ALM Refrigerant Dryers

ALM Refrigerant Dryers

Contents

ALMiG refrigeration dryers

Why use dry compressed air?

What is refrigeration drying?

Refrigeration dryer function Overview of ALM refrigeration dryers ALM refrigeration dryers ALM 25 – 110 ALM 150 – 1100 ALM 1320 – 2150 ALM 2400 – 5300 Advantages of „energy-saving-speed controlled version“ ALM -E Refrigeration dryer design

ALM Refrigerant Dryers

Why use dry compressed air?

• • • Untreated compressed air results in increasing leakage of the pipe system affects highly compressed air applications (e.g. pneumatic tools) results in - high maintenance costs - long production downtimes - serious quality issues in the production process 14 Average water content of air 12 10 g/m³ 8 6 4 2 0 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Pneumatic tool Compressed air pipe 3

ALM Refrigerant Dryers

The ability of compressed air to absorb water vapour depends solely on temperature and not operating pressure.

Ability of air to absorb water depending on temperature T [

°

C]

-5 0 5 10 15 20

Moisture [g/m 3 ]

3.23

4.87

6.79

9.36

12.74

17.15

T [

°

C]

25 30 35 40 45 50

Moisture [g/m 3 ]

22.83

30.08

39.29

50.67

64.85

82.26

4

ALM Refrigerant Dryers Classification of moisture reg. DIN ISO 8573-1:2010

1 5 6 2 3 4

Moisture classes acc. to DIN ISO 8573-1:2010

Class Pressure dew point 0 as specified by operator ≤ -70 ° C ≤ -40 ℃ ≤ -20 ° C ≤ +3 ℃ ≤ +7 ° C ≤ +10 ℃

Area for refrigerant dryers Application

Microchip production Varnishing (spray guns) Pharmac. industry Measurement and control technology Food and drink conveyance systems Cleaning of forming tools General plant air Breaker hammer

Compressed air quality classes acc. to DIN ISO 8573-1:2010 Residual water Class

1-2

Pressure dew point

-70 / -40 °C 3-4 2-3 3-4 -20/ +3 °C -40 / -20 °C -20/ +3 °C 2-4 2-4 4 4-5 -40/ +3 °C -40 / +3 °C +3 °C +3 / +7 °C 5

Condensation

Refrigeration dryer (PDP ≥ +3 ° C)

ALM Refrigerant Dryers

Main drying procedures

Adsorption

Adsorption dryer (PDP < 3 ° C to -70 ° C) 6

ALM Refrigerant Dryers

What is refrigeration drying?

Refrigeration drying is a process in which the compressed air is cooled by a refrigerant in a heat exchanger. This condenses the water vapour in the compressed air and separates it out. The greater the difference between inlet and outlet compressed air temperature, the greater the amount of water condensed. The lower the compressed air's cooling temperature, the less moisture remaining.

Drying comprises two phases: First phase: The warm compressed air enters an air / air heat exchanger in the opposite direction to the compressed air already cooled and exiting the unit. No extra energy is required for this process. Around 70 percent of the water vapour is removed as condensate.

Second phase: The compressed air flows through an air / refrigerant heat exchanger and cools to the specified pressure dew point (e.g. 3 discharged through a condensate drain.

° C). The remaining moisture condenses before this point is reached, is removed and 7

1 2

ALM Refrigerant Dryers

Refrigeration dryer function

4 Compressed air approx. +3 to +5

°

C 3

Reduction in moisture to ISO class 4, PDP: ≥ + 3 ° C Route travelled by the compressed air

1 2 3 4

Precooling of the fully saturated, warm compressed air in the air/air heat exchanger Cooling to the pressure dew point in the refrigerant / air heat exchanger Condensate collected is discharged by the separator / drain The dry compressed air exiting the unit is heated by the compressed air entering in the opposite direction

!

No condensate produced in compressed air network unless the compressed air temperature falls below +3 ° to +5 ° C!!

