CDA System After Upgrade :-

ISO Compressed air quality class : 1, 2, 1                

Compressor room tempresure : +35°C

Dryers' inlet temperature : +32°C

Pressure Dew Point : Better than -40°C

Residual Oil Content : < 0.003mg/m³

Oil content discharged from condensate drain : less than 10mg/liter

Compressed-air drying is a decisive factor for the process reliability in the production and for the operational reliability in compressed-air systems. Therefore, BEKO has offered a comprehensive program regarding compressed-air drying for many years. Amongst others, the cold-regenerated DRYPOINT^® AC adsorption dryers for volume flows up to 1500 m³/h are highly proven. However, for some compressed-air users, this is far from enough. With the heat-regenerated EVERDRY^® adsorption dryers for volume flows up to 20000 m³/h (and more), BEKO offers standardised system solutions for compressed-air drying on a grand scale.

"The new EVERDRY® product line stands for customer-orientated and made-to-measure plant construction. We therefore use standardised, efficient concepts with many variation possibilities", explains Berthold Koch, BEKO managing director. "In this manner, we meet all customer-specific requirements with individual solutions modelling on the case of application.“ This makes it clear: as far as EVERDRY® is concerned, it is not the available technology which determines the concept of a drying plant, but the solution-orientated, optimum technology. EverAir GmbH, a company of the BEKO group, is responsible for the engineering and production.  It has a sound experience with regards to plant construction.  This experience, the industry knowledge and the international capacities of the BEKO group complement one another optimally to provide a unique service offering for drying systems.

Four versions

Four basic versions of the heat-regenerated EVERDRY^® adsorption dryers are available, of which three are without purge air application (ZERO PURGE), and one with purge air consumption.

The EVERDRY^® FRA draws blower air for the cooling directly from the ambient air and thus, according to the ZERO PURGE principle, consumes no purge air. With a pressure dew point of -40 °C, the FRA is the optimum solution for the standard application from  600 m³/h onwards.

EVERDRY^® FRC is the name of the price-orientated adsorption dryer with a performance range between 600 and 3400 m³/h at a pressure dew point of -40 °C. As a ZERO PURGE dryer, it also cools using blower air from the ambient air.

In contrast, the FRP type cools air via a pressure-released partial stream of dry air, its purge air consumption amounts to two per cent of the volume flow on average. Lower investment costs make the EVERDRY^® FRP a well-priced heat-regenerated adsorption dryer for a performance range of 600 m³/h upwards.

As far as the EVERDRY^® FRL for a performance range from 900 to 20000 m³/h is concerned, cooling is effected via blower air in a closed loop (ZERO PURGE). Therefore, the EVERDRY^® FRL is particularly suitable for application in tropical climates. Furthermore, it offers highest process reliability with a pressure dew point of up to -70 °C.

Compressed-air users know the problem: the legal regulations applying to the processing of unavoidably accumulating condensate are becoming more and more strict and comprehensive.   Simultaneously, the costs need to remain within economically justifiable limits. Decentralised processing of condensates directly at the point of origin has therefore established itself as the most suitable and, above all, the most cost-effective solution. This is exactly what the new ÖWAMAT oil-water separator generation made by BEKO achieves better than ever before.

The completely newly developed ÖWAMAT^® devices meet the legal requirements on the introduction of purified water into the municipal wastewater system. This has been confirmed by the national technical approval of the "Deutsches Institut für Bautechnik", Berlin, Germany. A permit according to the law on water is not required: operation of an ÖWAMAT^® is only subject to the duty to give notice to the relevant water authority. "In this manner, ÖWAMAT^® devices are clearly superior to conventional light liquid separators in accordance with DIN 1999 or to gravity separators“, explains Thomas Buschmann, BEKO product manager.

Ingenious operating principle

BEKO's experience of more than two decades is reflected in the ingenious operating principle of the new ÖWAMAT^® devices. First, the oil-contaminated condensate reaches under pressure the newly developed pressure-relief chamber of the ÖWAMAT^®. There, the overpressure is relieved without causing turbulences in the following separation container. Entrained coarse dirt particles are retained in a removable receiver. In the separation container, which has been optimised with regard to size and flow behaviour, the oil settles at the surface through gravity separation. It is supplied to the spillproof oil receiver.

