ENERGY $AVING COMPRESSED AIR/GAS & WATER COOLING SYSTEMS SELECTION & SIZING GUIDE Representatived By = eS (£2oor hic systoms.. Visit : www.pioncerair.com * Toll Free : 1- 800-264- 1AIR(1247) E-mail : sales@pioncerair.com ¢ Fax : (423)-346-3865, NEnergy Efficient Compressed Air System ea is. ll. |(@)AUTOMATIC DRAIN < 4 ‘ , 4 At og @ "3 Components Functions 1. Compressor - Compresses atmospheric air into a useful and versatile utility. During the process, lubricants are commonly added. If not removed, dirt, oil and moisture will flow downstream, causing maintenance problems, product rejects, and costly production shutdowns. 2. After Cooler - Condenses over half of the moisture. 3. Separators - Separates condensed liquids. 4. Automatic Drain - Automatically drains condensate, 5. Receiver - Provides storage for compressed air. 6. Pre-filter- A Coalescer (or a Particulate and a Coalescer, in case of heavy oil concentration) used as Pre-filter, removes particulates and oil aerosols. 7. Dryer - Condenses and removes moisture. 8. Cold Coalescer - Condenses/removes most oil vapors. 9. Carbon Adsorber - Removes remaining oil vapors. 10.After Filter - Removes particulates. 11.Aqua Saver or Cooling Tower or Chiller or Hybrid Cooling Systems - Provides required cooling. ef ‘so Bim [How Much Moisture? |. At 75° F (23.9°C) and 75 % relative humidity 2500 SCFM (850 nm3/h), air compressor takes in approximately 90 gallons (340.6 liters) (of water in vapor form. After Cooler & Separator remove approximately ‘58 gallons of moisture by cooling air to 100" F G78'C). Remaining moisture ~ 32 gallons. 33. A Reftigerant or Super Deliquescent Dryer removes approximately 28 gallons of moisture Remaining moisture - 4 gallons 44. A Regenerative Dryer rated for -40°F (-40° C) removes approximately 31.2 gallons of moisture. Remaining moisture - 0. 8 gallons. 15. A Regenerative Dryer rated for -80F (-62 C) removes approximately 31.99 gallons of moisture. Remaining moisture - 0.01 gallons ~ VIRTUALLY MOISTURE FREE AIR. ‘Multiple Compressors Save Energy= (Compressors run most efficiently at full load. (Therefore, to meet your compressed air needs, itis better to select two or more compressors, allow one {compressor to run partially loaded and other (3) to loperate at full lond Lower Pressure Drop Saves Energy |An increase of 2 PSIG in air pressure, increases lenergy use by 1%, To reduce energy cos 'a. Design air system for minimum pressure loss, jb. Change filter elements at regular intervals- once in every 3 to 6 months. 2 “Custom Engineered Systems Are Our Specialty”Selection & Sizing - Compressed Air Equipment ESTABLISH- 1. The required compressor capacity (flow) in SCFM (or NM3/Hour)- A. Walk through your facility and make a list of the items (tools, instruments, machinery, blow-gun etc.) that use compressed air. B. Determine the total air capacity (SCFM or NM3/Hour) required, taking into consideration the air losses, the equipment you expect to add and with a 10-20% margin of safety. 2. The maximum air pressure (PSIG or Bar) required- Take into consideration the pressure drop through the piping system, dryer(s) and filter(s) Generally 10-20 PSIG over the maximum pressure required at a point of use is satisfactory. 3, The "QUALITY" of air required- A. Maximum (acceptable) Moisture Content or Pressure Dew Point B. Maximum (acceptable) Oil Content C. Maximum (acceptable) Particulate Concentration 4. Review ISO Standards to select proper equipment- MAXIMUM MAXIMUM ‘MAXIMUM MOISTURE, OL. PARTICULATE CONCENTRATION CONCENTRATION CONCENTRATION ISO] Pressure | Pressure [mein] Meso [Mgset [PPM AW] PPM/W PMaximun) mgm | ojscp Quality | Dew | Dew | @o} @o |f@ioo | @o | @ioo | Panicle} @o | Zig air | Point | Point | psig} psi |psic | psic | psig | siz | PSIG | bei Class # *E in Micron 1 : -34°F | 0.01 | 0.00028 |0.000036] 0.0083 | 0.00106 | 0.1 | 0.10 | 0.0036 2 ec | oF | 0.1 | 0.00283 | 0.00036 | 0.083 | cores | 1 1 | 0.0036 3 20c | 4 1 | 00238 | 0.0036 | 083 | o.to6s | 5 5 | oo1s 4 sc | arr | 5 042 | oois21 | 4.16 Is 8 | oo 5 src | +44er- | 25 | 0.708 | 0.09769] 208 | 2665 | 40 10 | 0.036 NOTES: 1, The contaminant limits stated above are for "Standard Air" (at 68° F / 200 C, 0 PSIG or 14.7 PSIA/ 1.01 Bar, 36 % Relative Humidity, and Density of 0.075 Ibs./cu. ft); however, the air quality is expected to meet the standards at the operating pressure. 