutdown provides reliable performance. Allen-Bradley PCL Controller PLC controller with panel view (300 standard) Energy saving indication Dryer status text display Adjustable cycle time Refrigeration compressor loading/unloading indicator Compressor run indicator Compressor off indicator Compressor sequencer (for multiplex option) Pump sequencer (for multiplex option) Alarm indicator Common alarm dry contact for customer remote Communication port (option) Temperature indicator for refrigeration suction, discharge, evaporator, and water/glycol Dryer hour meter indication Energy saving hour meter indication 3
Dimensions & Specifications Model Capacity @ CAGI* (cfm) Capacity @ ISO** (cfm) Connection (inches FLG) HP Installed (size) KW (full load) Dimensions (inches) Voltage for CAGI for ISO conditions conditions RLA MCC (Standard) Height Width Depth Pressure max. (psig) RTM-2500 2500 2950 4 13 9.70 9.00 25 41 460-3-60 60 55 4 150 2750 RTM-3000 3000 3540 6 2 x 7.5 11.84 11.00 32 48 460-3-60 70 130 6 150 3200 RTM-4000 4000 4720 6 2 x 10 14.90 13.90 42 62 460-3-60 70 130 6 150 4500 RTM-5000 5000 5900 8 2 x 13 19.36 19.00 50 82 460-3-60 75 130 8 150 6300 RTM-6000 6000 7080 8 30 22.40 20.10 50 70 460-3-60 90 130 8 150 7200 RTM-7000 7000 8260 8 35 26.00 24.20 66 92 460-3-60 90 130 8 150 8600 RTM-8000 8000 9440 10 40 29.84 27.80 70 98 460-3-60 90 140 10 150 9750 RTM-10000 10000 11800 10 50 37.28 34.63 91 127 460-3-60 95 160 10 150 12000 RTM-12000 12000 14160 12 60 44.74 41.60 96 135 460-3-60 106 170 12 150 13600 RTM-15000 15000 17700 12 2 x 40 59.70 55.50 140 196 460-3-60 109 180 12 150 17000 RTM-20000 20000 23600 14 2 x 50 74.60 69.40 182 254 460-3-60 120 190 14 150 21000 RTM-25000 25000 29500 16 125 93.20 96.60 178 250 460-3-60 126 210 16 150 23000 RTM-30000 30000 35400 18 150 111.84 104.00 192 270 460-3-60 126 240 18 150 26000 * Capacity rated in accordance with CAGI ADF 100 @ 100 psig, 100 F inlet,100 ambient, and a PDP of 38 F ** Capacity rated in accordance with ISO 7183 @ 7 bar (101.5 psig), 35 C (95 F) inlet, 25 C (77 F) ambient and a PDP of 3 C (37.4 F) Run Load Amps (RLA); Mimimum Circuit Capacity (MCC) Weight (lbs) Protection for your Investment To protect your investment, we recommend that you install a high performance prefilter directly in front of your dryer. By doing this, you will not only ensure trouble-free operation for years to come, but also ensure that the dryer will operate at its highest efficiency rating throughout its lifetime. Recommended Prefilters & Afterfilters* Housing Model Number Capacity 1 (scfm) Connection (FNPT/ANSI) SH0255STD 2550 4 FLG SH0355STD 3550 6 FLG SH0450STD 4550 6 FLG SH0685STD 6850 6 FLG SH0920STD 9200 8 FLG SH1200STD 12000 8 FLG SH1550STD 15500 10 FLG SH2200STD 22000 10 FLG To make the selection easy for you, Aircel has matched a filter range to the refrigerated dryer offering in connection size and flow rate. The fine coalescing filter is ideally suited for general applications and combines excellent efficiency with a very low differential pressure due to its patented binder-free media. 1 Capacity based on 100 psig inlet pressure. Standard SH filter housings include an Economizer differential pressure gauge and float-type condensate drain (not shown). Superplus filter housings with an Economizer differential pressure gauge and Ultramat (UFM-T) zero air-loss condensate drain valve are available as options. * For more information on Aircel housings and industrial filters, please refer to respective brochures. 4
