Latest trends in
Compressed Air purificationBy
Premier Equipments
The right choice is never fails………….
PROFILEPremier Equipments Private Limited
is a professionally managed ISO
certified, competent company
offering products, services and
complete systems for the treatment
of compressed air.
The right choice is never fails………….
In brief
• Founded in 1996
• Complete solution for Compressed Air Treatment
• Innovative Latest Technology
• Manufacturing Capabilities upto10000cfm and 400 bar Super Pressure
• Backed with Strong After SalesPREMIER
Need of Compressed Air Quality
Compressed Air Quality is vital.
•••• Consequences if not
maintained
► Dramatically
increased maintenance costs
► Increased downtimes
PREMIER
ANSI/ISA-S7.0.01-1996The Instrument Society of America has published its Quality Standard
for Instrument Air (ANSI/ISA-S7.0.01-1996). The purpose of the
standard is to provide a definition for instrument-quality air.
The scope of the standard includes:
• Limits for moisture content
• Limits for entrained particle size and oil content
PREMIER
Summary of ANSI / ISA-S7.0.01• The pressure dewpoint measured at the dryer outlet should be maintained at least 10°C below the minimum temperature to which any part of the instrument air system is exposed.
• The pressure dew point should not exceed 4°C at line pressure.
• Maximum particle diameter of 40 micrometers is designated as generally acceptable. Pneumatic control devices that require instrument air with less than 40 micrometer particle sizes shall be equipped with additional filtration to meet the particle size limits for the device.
• Lubricant content in instrument-quality air should be as close to zero as possible, and under no circumstances exceed 1 part per million by weight or volume.
PREMIER
Air Quality - ISO 8573-1:2001International Standard Organization has published its Quality International Standard Organization has published its Quality
Standard for Air Quality. The purpose of the standard is to guidStandard for Air Quality. The purpose of the standard is to guide the e the
user to select appropriate purification system depending on the user to select appropriate purification system depending on the
application. application.
The scope of the standard includes:The scope of the standard includes:
•• Limits for moisture content Limits for moisture content
•• Limits for entrained particle size and oil content Limits for entrained particle size and oil content
PREMIER
ISO 8573-1:2001
25.0+710.040.05
5.0+38.015.04
1.0-205.05.03
0.1-40.01.01.02
0.01-700.10.11
Max.
Concentration g/m3
Max. Particle Size Microns
Max. Oil
Content mg/m3
Max. Pressure
Dew Point ºC
Solid Contaminants
Air Quality
Class
Class 1Class 4Class 2Textile
OilWaterSolid
ContaminantsApplication
Table 2. Typical Air Quality Classes
PREMIER
Where from the contaminants originate
• Solid Particles
– From atmosphere
– From the air
compressor itself
– From Existing piping
system
PREMIER
Where from the contaminants originate
• Oil Particles
– From atmosphere as
hydrocarbons
– From the air
compressor itself
• 3 to 15 mg/m3
– 0.01 mg/m3 is termed
as technically oil free
air
200 cfm of air
275 L of water /day
275 L of water /day
64 L of water /day
211 L of water /day
59 L of water /day
5 L of water /day in Vapourform
Where from the moisture originate
Water ParticlesWater Particles
Mainly from atmosphereMainly from atmosphere
PREMIER
Devices to remove contaminantsDevices to remove contaminants
Particulate filtersParticulate filters – removal of solid contaminants
Coalescing filtersCoalescing filters – removal of oil residues
Bulk water separatorsBulk water separators – removal of moisture in droplet / aerosol form
Compressed Air dryersCompressed Air dryers – removal of moisture in vapour form
PREMIER
Particulate FiltersParticulate Filters
The compressed air The compressed air
penetrates the filter structure, penetrates the filter structure,
the solid contaminants are the solid contaminants are
caught in the deepest layers caught in the deepest layers
of the filter. of the filter.
PREMIER
Coalescing FiltersCoalescing Filters
AIR OUTAIR IN
Anti re-entrance barrier
Wet band
Separated liquids
The air travels through the filter media gradually slowing down.Particles are retained through 4 different process and held within the filter. Liquids are caught in the “wet band” and drain away into the filter bowl
PREMIER
Bulk Water Separator
Through the centrifugal force, Through the centrifugal force,
solid particles as well as oil and solid particles as well as oil and
water droplets are projected water droplets are projected
against the inner separator wall against the inner separator wall
and, driven by gravity, flow and, driven by gravity, flow
downwards into the separator downwards into the separator
bowl.bowl.