8

ALM Refrigerant Dryers

Overview of ALM type ALMiG refrigeration dryers

ALM 25 – ALM 110

5 models from 20 to 100 m³/h

ALM 150 – ALM 1100

10 models from 140 to 1000 m³/h

ALM 1320 – ALM 2150

4 models from 1200 to 2000 m³/h “E” version with energy-saving-speed control

ALM 2400 – ALM 5300

6 models from 2200 to 5100 m³/h “E” version with energy-saving-speed control

Larger types and special options on request !

9

ALM Refrigerant Dryers

ALM 25 – 110

On/Off switch Dew point indicator Integrated time-controlled condensate drain (standard) With static condenser

ALM Volume flow* [m³/h] Power consumption [kW]

25 20 0.24

35 65 30 60 0.24

0.34

85 80 0.42

110 100 0.58

* = inlet temperature 35 ° C; operating pressure 7 bar; pressure dew point +3 ° C

Standard version

• Dew point indicator • Time-controlled condensate drain • Refrigerant: R134a

Options

• Digital display • IP 55 protection • 60 HZ version • Electronically level-controlled condensate drain (A-DRAIN) • Bypass • Remote On/Off switch 10

ALM Refrigerant Dryers Benefits of ALM 25 - 110:

• Static condenser (refrigerator principle):  No fan required;     quiet, fewer wearing parts, no air turbulence, no dust    No influence from ambient temperature up to 45 ° C Time-controlled condensate drainage Warm outlet air (T-outlet = T-inlet + 5 ° C) thanks to exchange of relative heat • Easy to install: connect piping, plug in power cable , job done!

• Integrated demister separator (function: metal wool "captures" and collects water droplets from damp air) • Long service life through use of quality components • Using the heat produced by condensation means that there are no cold, damp pipes at the air outlet 11

ALM Refrigerant Dryers

ALM 150 – 1100

A-Drain: standard, electronically controlled condensate drain

ALM Volume flow* [m³/h] Power consumption [kW]

150 140 0.58

180 260 350 400 160 240 315 360 0.60

0.87

1.10

1.30

500 640 740 470 580 680 1.48

1.90

2.45

900 820 2.55

1100 1000 2.70

* = inlet temperature 35 ° C; operating pressure 7 bar; pressure dew point +3 ° C

Standard version Options

• Dew point indicator • Electronically level-controlled condensate drain (A-DRAIN) • Digital display (ALM-350 and higher) • Refrigerant: 150/180 R134a; 260-1100 R407c • IP 55 protection • 60 HZ version • Bypass • Remote On/Off switch • Potential-free fault message 12

ALM Refrigerant Dryers Vorteile ALM 150 - 1100

 Crossflow stainless steel plate-type heat exchanger (copper soldered)  Ensures optimum heat exchange and prevents condensation on cold pipes   Newly developed constant pressure valve  Constant refrigerant supply  Constant vaporiser and dew point temperature High-quality cooling compressors  Above average cooling rating

Crossflow

stainless steel heat exchanger  Piping not prone to vibration  Vibrations and oscillations are not transferred to connection points -> no leaks  Electronically level-controlled condensate drain   Automatically discharges the condensate collected No compressed air losses    Connections made of stainless steel Totally corrosion free system Housing designed for easy maintenance

A-DRAIN

Electronically level-controlled condensate drain 13

ALM Refrigerant Dryers Other benefits of ALM 150 - 1100:

• Compressed air inlet temperatures up to 55 ° C • Ambient temperatures up to 45 ° C • Maximum operating pressure of 16 bar(g) (higher pressures on request) • Very low pressure losses • Air / air heat exchanger with high effectiveness caused by small energy consumption • Easy to install: connect piping, plug in power cable, job done!

• LED dew point indicator on control panel (ALM 350 and higher) • Long service life through use of quality components • As a safety pressure limiter, the constant pressure valve (CPV) provides an overload shutdown mechanism: If the coolant temperature increases, the cooling medium pressure increases too  the dryer shuts down and an alarm is issued. This ensures that the dryer is not damaged.