Capacity Correction Factors RTM The leading manufacturers of compressed air and gas equipment in North America are organized in the Compressed Air & Gas Institute (CAGI). As the premier industry organization, CAGI has developed standards to protect users of this equipment. ADF 100 is the current standard for refrigerated compressed air dryers. ADF 100 specifies the dryers performance to be rated at 100 F inlet temperature, 100 F ambient temperature, and 100 psig system pressure. To adjust the dryer capacity from these CAGI conditions to your specific application, please use the correction factors below for differing ambient air temperatures (C1), inlet air temperatures (C2), system pressures (C3), and varying dew point requirements (C4). Capacity correction factors for differing ambient air temperature (C1) Ambient Temperature ( F) 70 80 90 100 110 115 120 Correction Factor 1.10 1.07 1.05 1.00 0.94 0.85 0.65 Capacity correction factors for differing inlet air temperature (C2) Inlet Temperature ( F) 80 90 100 110 120 140 Correction Factor 1.50 1.21 1.00 0.82 0.72 0.61 Capacity correction factors for differing system air pressure (C3) System Pressure (psig) 50 75 100 125 150 175 200 225 250 Correction Factor 0.85 0.95 1.00 1.07 1.13 1.18 1.20 1.22 1.24 Capacity correction factors for differing pressure dew point requirements (C4) Dew Point ( F) 38 41 45 50 Correction Factor 1.00 1.12 1.17 1.22 To Size the Dryer Capacity for Actual Conditions Adjusted Capacity = scfm x C1 x C2 x C3 x C4 To calculate the capacity of a given dryer based on non-standard operating conditions, multiply the standard capacity by the appropriate correction factor(s). EXAMPLE: Dryer Model: RTM-600 Standard Capacity: 6000 cfm Actual Operating Conditions: 90 F ambient temperature: C1 = 1.05 100 F inlet temperature: C2 = 1.0 125 psig working pressure: C3 = 1.07 38 F required dew point: C4 = 1.0 Adjusted Capacity = 6000 scfm x 1.05 x 1.0 x 1.07 x 1.0 = 6,741 scfm To Select the Dryer Model for Actual Conditions Adjusted Capacity = scfm/c1/c2/c3/c4 To choose a dryer based on a given flow at non-standard operating conditions, divide the given flow by the appropriate correction factor(s). EXAMPLE: Given Flow: 5000 scfm Actual Operating Conditions: 80 F ambient temperature: C1 = 1.07 90 F inlet temperature: C2 = 1.21 100 psig working pressure: C3 = 1.0 Required dew point : 38 F pdp: C4 = 1.0 Adjusted Capacity = 5000 scfm / 1.07 / 1.21 / 1.0 / 1.0 = 3861 scfm Selected Dryer Model: RTM-4000 5
AirCel Trust Aircel Compressed Air & Gas to deliver a complete range of compressed air purification solutions that improve air quality throughout your plant - from the compressor room to all points of use. With over 30 years of expertise in compressed air filtration and separation, Aircel manufactures a complete line of drying and filtration equipment in an innovative, cutting-edge design with energy efficient operation and reliable performance to increase your productivity and lower your operating cost for the air volume that fits your needs. Aircel Compressed Air & Gas offers a wide variety of solutions to reduce your energy costs, improve your productivity, guarantee production quality and help preserve the environment. PRODUCTS Activated carbon filters Adsorption dryers Breathing-air purifiers Cartridge filters Chillers Condensate drains Coolers Cyclone separators Demisters Disposable filters Elements Emulsion separators Filters Fine filters Filter housings High-performance filters High-pressure filters Medical vacuum filters Membrane dryers Oil/vapor absorbers Oil/water separation systems Pre-filters Pre-separators Process filter elements Process filter housings Pure gas filters Refrigeration compressed air dryers Silicon-free filters Steam filters Sterile filters Submicro filters Systems engineering System solutions Vacuum filters Vent filters ^áêåéä `çêéçê~íáçå POP `êáëé `áêåäé j~êóîáääéi qk PTUMN qéä UMMKTSTKQRVV Erp^F qéä USRKSUNKTMSS EiçÅ~äF c~ñ USRJSUNJTMSV p~äéë ë~äéë]~áêåéäåçêékåçã iáíéê~íìêé äáíêéèìéëí]~áêåéäåçêékåçã ïïïk~áêåéäåçêékåçã fåñçêã~íáçå áå íüáë ÇçÅìãÉåí áë ëìäàéåí íç ÅÜ~åÖÉ ïáíüçìí åçíáåék «OMMT ^áêåéä `çêéçê~íáçå mêáåíéç áå rkpk^k çå êéåóåäéç é~ééê _ìääéíáå kçk rcp_mnpq oqj MNJMT