PREMIER
Grade of Premier filters
0.0030.01A
0.010.01Y
0.51X
55P
Oil residue (mg/m3)
Solid particle retention (µµµµ m)
Grade
PREMIER
Compressed Air drying
•• Over compressionOver compression
••Chemical dryingChemical drying
•• CoolingCooling
PREMIER
Dew point - Definition
It is the temperature at which the air
attains saturation (100% RH). In simple
words it is the temperature below which
condensation will occur, at the given pressure.
It is the temperature at which the air
attains saturation (100% RH). In simple
words it is the temperature below which
condensation will occur, at the given pressure.
PREMIER
But, when does
Corrosion start ?+20
+10
0
-10
Pre
ss
ure
Dew
po
int
°C
Ambient Temperature °C
Condensation s
tarts
RH. 50-100%
Corrosio
n may sta
rt
No corrosion
0 10 20 30 40 50
Corrosion
PREMIER
Compressed Air drying – By Over
Compression
Pressure and moisture content are inversely proportional.Pressure and moisture content are inversely proportional.
PREMIER
Compressed air drying, working on the principle of cooling and condensation, makes use of refrigeration systems. Pressure dew points of down to 3°C are achieved by these methods.
Compressed Air drying – By Cooling
PREMIER
Compressed air drying, achieved through a process called adsorption is called Desiccant Dryers. Adsorption
is a process of deposition of water vapour onto the internal
and external surface of the adsorption medium, without the
formation of a chemical compound. Pressure dew points of down to -70°C are achieved by these methods.
Compressed Air drying – By Chemicals
PREMIER
Types of Desiccant Dryers
Heatless dryerHeatless dryer
Heat of Compression dryerHeat of Compression dryer
High Pressure dryerHigh Pressure dryer
PREMIER
Heatless Regenerative dryersHeatless Regenerative dryers
The principle of The principle of
heatless regeneration heatless regeneration
uses 14% of dry air, uses 14% of dry air,
expanded to expanded to
atmospheric pressure atmospheric pressure
and purge through and purge through
the adsorbent bed to the adsorbent bed to
regenerate. regenerate.
PREMIER
The quantity of air The quantity of air
required for required for
regeneration is blown in regeneration is blown in
by means of a blower by means of a blower
from the surrounding from the surrounding
atmosphere and the atmosphere and the
drawn in ambient air drawn in ambient air
heated by means of a heated by means of a
heat exchanger.heat exchanger.
External Blower Purge dryersExternal Blower Purge dryers
PREMIER
Heat of Compression Heat of Compression
dryers dryers utiliseutilise the hot oil the hot oil
free compressed air from free compressed air from
the outlet of the the outlet of the
compressor head which compressor head which
has a very high capacity has a very high capacity
to hold moisture for to hold moisture for
regeneration and the hot regeneration and the hot
air is further cooled in a air is further cooled in a
regeneration cooler regeneration cooler
before entering into before entering into
drying tower.drying tower.
Heat of compression dryersHeat of compression dryers
� -20 / -40°C Deg C Pressure Dew Point
�Moisture Content 80 / 10 ppm
�Relative humidity 1.4% / 0.17%
�Confirms to ISO 8573-1,Table 3,Class 2 & 3
Desiccant dryer – Air Quality
PREMIER
�+ 3 Deg C Pressure Dew Point
�Moisture Content less than 600 ppm
�Relative humidity 10%
�Confirms to ISO 8573-1,Table 3,Class 4
Refrigerated dryer – Air Quality
Premier Refrigerated Dryers – Series
EcotronikaWhy Why Why Why Why Why Why Why EcotronikaEcotronikaEcotronikaEcotronikaEcotronikaEcotronikaEcotronikaEcotronika Series Dryers?Series Dryers?Series Dryers?Series Dryers?Series Dryers?Series Dryers?Series Dryers?Series Dryers?••Latest technologyLatest technologyLatest technologyLatest technologyLatest technologyLatest technologyLatest technologyLatest technology••Energy savings by 30%Energy savings by 30%Energy savings by 30%Energy savings by 30%Energy savings by 30%Energy savings by 30%Energy savings by 30%Energy savings by 30%••EcofriendlyEcofriendlyEcofriendlyEcofriendlyEcofriendlyEcofriendlyEcofriendlyEcofriendly refrigerantrefrigerantrefrigerantrefrigerantrefrigerantrefrigerantrefrigerantrefrigerant••Highly reliableHighly reliableHighly reliableHighly reliableHighly reliableHighly reliableHighly reliableHighly reliable••Remote monitoring & controlRemote monitoring & controlRemote monitoring & controlRemote monitoring & controlRemote monitoring & controlRemote monitoring & controlRemote monitoring & controlRemote monitoring & control••User friendlyUser friendlyUser friendlyUser friendlyUser friendlyUser friendlyUser friendlyUser friendly
PREMIER
TubeTube--InIn--Tube Heat exchangerTube Heat exchanger
Conventional smooth bored heat exchangers allow
less overall heat transfer efficiency and hence
consumes more power
PREMIER
Highly reliable and most Highly reliable and most
energy efficient hermetically energy efficient hermetically
sealed scroll type refrigeration sealed scroll type refrigeration
compressors ensure very low compressors ensure very low
power consumption. These power consumption. These
compressors are compressors are tropicalisedtropicalised for for
Indian environment. Indian environment.
