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Compressed Air preparation

PM Air Supply / 7/5/2005 1

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Composition of Air

Other Gases
Oxygen
21%
1%
•Humidity
•Dust
•Industrial pollutants

Nytrogen
78%
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The Necessity of Compressed Air
Preparation

up to 180 million dirt particles

up to 80 g of water(at 50°C)

up to 0.03mg of oil

Various chemical contaminations

(lead, cadmium, mercury etc.)
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Why Compressed Air Preparation?
• Compressed air contains
• Water
– Corrosion damages
• Dust
– wear
• Oil
– Not suitable for food industry. Not suitable for Lubrication
of drives
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Possible Consequences for System
Operation and Environment

Rust due to condensate Residue and Condensate Corroded components

Containing
Contaminates
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Criteria for Compressed Air
Preparation
•Quality
-Water content
-Size of Airborne Particles
-Permissible / Maximum Oil Content

•Quantity
-Minimum and Maximum Volume for the Required Flow

•Pressure
-Minimum / Maximum Pressure
-Pressure Level Consistency
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What is Required for
Compressed Air Preparation?

Drying Filtering Oil Removal

Ensure Flow

Compressed Air Quality to DIN ISO 8573 -1

Regulate Pressure
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Definition of Compressed Air
Quality to DIN ISO 8573 -1

Compressed air to quality class 5. 4. 2.

Class 5 for Solid Contamination

Class 4 for Water Content

Class 2 for the Total Oil Content

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Air Quality Classification
ISO 8573-1
Solids Water Content Oil content
Class Max. Particle Max.Particle density Max. dew Max. oil density
size(µm) Density(mg/m3) (mg/ m3) point (0C) (mg/m3)
1 0.1 0.1 0.003 -70 0.01
2 1 1 0.12 -40 0.1
3 5 5 0.88 -20 1
4 15 8 6 +3 5
5 40 10 7.8 +7 25
6 - - 9.4 +10 -
7 - - - - -
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Allocation of quality classes
Solids Water dew Max.oil content
point
Application Class [pm] Class [0C] Class [mg,m3
]
Mining 5 40 7 - 5 25
Cleaning 5 40 6 +10 4 5
Welding machines 5 40 6 +10 5 25
Machine tools 5 40 4 +3 5 25
Compressed air cylinders 5 40 4 +3 2 0.1

Compressed air valves 3…5 5..40 4 +3 2 0.1

Cont…..
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Allocation of quality classes
Solids Water dew Max.oil content
point
Application Class [pm] Class [0C] Class [mg,m3
]
Packaging 5 40 4 +3 3 1
Micro-pressure regulators 3 5 4 +3 3 1
Measurement air 2 1 4 +3 3 1
Storage atmosphere 2 1 3 -20 3 1
Sensors 2 1 2..3 -40..-20 2 0.1
Foodstuffs 2 1 4 +3 1 0.01
Photographic processing 1 0.01..0.1 2 -40 1 0.01
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Air Humidity
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Dew point

•Atmospheric dew point: Lowest temperature to which atmospheric air can be

[°C] cooled without the precipitation of water

•Pressure dew point: Lowest temperature to which compressed air can be

cooled without the precipitation of water
[°C]

Example Max Water

Atmospheric D.P. at 80° F 1 oz /Cubic M
8 bar D.P. at 80° F 1/10 oz /Cubic M
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•Temperature, at which water is not yet condensed

Water Vapor
g/m 3

3.5 oz

Dew point

1/3 oz

50° F 150° F
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Dew point

• Pressure Dew point (PDP)

– The temperature at which the compressed air
reaches its humidity saturation point (100%
Frel) at its absolute pressure.
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•Air humidity is dependent on temperature

Water content Maximum Saturation

g/m 3

Temperature in °C
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•Air humidity is dependent on volume

•Air is compressible–water is not.