2. For customer convenience, Pioneer offers custom engineered, single skid, pre-piped and pre-wired systems, complete with compressor (s), dryer(s), filtration and drains. “Nonstandard Equipment Is Our Specialty” 35, Equipment Selection Guide- 180 AIR COMPRESSOR AFTER DRYER | FILTRATION Standard aes COOLER \ Class 1 | Non-Lubiieaied or, “Lbricaied Tie aftercooler | Regenerative 1 Coalescer Pre= | Compressors with proper Oil Acrosol | may be Airor | Blower Purge. e.g. | filter for dryer. | (Coalescers) and Oit Vapor Removal | Water cooled | PIONEER PHED Series, | Particulate After | (Carbon Adsorbers) equipment. For more | depending on the | -100°F(-72°C) PDP: or, | Filler for dryer, | stitical applications lke Food and satisfactory Hybrid, eg., PIONEER | Carbon Adsorber Pharmaceitical Industry, for safety availability ofthe | HDS Series, -100° (-72° | for Oit Vapor | reasons, more expensive Non-Lubricated | cooling sources- | C) PDP: based on cost | Removal (vith | Compressors arethe equipment of choice. | Airor Water, | analysis. | Lubricated | The Compressors may be Air or Water | location and cost Compressors | Cooled, depending on the satisfactory | factors. | onty) and 0.01 availability of the cooling sourees - Air or | Micron Final | ‘Water, location, and cost factors. | Fite | Class?) Wen-Cabeicaed or, “Lubricated “The aftercooler | Rogenerative- Coatescer Pr | Compressors with proper Oil Aerosol | maybe Air or | Blower Purge, filer for deye, | (Coalescers) and O11 Vapor Removal | Watercooled | eg, PIONEER PHEB | Paniculate After | (Carbon Adsorbers) equipment. For more | depending onthe | Series 60°F (51°C) _ | Filter for dryer. ctitcal applications like Food and satisfactory PDP: or, Hybrid, eg. | Cathon Adsorber Pharmaceutical Industry, for sfety availabilty ofthe | PION for Oil Vapor reasons, more expensive Non-Lubricated | cooling sources- | HDS Series /-60F (1° | Removal (vith Compressors are the equipment of choice. | Airor Water, | C)PDP: or, Heatles. | Lubricated ‘The Compressors may be Air or Water | location and cost | eg, PIONEER PHL | Compressors Cooled, depending on the satisfactory | factors, Series /-60°F (31°C) | onlyyand 0.1 | availability ofthe cooling sourees- Air or PDP based on cost | Micron Final Water, lcation, and eas ctr analysis. Filer Class 7) Fabricated Compressors with proper OT | The aller cooler | Reenerative: Blower | Coalescer Pre AAcrorol (Coalescers) Removal equipment. | maybe Airor | Purge.eg. PIONEER filter for deyer and For mare critical applications tike Food| Water cooled | PHEBS Series/-10"F | Particulate After and Pharmacetiea Industry, fo salty | depending on the | (40°C) PDP; or Hybrid, | Fier for dryer. | reasons, more expensive Now-Lubricated | satisfactory PIONEER HDS Series! | Comprstrs are the equipment of Choke. | avabiy othe | A0°F (AOC) PDPor, ‘The Compressors may be Ait or Water | cooling sources- | Heatless, PIONEER Cooled, depending onthe satisfactory | Air or Water, | PHL Series 40°F (40° svailablity ofthe cooting scurees- Air or | locaton and cost_ | C) PDP: based on cost | Water, eation, and cos ators factors. analysis | Gass, “Lubricated Compressors with proper Oi | The ater cooler | Refrigerant Dryers | Preter | Aerosol (Coatecers) Removal equipment. | may