EcotronikaEcotronika –– Salient featuresSalient features
PREMIER
EcotronikaEcotronika –– Salient featuresSalient features
0% Ozone Depletion Potential Refrigerants
R134a/R404a/R407C
PREMIER
EcotronikaEcotronika –– Salient featuresSalient features
Customized air cooled condensers with large cooling surface area to suit the extreme ambient temperatures.
Maintenance free EBM, Germany make fans with child safe cowling arrangement.
The large cooling surface area ensures effective sub-cooling which increases the efficiency of the refrigerant system and saves power.
PREMIER
EcotronikaEcotronika –– Salient featuresSalient features
Fitted with system protectors Fitted with system protectors
like accumulators, refrigerant like accumulators, refrigerant
suction strainers, liquid line suction strainers, liquid line
moisture indicators, moisture indicators,
refrigerant filter dryers, liquid refrigerant filter dryers, liquid
solenoid valves, pressure solenoid valves, pressure
switches, etc to safeguard the switches, etc to safeguard the
system and refrigerant system and refrigerant
compressor.compressor.
PREMIER
EcotronikaEcotronika –– Salient featuresSalient featuresIndications
� Dew point temperature
� Inlet temperature of air
� Condensing temperature of refrigerant
� Compressor running
� Fan motor running
Visual alarms
� High dew point temperature
� High condensing temperature
� High inlet temperature
RS232 communication for remote operation
Controls•Automatic drain valve operation•Condenser cooling fan cut in/cut off•Dryer on /off •Compressor run control•Provision for changing setpoints.
PREMIER
200 cfm of air
275 L of water /day
275 L of water /day
64 L of water /day
211 L of water /day
59 L of water /day
5 L of water /day in Vapourform
59 liters of water/day is thrown additionally to the compressed air network if not dried by a Refrigerant Dryer; this may result in damaged Pneumatic Equipment and Contaminated End Products !
Need of Refrigerated Dryer
PREMIER
Factors considered for the
selection of dryer
• Air Compressor Max. Flow
• Working Pressure
• Air Inlet Temperature to the Dryer
• Ambient Temperature
• Cooling medium
PREMIER
Pressure Vs Moisture content
Pressure and moisture content are inversely
proportional. Moisture content at different pressure range
0
10
20
30
40
50
60
70
0 2 4 6 8 10 12 14 16 18
Pressure (bar)
Mo
istu
re c
on
ten
t (g
/m3)
PREMIER
Temperature Vs Moisture contentTemperature and moisture content are directly proportional.