•For this reason air can be “squeezed” like a lemon.
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Air Humidity

Volume-dependent

•Maximum Air Humidity: At X°C with m³ maximum possible quantity of water

vapor [ g/m³]
Temperature-dependent

•Absolute Air Humidity: With m³ actual contained quantity of water vapor [ g/m³]

•Relative Air Humidity: Absolute / maximum air humidity [ %]

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Drying
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Refrigerant dryers

A Compressed air with a

temperature of about 30°C
B Heat-exchanger

C Cooling unit

D Condensate drain
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Refrigerant dryers

PDP + 3 oC
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Membrane dryers

1 Air flows through a Micro-Filter

2 Membrane Fibers

Vapor Passes through the

3
Membrane Wall

4,5 Dry air (purge)

6 Wet air

(A Entry / B , C Bypass / D Silencer )

PDP -20 oC
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Adsorption dryers
Hot air regenerated

PDP -70 oC
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Adsorption dryers
Cold regenerated

A compressed air with a

temperature of about 30°C
B switching valve
C purge

1 drying chamber
2 regeneration chamber

• Desiccant (Drying agent):

– Silicon dioxide
– Activated carbon
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Adsorption dryers

5 dry air passes

through the filter 3 regeneration of the
desiccant with the
purge air

2 moisture is being 4 expanding from line

adsorbed into the pressure to atmospheric
surface of the desiccant pressure

6 moisture is being 1 wet air passes

evacuated from through the filter
the system
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Theoretical desiccant bed geometry :

PDP -40°C

length of unused bed

(spare capacity)

absorption zone PDP -40°C

mass transfer zone

all based at 7 bar and 35°C

100% saturation 0% inlet air temperature
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Traditional system

high pressure drop bulky

causes by many pipes

heavy
welded carbon
steel vessels
unreliable
no corrosion
protection
inefficient
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Traditional system Loose filled bed

difficulties in
channeling of the
changing the
desiccant
desiccant
waste of desiccant

granules are loose and desiccant surface area

able to rub against one not fully utilized
another
inefficient regeneration

dust & attrition

inconsistent performance
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Absorption Drying
•Chemical process
•Drying Agents
•Dehydrated calcium (s)
•Magnesium salt (s)
•Lithium chloride (liquidizing)
•Calcium chloride (liquidizing)
•Sulphuric acid (l)
•Glycerin (l)
•Oil vapor and oil particles separated
•Simple installation
•Low mechanical wear
•No External energy requirement
•Operating cost too high
PDP -20 oC •Efficiency too low
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Dryers - comparison

Refrigerant Adsorption Membrane

dryers dryers dryers
Pressure
+2°C (35°F) -70°C (-94°F) -20°C (-4°F)
Dew point
high medium/high low
Flow rates (500->20000 l/min) (55-1820 l/min) (50-340 /min)

Clean air
categories 4 1 3

size big medium small

where ? Compressor Room Point of Use Point of Use

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Refrigerant Adsorption Membrane

dryers dryers dryers

-Reliable -Always same -No Electrical

Benefits Pressure Dew Supply
-No Desiccant Point Necessary
Dust Migration
-High Efficiency -Explosion Proof
-Economical
-Ready to Connect -No Desiccant
-No Purge Air Dust Migration
Necessary -PDP -70°C Possible

-High Flow Rates

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Filtering
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Particle Sizes

Visible
Ultraviolet Near infra red Far infra red
Solar Radiation

Fume Dust
Mist Spray
Silt Fine Sand
Smog Cloud and Fog Mist Drizzle
Rosin Smoke Fertilizer Ground Limestone
Oil Aerosol Fly Ash
Tobacco Smoke Coat Dust
Metallurgical Dusts and Fumes
Ammonium Chloride Cement Dust
Fume Sulfuric Beach Sand
Concentrator Mist
Pulverized Coal
Zinc Oxide Fume Insecticide Dusts
Ground Talc
Colloidal Silica Spray Dried Milk Plant Spores
Alkali Fume Pollens

0.01 0.1 1 10 100

The smallest particle the human eye can see is in the order of 40 microns.
A major contaminant oil aerosol, is in the region of 0.01 to 0.8 micron.
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Filter Types
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Basic Filtration
Principle of Filtration Mechanisms
Polluted Air Filter Element Clean Air

Coalescing Filters:
•Coalescing filters rely on what is known as mechanical filtration for their effectiveness.
•The main mechanisms of mechanical filtration are;
Direct Interception
Inertial impaction
Diffusion.
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Principle of Filtration Mechanisms

Polluted Air Filter Element Clean Air

DIRECT INTERCEPTION

Direct Interception:
Occurs when a particle collides with and adheres to a fiber of the filter material without
deviating out of the streamline flow.
This mechanism tends to take place on the surface of the filter material and affects mainly
larger particles over 1 micron in size.
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Principle of Filtration Mechanisms