be Airor | For Compressors with | removes il and For more eritial applications like Food| Water cooled | After Coolers. Series | diet and keeps | Ciass6 | and Pharmaceutical Industry, for safety | depending an the | (Non Cycling) or CC | dryer heat Feasons, more expensive Non-Labricated | satisfactory Series (Cyeling- for | exchangers clean | ‘Compressors are the equipment of choice. | availabilty ofthe | eneruy savings). For | t@ provide reliable | ‘The Compressors may be Ait or Water | cooling sources- | Compressors without | performance. A | Cooled, depending on the satisfactory | Airor Water, | Aer Coolers PIONEER | availability ofthe cooling sourees- Air or | locaton and cost | PIONEER. ADR Series | reftgerant dryer Water, location, and cost cts factrs (Non Cyeling) or CC | with cold | | Series (Cycling: for | caalescer provides | deel | eneray savings) | nearly oil free i Caution: * For Food, Pharmaceutical and similar application, food grade lubricant shall be used. “Custom Engineered Systems Are Our Specialty”Regenerative Dryers Operation Cost Comparison A. Heatless Dyer (13-15 % Purge Los: Minimum required compressor capacity 100 SCFM Purge Loss = 0.15 x 1100 = 165 SCFM Yearly purge loss = 165 x 60 x 8760 = 86,724,000 SCF Cost of purge loss per year = 0.35 x 86,724,000 / 1000 = $ 30,383 A Heatless dryer uses minimal electrical power for controls - about 0.05 KW Cost of power for controls per year = 0.05 x 8760 x 0.10 = $ 44 Total yearly operating cost = $ (30,353 + 44) = $ 30,397 100 + Purge Loss + Safety Margi B, External Heat Reactivated Dryer (4-6 % Purge Loss): Minimum required capacity = 900 + Purge loss + Safety Margin = 1000 SCFM Purge loss = 0.06 x 1000 = 60 SCFM Yearly purge loss = 60 x 60 x 8760 = 31,536,000 SCF Cost of purge loss per year = 0.35 x 31,536,000 / 1000 = $ 11,038 [Assmmptions: Heater power usage = Heat required to evaporate moisture from desiccant Moisture removal per 1000 SCFM of compressed air = 23 Ibs. / hour Sensible & latent heat required to evaporate moisture = 1500 BTU / hour. Required heater capacity for 23 Ibs. moisture per hour = 23 x 1500 x 1.20 1. Cost of compressed air US $.035per 1000 standard cubic feet (SCF) 12. Power Cost - US $.010 (loses to desiccant & vessel- 20 %) = 41,400 BTUH = 12.13 KW per KWH (average) Recommended heater- 15 KW / 1000 SCFM (heater is ‘off 3. Averaue compressed air during cool down and heater cycles on-off to maintain desired temperature) |” sage - 900 SCFM, 8760 Heater opetating cost per year = 12.13 x 8760 x 0.10 = $ 10,626 hour/year Cost of power for controls per year = $ 44 (from "A" above) 14. For steam heat (in Hew of Total yearly operating cost = $ (11,038 + 10,626 + 44) = $ 21,708 electric) at least 150 PSIG pressure is required. C. Internal Heat Reactivated Dryer (2-3 % Purge Loss): |S: Latent heat of steam @ 150 ‘Minimum required capacity = 900 + Purge + Safety Margin= 1000 SCFM__|® aes eee ahee | Purge loss = 0.03 x 1000 = 30 SCFM SErUnl readiod to her a Yearly purge loss = 30 x 60 x 8760 = 15,768,000 SCF FEatrrericrereneatis Cost of purge loss per year = 0.35 x 15,768,000 / 1000 = $ 5,519 wise (F) Heater power usage = Heat required to evaporate moisture from desiccant |g} Hp = 0.246 KW Heater operating cost per year = 12.13 x 8760 x 0.10 = $ 10,626 9. Latent Heat of Steam - (From"'B" above) 97 BTU / I Cost of power for controls per year = $ 44 (from "A” above) 10Sensible & latent heat required Total yearly operating cost = (5,519 + 10,626 + 44) = $ 16,189 © cveporate;mcisire = 1500 x 1.20 D. Blower Purge Dryer (1% Purge Loss): Leak Prevention Saves Energy = ‘Minimum required capacity = 900 + Purge + Safety Margin = 1000 SCFM Air leaks are expensive. Dry air Purge loss =0.01 x 1000 = 10 SCFM [prevents leaks. At 100 PSIG ‘Yearly purge loss = 10 x 60 x 8760 = 5,256,000 