The thus pre-cleaned condensate now flows through the newly constructed oleophilic prefilter, which boasts a noticeably extended active filter surface. With a physically optimal through-current from the inside to the outside, the prefilter fixes the remaining oil droplets in its material. In addition, it is able to take up oil floating in the filter chamber.

The heart of the new ÖWAMAT® generation is the cartridge technology of the main filters. "The new ÖWAMAT® filter cartridge technology contains no activated carbon. As a result of our research work, we now rely on a significantly more effective material". Residual oil components are reliably retained. What remains is dischargeable water, which may be introduced directly into the sewerage system.

"The cartridge technology allows a fast and clean change. It is, therefore, a low waste solution that is easy to dispose of", adds Thomas Buschmann.

The new ÖWAMAT^® series, which boasts the plus of improved performance specifications, is available in a whole array of plant-specific installation sizes. They can be adjusted optimally to the compressor capacity, to the compressor oil and to the climatic conditions. The ÖWAMAT^® is available in five sizes and container volumes of 10 to 228 l. Versions with and without preseparator are in stock at each size range. A heater can be retrofitted at any time for sizes 12-16. The second plus is the cost-effectiveness as far as the operation is concerned: "As regards the maintenance intervals, we have made a great step forward", points out the BEKO product manager. "We were able to significantly extend the intervals of the new ÖWAMAT^® devices, so that they can now be perfectly synchronised with the service contracts of compressors".

Earlier this year The University of Leeds held a training course entitled "Pharmaceutical Medical Gas Testing". This was held at the new training facility of Midland Medical Services Ltd, Rowley Regis, West Midlands. 32 delegates were in attendance for 5 days.

The aim of the course was to teach delegates about practical testing procedures as well as legislative issues and production methods. Midland Medical are a leading supplier and installer of medical gas installations worldwide.

As part of the course, the new BEKOKAT from BEKO TECHNOLOGIES was tested. BEKOKAT is a device designed to remove all trace of hydrocarbons, including oils from compressed air systems. It has particular relevance in the food and medical sectors.

A BEKOKAT CC060 was installed after the lubricated compressors installed in the training room, and the compressed air content was analysed downstream. The results were conclusive: oil content was below the measurable range, that is, less than 0.1 mg/m³. In fact, BEKOKAT delivers oil content below 0.001 mg/m³. The advantages are clear:

• System security with fail-safe alarm and monitoring
• Total quality of compressed air, regardless of ambient conditions (Something not possible with oil-free compressors)

BEKO TECHNOLOGIES also offer a range of compressed air monitoring equipment. This includes MEDBAC, a device which monitors oxygen, carbon monoxide and dioxide, water vapour, sulphur dioxide and nitrous gases in real time. MEDBAC has an alarm system that notifies the user if any gas levels in compressed air rise above a pre-determined level. This is the first such device on the market at a realistic price.

See also:

BEKOKAT - Constant, oil-free compressed air...

MEDBAC - Medical breathing air control...

How much oil is your compressed air allowed to contain?

Sensitive applications e.g. food, electronics, medicine, painting plants, breathing air etc. have to meet particularly high requirements concerning the purity of compressed air.

Activated carbon filters and adsorbers have only limited capacity to absorb oil and it’s difficult  to find the best point in time for changing elements. The concentration of oil vapours in the suction air is subject to considerable fluctuations and overloading can lead to damages of the filter elements. Sudden oil break-through cause high consequential costs.

In order to achieve higher process security in compressed air treatment BEKO Instruments GmbH has developed measuring instruments for supervising the remainder oil rate . Conventional differential pressure manometers only indicate the due exchange of air de-oiling elements and fine filters. Serious defects e.g. pitting corrosion or assembly error aren’t covered by this devices. OILCONTROL however does not react to the rise of the differential pressure, but on changed remainder oil rates  in the streaming compressed air. The residual oil content is measured according to the ion exchange method (MHCMdynamic). The crucial advantages are :

• insensitivity in relation to dampness influences
• independence from changing flow conditions
• freely adjustable alarm values (before/main alarm)

The central, as well as decentralized monitoring of compressed air, with shut-off or bypass of compressed air after alarm now is possible with OILCONTROL. You always have the proof of oil content at any building part or pipeline. You can protect production machines against high oil entry and thus avoid unforeseeable costs for repair and waste.