14

ALM Refrigerant Dryers

ALM 1320 – 2150

ALM-

1320 1530 1850

Volume flow* [m³/h]

1200 1400 1700

Power consumption [kW]

2.55

2.95

5.70

Standard version Options

• Dew point indicator • Electronically level-controlled condensate drain (A-DRAIN) • Potential-free fault message • Digital display • 50/60 HZ version • Refrigerant: 1320/1530 R134a; 1850/2150 R404a • Plain text display • IP 55 protection • Special voltages • Cold air outlet mix • Bypass • Remote On/Off switch • Water-cooled • Sea water-cooled 2150 2000 5.80

* = inlet temperature 35 ° C; operating pressure 7 bar; pressure dew point +3 ° C 15

ALM Refrigerant Dryers Benefits of ALM 1320 - 2150:

• Space-saving installation thanks to narrow, vertical design • Low power consumption • Heat exchanger version optimised for compressed air applications:   Sinusoidal, large, smooth air ducts Low pressure loss through dryer • Outstanding accessibility for service as sheet metal panels can be removed on all four sides • Robust, reliable refrigeration control (HGBV: hot gas bypass valve) • Use of R134a or R404A refrigerants, typically used by industry • Temperature displays for compressed air inlet, compressed air outlet and dew point 16

ALM Refrigerant Dryers

ALM 2400 – 5300

ALM-

2400 2650 3550 4000 4900 5300

Volume flow* [m³/h]

2200 2500 3200 3650 4600 5100

Power consumption [kW]

5.50

7.00

8.70

9.20

10.80

13.40

* = inlet temperature 35 ° C; operating pressure 7 bar; pressure dew point +3 ° C

Standard version Options

• Dew point indicator • Electronically level-controlled condensate drain (A-DRAIN) • Potential-free fault message • Multi-functional, digital display • 50/60 HZ version • Refrigerant: R404a • IP 55 protection • Special voltages • Cold air outlet mix • Bypass • Remote On/Off switch • Water-cooled • Sea water-cooled • Marine specification • Integrated separator • Integrated separator and fine filter • Low temperature (until T amb =-20 ° C) • Digital scroll (EM**) ** = energy management 17

ALM Refrigerant Dryers

• 

Benefits of ALM 2400 - 5300:

• Plate-type stainless steel heat exchanger, copper soldered Heat exchanger version optimised for compressed air application: Sinusoidal, large, smooth air ducts •  Low drop in pressure through dryer • Use of R404A refrigerant as standard • Low installation cost; easy to maintain as panels can be removed • High reliability, efficiency and durability Filter separator and/or coalescence filter Demister separator Digital Scroll (Otion) • • Dryers can be positioned with one side facing the wall, which reduces the installation area required Cold air output: no need for an air/air heat exchanger on the output side if very cold compressed air is required.

Very fine oil filtration in cold air flow • Energy saving from use of Digital Scroll: If the dryer runs without load, the scroll wheels move apart thereby reducing internal resistance. Energy saving compared with standard refrigeration dryers: up to 80% !!

18

ALM Refrigerant Dryers

Overview of ALMiG-Energy-Saving-Drier“ type ALM

E

ALM 1320 – ALM 2150

4 models from 1200 to 2000 m³/h “E” version with energy-saving-speed control

ALM 2400 – ALM 5300

6 models from 2200 to 5100 m³/h “E” version with energy-saving-speed control 19

ALM Refrigerant Dryers Energy-Saving-Drier ALM 1320 – 5400

E

:

ALM E : Constructive difference to the ALM series • Replacement of the Danfoss "standard cooling unit" with a Danfoss high efficiency "speed-controlled cooling unit" and a "Danfoss frequency converter" that also has to be fitted • In technical terms, this means:  minor design changes resulting from simply replacing the cooling unit using a "plug’n play" system.  all other components are identical. 20

ALM Refrigerant Dryers Energy-Saving-Drier ALM 1320 – 5400

E

:

Note: ALM – E has: • same max. volume flow • same pressure dew point • same pressure losses • same dimensions • lower power consumption The power consumption depending on the utilisation (30 - 100%) consists of 3 factors:: 1.