Polluted Air Filter Element Clean Air

INERTIAL IMPACTION

Inertial Impaction:
Occurs when a particle is unable to follow the tortuous path around the filter fibers
and eventually collides with and adheres to one of the fibers.
Typically affecting particles in the 0.3 micron to 1 micron size range.
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Principle of Filtration Mechanisms

Polluted Air Filter Element Clean Air

DIFFUSION

Diffusion:
Occurs with extremely small particles which tend to wander within the gas stream
increasing their chances of colliding with and adhering to a fiber.
This usually affects particles below 0.3 micron in size. A degree of overlap takes place
with the mechanisms, the extent varying on the conditions.
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Basic Particulate Filter Principle
General Purpose Standard Filters: Air Out

•Removal of solid particle

Baffle
contaminants
Air In
down to 40 microns or 5
microns Filter
and for the separation of bulk Element
Bowl
liquids. Guard

•This type of filter is Accumulated

liquid
generally used in
industrial applications where Drain
liquid
water and oil, and harmful
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Basic Coalescing Filter Principle
Fine and Micro Filters (Oil Removal): Pressure
Differential
Indicator
• Two filter element grades (1 micron and 0.01
micron) are offered to meet air quality
requirements.

• These filter elements are specifically designed

for the removal of solid particles, water and Coalescing
oil aerosols down to 0.01 micron. Element

• With a micro filter maximum remaining oil Transparent

Bowl Auto
content of air leaving the filter down to 0.01
Drain
ppm at 70°F (21°C) at a pressure of 100 psi
(7 bar) using a typical compressor lubricant.
Bowl
Guard
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Basic Absorption Filter Principle
Differential
Active Carbon Filters: Indicator

• The active carbon filter element is used for the

removal of oil vapor and oil associated odors.

• Maximum remaining oil content of air leaving the

filter is 0.003 ppm/wt at 70°F (21°C) at a 0.0003
pressure of 100 psi (7 bar). ppm/wt
Active
• Where the application requires very high air Carbon
quality, an active carbon filter is used, in Element
conjunction with a micro filter element.

• Typical applications are food processing and Transparent

packaging, pharmaceutical, fermentation, Bowl Bowl
electronics and semi-conductor, and critical air Guard
control. Drain
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Pressure Regulator Filter Regulator Particle Filter Fine Filter Micro Filter Lubricator
LR / LRS / LRVS LFR LF 40 or 5 µm LFMB LFMA LOE
1 µm 0.01 µm

On-off valve HE On-off valve Soft start valve Branching Module Installation
Manual HEE / HEP HEL FRM Components
electrical / pneumatic (gradual start)
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• Sizes: 1/8“ to 1“
Range Sizes- Mini, Midi, Maxi

•2 pressure ranges: 0.5 ... 7bar

0.5 ... 12bar

•Flow rates: Mini up to 1700 l/min

Midi up to 3500 l/min
Maxi up to 11500 l/min

•Grade of filtration: 0.01 / 1 / 5 / 40 µm

•Condensate drain: Manual, Automatic

•Metal bowl guard: To Standard EN 983

•Regulating knob : Lockable

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Micro Filter

•Sizes: 1/2“ 3/4“ 1“

•Pressure range: max. 16 bar

•Flow rates: 1100 l/min to 5200 l/min

•Grade of filtration: 0.01 / 1 µm

•Filter: Borosilicate glass fiber

•Special characteristics : -Vapor Removal

-Red/Green Differential Pressure Gauge
-High Flow Rates
-Automatic Condensate Drain
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Adsorption Dryer

• Sizes: 1/4“ 1/2“ as H1...H7

•Drying agent: Aluminum Oxide

•Quality: 1.2.1 at nominal flow rate

1.1.1 at 70% nominal flow rate

•Dew point: -40°C at nominal flow rate

-70°C at 70% nominal flow rate

•Flow rate:Up to 1800 l/min

• Purging air: 20...22% of flow rate for decentralized drying

Adsorption Dryer for •Voltage: 24 V DC / 110 or 230 V AC

Decentralized Drying
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Pure air System
Remote
monitoring/ Microfine filter
auto-dialing (filtration according
to required Flow
air quality) Control

Oil level
detector

Oil Mist Air receiver tank Dryer for Oil-water

Screw Cyclone with condensate high air quality separator tank
compressor separator Eliminator
drain requirements