SCF(From"B" above) [pressure, a/” hole leaks 103 SCFM] Cost of power for controls per year = $44 (from "A" above) jof compressed ait. Cost of lost ait | Cost of purge loss per year = 0.35 x 5,256,000 / 1000 = § 1,840 in 24 hours = (0.35 / 1000) x 103 Heater power usage = Heat required to evaporate moisture from desiccant fx 24x 60=$51.91/ day. Heater operating cost per year 2.13 x 8760 x 0.10 =$ 10,626 For 300 days a year, cost = (From"B" above) (300 x 51.91 = $15,873 / year. “Nonstandard Equipment Is Our Speciality” 5Required blower capacity (15% of inlet SCFM) = 0.15 x 100 Required Blower Motor- 5 HP Purge air temperature rise = (15 KW- Heater x 3414 BTUH / KW) /(1.08 x 150 SCFM) = 316 'F Blower ‘on’ 150 minutes out of 240 minutes or 62.5% Cost of operating blower per year = 5 x 0.746 x 0.625 x 8760 x 0.10 = $ 2,042 Cost of power for controls per year = $ 44 (from "A" above) ‘Total yearly operating cost = $ (1,840 + 10,626 + 2,042 + 44) = $ 14,552 = 150 SCFM @ 2 to 4 PSIG E, Hybrid Drying System (3 % Purge Loss): Minimum required capacity = 900 + purge + Safety Margin = 1000 SCFM Purge loss = 0.03 x 1000 = 30 SCFM Yearly purge loss = 30 x 60 x 8760 = 15,768,000 SCF Cost of purge loss per year = 0.35 x 15,768,000 / 1000 =$ 8,519 Refrigeration system power usage = 5 KW / hour Cost of operating refrigeration dryer for one year = 5 x 8760 x 0.10 = $ 4,380 Cost of power for controls per year = § 44 (from "A above) ‘Total yearly operating cost = (5,519 + 4,380 + 44) = $ 9,943 (LOWEST) COMPARISON OF YEARLY OPERATING COST. Heatiess (PHL) | EXT. Heat (PHE) | Int. Heat (PHD) [ Blower Purge (PHEB) | Hybrid (HDS) $30,397 $21,708 $16,189 $14,522 39.943 NOTES 1. Above estimates are for comparison purposes; customers shall do calculations based on their costs. 2. For air flow other than 1000 SCFM, customer may use the following formula- ‘Cost estimate = (SCFM / 1000) x Cost estimate, same type, for 1000 SCFM from above Example: For 1500 SCFM, hybrid, cost estimate, $ (1500 / 1000) X 9,943 = $ 14,915 / year 3. Steam Consumption: 1 KW = 3.5 Ibs of steam @ 150 PSIG Example: For PHE1000, average steam consumption = 12,14 x 3.52 = 42.7 Ibs./ hour Required steam capacity = 15 x 3.5 = 52.5 Ibs. / hour @ 150 PSIG Useful Definitions: Absorb - To take in and hold, not just on the surface, but deep into the material, usually | forming a mixture out of two or more substances. Adsorb - To take in and hold liquid and gas on the surface of a porous material without causing a change in the basic structure of the material. Dew point - The temperature at which moisture begins to condense A. Atmospheric Dew Point- Dew point at atmosphere pressure, B. Pressure Dew Point - Dew point at pressure (in selecting a drying system, only the pressure dew point is important, because the compressed air is normally used at a pressure), Latent Heat - Heat absorbed or released without any change in temperature 6 “Custom Engineered Systems Are Our Specialty”Selection & Sizing Water Cooling Equipment ESTABLISH- 1. The required cooling capacity- Walk through your facility and determine heat load (BTUH), temperature, pressure and flow (GPM) requirements. The following formula may be helpful in calculating heat load- Q (BTUH) = 500 X GPM X (Temp. ('F - Temp. Out /*F) X Specific Heat (1. 0 for water) Size cooling and pumping system with a safety margin of at least 15-25% to allow for losses thra the piping systems. 