Compressed air treatment Refrigerated compressed air www.newgatetechnologies.com dryers Totally Integrated compressed air treatment system
Why invest in compressed air treatment? Investment in compressed air treatment pays huge dividends More than ever, pure, clean dry compressed air for manufacturing and general industry is no longer considered an option, rather a necessity in today s modern manufacturing environments. However, there are still misconceptions about how investing in a quality compressed air treatment system can be beneficial. Listed below are some examples illustrating how a contaminated, untreated compressed air system can affect your operations. compressed air treatment Maintenance costs: Properly treated compressed air, free of contaminations, reduces maintenance costs and enhances the life of all pneumatic equipment and tools, and typically doubles or triples their useful life. No other single preventative measure can deliver such significant cost savings or improvement in performance in your plant. Production stoppages: By minimizing maintenance time and associated costs, treatment of compressed air makes it possible for you to achieve productivity gains by eliminating unexpected stoppages in your manufacturing processes. Power consumption: The presence of contaminants in compressed air alters the physical and chemical characteristics of compressed air and reduces the performance and reliability of pneumatic equipment by up to 40%. Rejection of products and services: Contaminated compressed air compromises final product quality, resulting in product rework of as much as 15%, and effects production through put. It can affect long term product durability and performance. As an example, quality painting is now considered a critical necessity even for industrial products; it has become a high focus QC item for all manufacturers in today s competitive environment. The repainting of products as a consequence of oil and water contamination of the paint results in millions of dollars in rejects and rework annually in the USA. When treated in accordance with international quality standard ISO-8573, the estimated average savings are 3 per 100 scft of air used. This estimate includes installation, operation, maintenance and depreciation costs for compressed air treatment systems as recommended on page 7 for ISO-8573-1.4.1. How to treat compressed air Compressed air quality is governed by the international quality standard ISO-8573-1. This standard is described in detail on page 7 of this brochure. This quality standard recommends the use of a pre-filter and an after-filter along with the dryer, as illustrated hereunder: Other internationally recognized agencies such as CAGI, PNEUROP, and ISA similarly recommend the use of a pre-filter and after-filter in conjunction with the dryer, clear evidence of the importance of these components. Essential components of a compressed air treatment system: Compressor 1 -Aftercooler 2 -Coalescing 3 -Refrigerated 4 -Coalescing Application Pre-filter Dryer After-filter
A New revolutionary product Integrated compressed air treatment center Integrated pre-filter and cold coalescing after-filter with dual electronic drains 3in 1 Coalescing Pre-filter Removes aerosols from the aftercooler and protects the heat exchanger of the dryer against oil and contaminants from the compressor. Refrigerated Dryer Cools the compressed air down to the temperature of 36 F - 39 F making it possible for the condensation of most water vapor. Cold Coalescing After-filter Removes up to 99.99% of the remaining aerosols and assures a dew point of 36 F - 39 F. It is the most important feature of the EnergyPlus dryer series. What is the big difference Only a cold coalescing filter removes aerosols and assures a dew point of 36 F - 39 F at all flow rates. Volume of Condensate 1 MDR Energy High-Efficient Coalescing with Borosilicate Microfibers (D.O.P.= 99.99%) 2 Centrifugal Mechanical Separators 3 Demister Type Separator 4 Inertia Impaction Separator? THE POWER OF COLD COALESCING -WORKS WERE MOST CONTAMINANT IS IN LIQUID FORM - 75 TIMES LESS OIL CONTAMINATION - MOST EFFECTIVE IN AEROSOL CAPTURE AND REMOVAL - HIGH SEPARATION EFFICIENCIES AT ALL FLOWS - CONSTANT LOW DEW POINTS - LOW SYSTEM PRESSURE DROPS - SIGNIFICANT ENERGY SAVINGS At any temperature, aerosols make up 30% of the liquid contamination in the air*. Aerosols do not respond well to inertial separation because of their small mass. Only a fine coalescing effect is capable of removing aerosol contamination. NewGate dryers have an integrated fine coalescing filter strategically placed at the point of lowest air temperature in the dryer, just before the compressed air is heated again in the reheater. This ensures removal of all condensate including aerosols which could otherwise escape into the air stream and reevaporate, raising its dew point. Conventional Centrifugal mechanical type and/or Demister type separators used in competitive brand dryers do little to remove aerosols, as illustrated in the adjacent chart. Additionally, the efficiency of Separators 2, 3 and 4 is based on air velocity. At lower than design air flows, their efficiency drops off drastically, resulting in liquid re-entrainment, re-evaporation and dew point deterioration. Pleated Elements for Ultimate Life and Performance Integrated Cold Coalescing 3