Savings due to intelligent energy ‐ saving speed control 2.

Savings by reducing the amount of heat sucked into the energy ‐ saving refrigeration dryer based on 3.

Summer time and Winter time (warm/cold) Savings by reducing the amount of heat sucked into the energy ‐ saving refrigeration dryer based on a lower outlet compressed air temperature in normal operations, for speed ‐ controlled compressors.

21

ALM Refrigerant Dryers

Refrigeration driers can work in very different ways, for example:

Refrigeration dryer with energy-saving control

  In the case of these refrigeration dryers an intelligent energy-saving speed control air throughput ensures that the electrical power consumption always rises or falls almost proportionally to the compressed  The electrical power consumption is always at the optimum level, in energy terms  Unnecessary energy costs are avoided   If the compressed air production goes into stand by or is switched off:  the energy-saving dryer also goes into stand-by operation  the electricity uptake is reduced to a minimum Important:  • The refrigeration dryer is not completely switched off, but is permanently ready for use but with reduced electricity uptake  • A constant low pressure dew point is guaranteed, even if the compressor goes into operation for a short time

Standard refrigeration dryers

In the case of standard refrigerant driers the current consumption is always 100%.  no matter whether the compressed air throughput through the refrigeration dryer is at 100%, varies, or is zero   once it is switched on, the refrigeration dryer always uses 100% energy a standard refrigeration dryer causes unnecessary energy costs

ALM Refrigerant Dryers

Field of applications for „energy-saving-speed control“ drier?

1) Production of compressed air using a speed-controlled compressor , refrigeration dryer installed before compressed air receiver The compressed air generated by the variable speed compressor varies depending on the air requirement  „ Energy-saving-drier “ adjusts its power requirement to the air output  „ Standard drier “ operates with 100% power consumption.

Compressor is turned off or in standby (no FAD)  „ Energy-saving-drier “ is in stand-by, energy consumption reduced to a minimum, ready to operate  „ Standard drier “ operates with 100% power consumption even if no air is passing through the drier

ALM Refrigerant Dryers

Field of applications for „energy-saving-speed control“ drier?

2.) Production of compressed air using a fixed speed compressor , refrigeration dryer installed before compressed air receiver Constant FAD (100%) from the compressor  „ Energy-saving-drier “ operats with 100% power consumption  „ Standard drier “ operates with 100% power consumption Compressor is turned off or in standby (no FAD)  „ Energy-saving-drier “ is in stand-by, energy consumption reduced to a minimum, ready to operate  „ Standard drier “ operates with 100% power consumption even if no air is passing through the drier

ALM Refrigerant Dryers

Field of applications for „energy-saving-speed control“ drier?

3.) Production of compressed air using a fixed speed or speed controlled compressor , refrigeration dryer installed after compressed air receiver The FAD generated by the compressor passes into the compressed air tank. In response to the compressed air demand the FAD after the tank varies.

 „ Energy-saving-drier “ adjusts its power requirement to the air output  „ Standard drier “operates with 100% power consumption Compressor is turned off or in standby (no FAD)  „ Energy-saving-drier “ is in stand-by, energy consumption reduced to a minimum, ready to operate  „ Standard drier “ operates with 100% power consumption even if no air is passing through the drier

ALM Refrigerant Dryers

Calculation of the energy saving potential

Example:

ALM 1320 vs ALM 1320 "E" Energy price: € 0.15/kWh Working hours compressor station: 4000 Drier utilisation: 70%

ALM Refrigerant Dryers

Calculation of the energy saving potential

Example:

ALM 5300 vs ALM 5300"E" Energy price: € 0.15/kWh Working hours compressor station: 4000 Drier utilisation: 70%

ALM Refrigerant Dryers

Market overview „Energy saving dryer“ In addition to the energy saving dryers with "Speed control“ the market offers also energy-saving dryer with "Cold accumulator”.