At every 12°C rise the moisture content doubles.Moisture content at 7 kgf/sq.cm
0
2
4
6
8
10
12
14
16
18
-60 -40 -20 0 20 40 60 80
Air temperature (Deg.C)
Mo
istu
re c
on
ten
t (g
/m3)
PREMIER
Inlet Temperature Vs Power
ConsumptionThe Power Consumption increases proportional to inlet temperature
Inlet Temperature Vs. Power Consumption
1.61.7
1.8
2.2
2.5
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
30 35 40 45 50 55 60
Temperature (Deg.C)
Po
wer
(kW
)
The chart represents 300 cfm capacity
PREMIER
Ambient Temperature Vs Power
ConsumptionThe Power Consumption increases proportional to ambient temperature
The chart represents 300 cfm capacity at 45 Deg.C inlet
Ambient Temperature Vs Power Consumption
1.4 1.51.75 1.85
2
2.4
0
0.5
1
1.5
2
2.5
3
0 10 20 30 40 50 60
Temperature (Deg.C)
Po
wer
Co
nsu
mp
tio
n (
kW
)
PREMIER
Consequences of Temperature in
Selection
Higher Ambient and Inlet Temperatures causes
•Poor Dew Point
•Overload on the Refrigerant compressor
•Chance of Refrigerant compressor failure
PREMIER
Reference conditionsISO 7183 standard prescribes reference conditions as
Air inlet temperature – 35 Deg.C
Ambient temperature – 25 Deg.C
Working pressure – 7 bar (g)
Our reference condition based on Our reference condition based on
Indian tropical environmentIndian tropical environment
Air inlet temperature Air inlet temperature –– 45 Deg.C45 Deg.C
Ambient temperature Ambient temperature –– 40 Deg.C40 Deg.C
Working pressure Working pressure –– 7 bar (g)7 bar (g)
PREMIER
Right Sizing
Apply correction factors for various inlet
pressure, inlet temperature & ambient
temperature
Correction factors vary manufacturer to manufacturer
PREMIER
Dryer Layout
•Standalone dryer
Individual placement of
air compressor, air
receiver, filters and air
dryer.
• Integrated dryer
Air compressor, Air
dryer, filters and air
receiver as a single unit
PREMIER
Myths of Integrated package
•ClaimIntegrated Dryer ensures a constant supply of Clean & Dry Compressed air.
Correct Dew Point (PDP) meeting Industry demand
Accurate Dew Point Control suits applications
•TruthThe refrigerant compressor shuts off during unloading process.
During loading the refrigerant compressor starts and takes minimum 3 minutes to supply air at +3 Deg.C Dewpoint.
PREMIER
Myths of Integrated package
•Claim
Designed & Tested for all climatic conditions
• Truth
The dryer is sized forAir inlet temperature – 35 Deg.C
Ambient temperature – 25 Deg.C
Working pressure – 7 bar (g)
At Indian environment, the dryer will under perform and +3 Deg.C dew point will not be attained.
PREMIER
Myths of Integrated package
•Claim
Easy access to internal components
•Truth
Congested layout does not permit even for minimum maintenance.
PREMIER
Myths of Integrated package
•Claim
Pressure measurement at final discharge point
•Truth
The pressure drop across
the dryer can not be
measured. Chance of
compressor running at
higher pressure results in
more power
consumption.
PREMIER
Myths of Integrated package
Other points of concern
More vibration
Failure of Refrigerant compressor
High surrounding temperature
Poor dewpoint
Shorter life
PREMIER
To get best quality air at lesser power To get best quality air at lesser power
and lesser maintenanceand lesser maintenance
Install stand alone dryer system Install stand alone dryer system
which is suitable for Indian which is suitable for Indian
Environment.Environment.
PREMIER
Hybrid dryersHybrid dryers
Combination of Refrigerated dryer & Heatless dryer to
achieve -20°C PDP / -40°C ADP
Air from Compressor :
45°C / 100 % RH / 7 bar / 7.84 g/m3
Air from Refrigerated dryer :
40°C / 10.3 % RH / 7 bar / 0.61 g/m3
Air from desiccant dryer:
40°C / 1.4 % RH / 7 bar / 0.08 g/m3PREMIER
Hybrid dryers Hybrid dryers –– Power analysis Power analysis –– 500 500 cfmcfm
Power consumption of Refrigerated dryer
2.5 kW
Power consumption of Heatless dryer
(4 % purge loss)
3.7 kW
PREMIER
Power analysis Power analysis –– 500 500 cfmcfm –– Various typesVarious types
((--2020°°C PDP / C PDP / --4040°°C ADP)C ADP)
Power consumption of Blower reactivated
dryer 19 kW
Power consumption of Heatless dryer
(14 % purge loss)
13 kW
Power consumption of Hybrid dryer
(Refrigeration dryer power + 4 % purge loss)
6.2 kW
PREMIER
Premier – Product Range
•Refrigerant Compressed Air Dryers
•Heatless Air Dryers – Standard
•Heatless Air Dryers - Pneuzorb
•Blower Reactivated Air Dryers
•Heat of Compression Dryers
•Compressed Air filters
•Automatic Drain Valves
•Air Receivers
•After Coolers
•Centrifugal Water Separators
•And many more custom
based productsPREMIER
Thankyou
Premier Equipments Pvt. Limited
139, Civil Aerodrome Road,
Coimbatore – 641033.
Tel : 0422-2273040
Fax : 0422-2273066
Email : [email protected]
PREMIER
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