37 F MDR Energy Dryer 70 F 4 gals Water Vapor 250 F 90 gals Water Vapor Coalescing Pre-filter 100 F 33 gals Water Vapor 37 F Real Dew Point 29 gals Condensate Compressor Aftercooler 37 F Competitors 70 F 13 gals Water Vapor 57 gals Condensate Typical 500 scfm system at 100 Psig (Inlet of 75 F and 75% RH) Inefficient separation 20 gals Condensate 70 F Real Dew Point Inlet All NewGate MDR Energy dryers incorporate a cold coalescing filter located at the coldest point of the system. Coalescing Pre-filter 1 micron Outlet High performance coalescence NewGate s pleated element tolerates higher levels of flow and contamination. The coalescing pre-filter is rated for 1 micron particle removal and 0.05 ppmw oil removal. The cold coalescing filter is rated for 0.01 micron particle removal and 0.001 ppmw oil removal. Coalescence is the combining of small drops of aerosols (< 0.3 microns) into bigger drops to a point where these large drops, due to their large mass, drain by gravity to the filter bottom. Direct interception (> 1 micron) Inertial impaction (0.3 to 1 micron) Diffusion & coalescence (< 0.3 microns) Electronic Drain Pre-cooler/Re-heater (air x air exchanger) The microfibers of borossilicate, which create the coalescence effect, are microscopic fibers of glass. They are totally impermeable to oil and water, and continuously repel them. Refrigeration Circuit Evaporator (air x refrigerant exchanger) Therefore, the life of a coalescing filter is solely determined by the amount of solid contaminant that can be held by the filter media. NewGate s pleated filtering elements offer the following advantages: Pleated Cold Coalescing After-filter 0.01microns Electronic Drain 8 to 22 times more filtering area than conventional non-pleated elements with the same dimensions Much higher flow capabilities Longer element life Consistent performance even with flow fluctuations between 20% and 120% of nominal flow Extremely low pressure drop Conventional 4
Why MDR ENERGY? Because the MDR Energy dryer design translates directly into operational efficiencies and electrical cost savings. The unmatched energy performance of the MDR series dryers is achieved because of these design features: Monobloc, 100% copper heat exchanger designed without any internal joints ensures you ll never experience an internal leak and delivers a lifetime of performance. 5 Year Warranty! Efficient utilization of the refrigerant gas due to it s superior circulation and flow path, combined with the exceptional heat transfer properties of 100% copper. Refrigerant The MDR dryer has an extremely low air side pressure drop through the Monobloc heat exchangers; our design eliminates the traditional elbows, unions, joints and tortuous flow paths common to most heat exchangers today. High energy cost of pressure drop Electrical power savings Understanding the relationship between pressure drop and energy consumption will allow you to make decisions that most impact your operating costs. As a rule of thumb, for every 1 psi of system pressure drop you increase your electrical cost by 1/2%. Remember that your air compressor utilizes more than 95% of the total energy required to run your entire compressed air system. Lowering the system pressure drop will therefore have more significant impact on your energy savings than any other measure. All MDR Energy dryers have a max 4.5 psig system pressure drop, including the internal cold coalescing filter. This is typically 1/2 that of our competitors. Cycling compressors Large MDR Energy dryers come with additional standard power saving options. Models MDR3000 and above incorporate multiple refrigerant compressors, allowing the dryers to cycle on and off based on compressed air demand and load. The resultant energy savings can be significant. Ask us about your application. World class refrigeration compressors; parts and services available world wide. MDR Energy dryer series offer 3 types of control panels, depending on the dryer model: Logic, Energy & Master Control From the basic Logic analog controller up to and including the electronic sophistication of the Master Control, all electrical controllers offer you the information and controls you need and expect to operate the dryer. Dryer flow schematic LED to indicate change-out requirement of integrated filters Test drain button Power on indicator Digital indication of four main temperatures Remote