Nowadays, for most industrial manufacturing processes, reliable compressed air purification with a degree of purity tailored to the application is a basic requirement. The growing demands that the manufacturing industry has to meet due to digitalization and the commitment to save energy, have led to the development of a compressed air purification system that combines all process steps - from pre-filtration to drying, to fine filtration and condensate management. In a compact stand-alone design, this system can be used as a plug and work solution.
Compressed Air Purification System:
- Dryer inlet
- Integrated UltraPleat™ prefilter
- Condensate drain
- Desiccant cartridge
- Electronic control
- UltraSilencer
- Dew point transmitter (Superplus version)
- Integrated UltraPleat™ afterfilter
- Touch display
- Dryer outlet
For the economical use as instrument air or process air, the selection of the purification components downstream of the compressor is of decisive importance. The coolers, cyclone separators, coalescence filters, condensate drains, refrigeration compressed air and/or adsorption dryers and particle filters are arranged in series according to the application profile. This is standard for central purification. This does not rule out decentralized treatment at such consumers who place particularly high demands on the compressed air, because it is uneconomical for many applications to provide a high compressed air quality centrally for the entire compressed air network, especially as contamination with pollutants in the compressed air networks cannot be ruled out. Therefore, to support process and product integrity, especially in the food and beverage industry, the pharmaceutical industry and for the supply of, for example, paint shops, it is not only for economic reasons that an additional treatment stage should be used directly at the point of use.
Supply of compressed air of defined quality at the point of consumption
The flexible modularity allows a variety of installation and mounting options
The Ultrapac™ Smart dryer comes with a modular design that allows a wide range of installation and mounting options in machines and systems.
Compressed Air Purification in Three Stages
- The integrated pre-filter retains solid particles and suspended matter as well as liquid aerosols (oil/water).
- The adsorption dryer adsorbs the moisture in the compressed air up to a pressure dew point of -70 °C/-94 °F, at 70 % nominal load (standard -40 °C/-40 °F).
- In the last step, remaining solid particles up to 0.01 μm are retained in the integrated after-filter.
Depending on operating conditions, the three-stage purification system can be used to comply with purity class 1-2:1-2:1-2 according to ISO 8573-1:2010.
Low Noise, PDP Control and Low Differential Pressure
During the development of the system, several requirements had to be met which are essential for direct use: Controlled and consistent quality of the compressed air in accordance with the specifications for the respective application, low-noise operation, simple maintenance and, finally, the possibility of integrating the control system into existing production lines. The recording and control of the specified pressure dew point (PDP) is of particular importance. The PDP is set to -40 °C / -40 °F as standard. This is of particular importance as the dew point temperature changes with changing pressure. The system version with integrated dew point transmitter, which measures directly in the compressed air flow, proves to be particularly efficient. Switching between the two dryer cartridges - which are filled with a highly adsorptive stable desiccant - only takes place when the desiccant is saturated. This minimizes the compressed air requirement of this heatless regenerated adsorption dryer, which, in contrast to heat regenerated dryers, does not require any heating energy for the regeneration process.
The noise development during the change-over process could be reduced to the range of 60 dB(A) with a newly developed silencer. The Ultrapac™ Smart dryer can therefore be used directly at the workplace without sound insulation or integrated into machines without increasing their noise level.
The filters used in this system provide efficient filtration performance at low differential pressure. When the compressed air enters the unit, the prefilter effectively separates or retains liquid and solid particles before the air flows into one of the two desiccant cartridges. The afterfilterremoves solid particles down to 0.01 μm.