2, Ambient Conditions- A. Maximum and Minimum (Dry Bulb) Ambient Temperatures B. Maximum (Wet Bulb) Ambient Temperature (Required for Cooling Towers only) 3. Quality of Water & Type of System Required- Do you need or prefer a Closed Loop System ot an Open Loop System? In an "Open Loop" system, the cooling water is exposed to atmosphere- dirt, pollution, bacteria etc.; whereas, in a "Closed Loop" system, the cooling water stays clean, because it is sealed from the atmosphere. Therefore, many applications require cleaner "Closed Loop" systems, Generally, Chillers and ‘Aqua Savers are "Closed Loop," although they can be "Open Loop,” whereas Cooling Towers is "Open Loop." 4, Equipment Selection- The required temperature and cleanliness determine the equipment choice. Following analysis of the various types of equipment should be helpful in selecting the equipment- A. CHILLERS: Standard chillers are designed to cool fluids from 90° F (32°C) to 32° F ( 0" C). PIONEER offers custom engineered systems to cool fluids from virtually any temperature down to -40°F (-40°C). Advantages: Can achieve outlet temperatures much below the ambient temperature. Can maintain near-constant outlet temperature. No Water Loss. Except for the freeze protection in low temperature applications, chemical treatment of water is not required, Pepe Disadvantages: 1. Higher energy requirement than Cooling Towers and Aqua Savers. 2. Requires a cooling source (air or water) for condenser 3. Relatively high initial cost “Nonstandard Equipment Is Our Specialty” 7B. AQUA SAVERS: Use ambient air to cool fluids. The process limits the cooling to a temperature approximately 10 F (5.5°C) over the ambient temperature; however, Aqua Savers are cost effective and reliable in providing cooler water temperatures when used in conjunction with a trim cooler or a chiller. PIONEER offers packaged Aqua Saver Systems with pumping system, chiller and trim cooler, specifically sized for air compressors and other applications. Advantages: 1. Closed-Loop system; except for the freeze protection in low temperature applications, chemical treatment of water is not required. 2. No Water Loss. Low power requirement, 4. Moderate initial cost. Disadvantage 1. Temperature limitation (if used alone). C. COOLING TOWERS: Depend largely on evaporation, and cool water down to 5° F ( 3° C) over the wet bulb temperature, which is usually below the ambient temperature. Therefore, Cooling Towers cool water below the ambient temperatures, generally down to 85°F (29° C), or lower, depending on the web bulb temperature in the area Advantages: 1. Provide cooler water than Aqua Savers. 2. Low power requirement. 3. Low initial cos Disadvantages: 1. The "Open Loop System" design is subject to contamination from atmosphere. 2. Generally require chemical treatment of water. 3. Water loss due to evaporation and drift ( Induced draft, and vertical air discharge, as in Pioneer Evap-Kool Aluminum Cooling Towers, minimizes water loss). [Useful Definitions: ‘Energy Saving Tips: [Dry Bulb Temperature - The temperature of the air as 1. Design system for lower pressure drops, it reduces- indicated by an ordinary thermometer. a, Pump (8) energy use; b. Pumping heat load hwet cloth and exposed to the atmosphere, the temperature Pelee e eaeleay eee ead by itis lower because the evaporation of water cools the thermometer. This is called the "Wet-Bulb Temperature”. It fs‘an indicator ofthe humidity (or lack oft) n the alr, and lies between Dry- Bull Temperature and the Devs Point. At [saturation the Wet-Bulb Temperature, the Dry-Bulb Temperature and the Dew Point are the same ‘Wet Bulb Temperature - If thermometer is covered was] 2. Insulate piping at temperatures over 20" F (11°C) | 5. Motors run most efficiently at fll load, Modslsr approach , ora system with multiple motors, and Résmostale on-off contro, save ener. 4. Load sharing or hybrid approach , such a5 using | | © Agno Sever at higher tontperature’ and Chile 8 a | [__Sstondary cooling sources saves enersy Disclaimer ;Iformation provide here is deemed comect and curent at the time of publication, however, PIONEER disclaims all liability for any errors resulting in loss or damage. 8 “Custom Engineered Systems Are Our Specialty’