start/stop & dryer status Communication serial port Easy maintenance Fast, practical and easy access for cold coalescing filter change-out results in simplified maintenance. Monitoring & shutdown annunciation of: - high/low refrigerant temperature - high/low refrigerant pressure - high inlet & ambient temperatures - filter change-out - energy saving mode - compressor overload - low compressor oil pressure Password protection of control panel Built-in hour meter Full cabinet for all models is standard. Small footprint & quad hook-up Our vertical design requires less installation space, typically 1/2 the footprint. We also offer 4 options for air inlet/outlet connections, called quad hook-up on Models MDR-1600 and above, a huge installation and cost savings benefit. These two great features simplify and reduce contractor installation costs. 5
Safety and Reliability MDR Energy dryers are designed for top rated performance even in TROPICAL CLIMATES, in accordance with ISO-7183 option B standards. This ensures that these units will perform and maintain dew points even in the toughest conditions and high ambients encountered during the summer time. MDR Energy dryers use only environmentally friendly refrigerants approved by EPA such as R22, R134a and R404a. Electronic leak detectors used during the manufacturing of these units assure years of trouble free operation. MDR EnergyPlus dryers incorporate factory engineered and installed coalescing pre-filter and cold coalescing filter as standard. Compare this to conventional competitive units with the added costs of field installed filters. 5/2/1 WARRANTY All MDR Energy dryers are warranted to be free from defects in material and workmanship for a period of 12 months from start-up, not exceeding 18 months from shipment. NewGate Technologies also extends this 1 year limited warranty for a 2nd full year on major components. To qualify, customers must return the Certificate of Extended Warranty directly to the factory. All MDR Energy MONOBLOC heat exchangers come with a 5 YEAR warranty. Built-in Pre- Dryer Built-in Cold Coalescer 1,2,3 Flow Scfm Connection Inches NPT Dimensions (inches) Length Height Width Power (W) EA20U MDR-020 EA20H 20 3/4 22 20 13 300 EA20U MDR-040 EA20H 40 3/4 22 20 13 500 EA30U MDR-060 EA30H 60 3/4 22 29 13 650 EA30U MDR-080 EA30H 80 3/4 22 29 13 650 EA55U MDR-100 EA55H 100 1 22 39 14 1450 EA55U MDR-125 EA55H 125 1 22 29 14 1450 EA55U MDR-160 EA95H 160 1 22 47 14 1450 EA95U MDR-200 EA150H 200 2 31 50 19 2400 EA95U MDR-250 EA150H 250 2 31 50 19 2400 EA95U MDR-300 EA220H 300 2 40 66 21 2200 EA150U MDR-400 EA220H 400 2 40 66 21 2900 EA220U MDR-500 EA220H 500 2 40 66 21 3500 MDR-600 EA290H 600 4 FLG 58 83 22 3800 MDR-800 NGT01045H 800 4 FLG 58 83 22 4930 MDR-1000 NGT01045H 1000 4 FLG 62 83 22 5800 MDR-1250 NGT01045H 1250 4 FLG 68 83 22 6400 MDR-1600 CF 1600 4 FLG 61 99 24 8130 MDR-2000 CF 2000 4 FLG 70 99 24 10700 MDR-2500 CF 2500 4 FLG 80 99 24 13410 MDR-3000 CF 3000 6 FLG 61 99 39 16220 MDR-4000 CF 4000 6 FLG 70 99 39 21340 MDR-5000 CF 5000 6 FLG 80 99 39 26800 MDR-6000 CF 6000 8 FLG 61 99 57 26900 MDR-8000 CF 8000 8 FLG 70 99 75 37000 MDR-10000 CF 10000 8 FLG 80 99 75 45800 External Optional Standard Standard Standard Voltage Condenser 4 5 460/3/60 230/1/60 115/1/60 Air Cooled Standard / Water Cooled Available Air Cooled Control Panels Logic Energy Master Control Control Standard Standard Standard 6 1. Design inlet temperature of air:100 F Maximum inlet temperature of air:120 F Design ambient temperature:100 F Maximum ambient temperature:110 F Do not exceed maximum values specified above. www.newgatetechnologies.com 2. Capacity in Scfm is at 100 psig inlet pressure, 100 F inlet temperature and 100 F ambient temperature (air cooled) and 86 F (water cooled).! 3. Maximum working pressure: 180 psig (MDR-010 to MDR-1250) 150 psig (MDR-1600 to MDR-10000) High pressure units to 600 psig available, contact NewGate. 4. Also available in 50Hz version. 5. Water cooled models: water flow requirement is around 1.8 gpm for each 100 Scfm of compressed airflow. Dryer capacity should be corrected if actual operating conditions are different than the design conditions stated above. Please contact NewGate Technologies for correction factors. The average life of any filter element is mainly dependent on the size and concentration of contaminants passing through the element, besides other less important variables. The estimated 4000 hour life of our filter elements is basis the normal contamination encountered in a typical industrial application. Naturally, conditions other than standard will affect element life. Therefore, every MDR Energy Plus dryer offers a LED filter element change-out indicator as standard. This LED indicator works basis real time pressure differential across the element, contrary to most conventional competitive dryers, which use an electronic timer instead.