Function description according to manufacturer: The cold accumulator with high specific capacity is cooled by the refrigerant circuit and extracts the compressed air heat. If necessary, the coolant compressor cools down the accumulator again. Note ALMiG: Very often normal sand is used as „cold accumulator“ 1 Cooling compressor on, cools compressed air + 'cooling reservoir' 

Pressure dew point falls

2 Cooling compressor off. Cooling of compressed air depends solely on cooling reservoir 

Pressure dew point rises

Result: More moisture in the compressed air network 3 If more compressed air is needed suddenly when the cooling compressor is off (see point A), the system oscillates in response.



Pressure dew point rises very fast

; the system is too slow to absorb these fluctuations!

Result: Much more moisture in the compressed air network ALMiG measurement protocol of a "refrigerated dryer with cold accumulator

ALM Refrigerant Dryers

Installation upstream or downstream of receiver?

or

Installation upstream of receiver

+

Dryer is always subject to constant volume flow by compressor (dryer is not "bypassed").

+ -

No condensate is collected in the compressed air receiver  Receiver remains dry.

High compressed air inlet temperature because short cooling section (install larger dryer if required).

Installation downstream of receiver

-

In the event of high consumption, the refrigeration dryer can be "bypassed" – especially if there are a only few, but large compressed air consumers.

-

Condensate collects in the receiver  walls must be protected from rust.

Inner

+

Compressed air cooling up to dryer inlet (smaller dryer available if required).

29

ALM Refrigerant Dryers

Refrigeration dryer design

The ALMiG refrigeration dryer design is based on:    the compressed air inlet temperature in the refrigeration dryer  the higher the inlet temperature, the lower the throughput the ambient temperature at the dryer installation site  the higher the ambient temperature, the lower the throughput the operating pressure of the compressed air  the higher the operating pressure, the greater the throughput In accordance with DIN ISO 7183, as a rule, all standard refrigeration dryer details relate to • compressed air inlet temperature of +35 ° C • ambient temperature of +25 ° C • operating pressure of 7bar 30

ALM Refrigerant Dryers

Example of dryer design: • Specified parameters      Volume flow: 725 m 3 /h Pressure dew point: +3 ℃ Compressed air inlet temperature: 40 ° C Ambient temperature: 30 ℃ Operating pressure: 11bar • Design   Advance dryer selection: ALM 900 where V=689 m 3 /h Volume flow correction: V  corr = V x f 689 x 0.94 x 1.13 =732 m 3 /h tu x f pu  ALM 900 fits the bill !! (with a reserve !) Ambient temperature ( ° C) Factor ftu 25 1 30 0.94

35 0.89

40 0.83

45 0.78

Operating pressure (bar) Factor fpü 3 0.79

4 0.87

5 0.92

6 0.96

7 1 8 9 10 11 12 13 14 1.03

1.07

1.1

1.13

1.16

1.18

1.21

31

ALM Refrigerant Dryers

Example of dryer design: The „game“ with parameters: If the pressure dew point is not decisive and can be set on +10 ° C, the calculation will be as follows: • Specified parameters   Volume flow: PDP: 725 m 3 /h +10 ° C    Compressed air inlet temp.: 40 ° C Ambient temperature: 30 ° C Operating pressure: 11bar • Design   Advance dryer selection: ALM 740 where V=685 m 3 /h Volume flow correction: V  corr = V x f 685 x 0,94 x 1,13 =728 m 3 /h tu x f pu  ALM 740 fits !!

Result: If temperatures inside the pipe system never fall below +10 ° C, there will be no condensate, and customer may choose a smaller dryer type..

32

ALM Refrigerant Dryers

Example of dryer design: Comparison pressure losses ∆P for ALM 740: 0,23 bar ∆P for ALM 900: 0,16 bar Difference in price: ALM 900 : ALM 740  ca. 15% Result: Customer may choose, if he prefers a smaller pressure loss or a lower price for the dryer.

33

ALM Refrigerant Dryers

ALMiG Kompressoren GmbH Adolf-Ehmann-Stra ss e 2 • 73257 K ö ngen Sales tel. no.: +49 (0)7024 9614-240 Sales e-mail address: [email protected]

www.almig.de

34