Quality Standards and Applications Choosing the right product for a specific application ISO-8573 Class Application Rotary Compressor screw, vane, etc. 1.7.1 General use: protection of valves, cylinders, air guns, painting systems, pneumatic tools, automation, sandblasting, etc. Note: Air is clean but not dry in this scenario. Check applications for air quality requirements. Reciprocating Compressor Water Cooled Aftercooler Air Cooled Aftercooler MDR Refrigerated Dryer NPS Desiccant Dryer C Grade 1.4.1 1.4.1 2.2.1 2.1.1 Typical requirement for most industrial applications. Due to its protection level, this treatment system is most ideal for automotive, paper, plastics, textile and other general manufacturing industries. Air quality similar to the above system, but with the additional elimination of odors, taste; less residual oil carry over. 0 2 and N 2 generation, inhalation without the elimination of CO and CO 2 and for food, chemical and pharmaceutical industries, among others. For applications where the air is in contact with the product. Examples: cement, food, grain, pharmaceutical, etc. where the risk of absorption of water vapor in the product is not permissible. Also, any application where the operating environments are below freezing. Dew points to 40 F. 1.2.1 1.1.1 Highest air quality standard where the demand for lowest dew points is required, down to 100 F. Applications such as electronics, fiber optics, film processing, integrated circuits, medical, nuclear power plants, etc. ISO-8573-1 Quality Standard* Quality Class Maximum Particulate Pressure Maximum Oil Size, microns Dew Point, F Residual, ppmw 1 0.1-94 0.001 2 1-40 0.01 3 5-4 0.1 4 15 +37 0.5 5 40 +45 2.5 6 -X- +50 -X- 7 -X- not specified -X- *1991 7
Why NewGate Technologies? Over the last decade and a half, NewGate and its affiliates worldwide have produced more than thirty thousand dryers and related equipment for the treatment of compressed air, making us a global leader. Our products are installed in facilities of all sizes, from small industry to large automotive and petrochemical industries. Through our global alliances, we sell and service products all over the world, most significantly in North and South America. A large pharmaceutical company; 25,000 Scfm of clean and dry air. Refrigerated Dryers compressed air Our equipment is designed, produced and tested in accordance with the rigorous ISO-9001 Quality standards, assuring our customers a world class quality product. We have testing facilities for the analysis of filtration products and drying equipment per ISO-7183 standards, and can analyze air quality to ISO-8573. We incorporate only brand name components sourced directly from major manufacturers in all of our products. This ensures quality and enhances longevity and reliability; most importantly, it assures easy parts availability to our customers. And to support all of this, we have a customer service group which is second to none, YOU CAN COUNT ON US! That s why, when it is time to decide, don t take any chances. Choose a NewGate Technologies product or service - it will be a decision you will not regret! N E W G A T E T E C H N O L O G I E S, I N C. w w w. n e w g a t e t e c h n o l o g i e s. c o m 1 1 3 7 S W 7 T H R O A D O C A L A, F L O R I D A 3 4 4 7 4 T E L : ( 3 5 2 ) 3 5 1-9 9 9 2 F A X : ( 3 5 2 ) 3 5 1-9 9 7 9