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COMPRESSED AIR TREATMENT

COMPRESSED AIR TREATMENT
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COMPRESSED AIR TREATMENT

Product catalog summary
Overview of Compressed Air Treatment Components
This document provides a comprehensive overview of components involved in compressed air treatment, including air filters, cyclone separators, dryers, air receiver tanks, condensate drains, oil/water separators, industrial chillers, and EPL piping systems.
Compressed Air Quality Standards
The document outlines ISO 8573-1:2010 standards for compressed air quality, detailing particle count, pressure dew point, and oil concentration to ensure suitability for industrial applications.
Key Components and Their Functions
  • Compressor: Increases air pressure by reducing volume.
  • Cyclone Condensate Separator: Removes liquid water using centrifugal motion.
  • Pressure Vessel: Dampens pulsations and supplies peak demands.
  • Compressed Air Dryer: Prevents corrosion by removing moisture.
  • Condensate Drain: Prevents system overload by removing liquid condensate.
  • Filter: Removes particles, water, oil aerosols, and vapours.
  • Activated Carbon Tower: Provides oil-free air by eliminating vapours and odours.
  • Oil/Water Separator: Complies with regulations by separating oil from water.
  • Nitrogen Generator: Extracts nitrogen using Pressure Swing Adsorption.
End User Recommendations
Advice includes replacing inappropriate applications, installing flow controllers, turning off unused equipment, and maintaining tools.
Filtration Technology
The Champion filtration range is noted for reliability and efficiency, meeting ISO standards for industrial applications.
Technical Specifications
Technical data for filters and separators includes flow rates, pressure ratings, and dimensions.
Specifications
  • Filter Grades:
    • Grade M: Removes particles to 0.1 micron, oil content 0.03 mg/m³.
    • Grade S: Removes particles to 0.01 micron, oil content 0.01 mg/m³.
    • Grade A: Removes oil vapour, oil content <0.003 mg/m³.
    • Grade R: Removes dust to 1 micron.
  • Operating Limitations: Max pressure 17.2 bar g, temperature limits vary by grade.
Correction Factors
Correction factors adjust filter capacities based on pressure and temperature.
Technical Data
Tables list specifications for filter models, including connection sizes and flow rates.
Refrigeration Air Dryers
  • Features include variable speed fan and energy-saving modes, suitable for various industries.
Modular Desiccant Dryers
  • Compact systems providing high air quality and reliability, suitable for many applications.
Applications
Systems are used across industries for efficient compressed air management.
Specifications
  • Operating Pressure and Correction Factor: Table lists pressures and correction factors.
  • Heat Recovery Units: Designed for efficient heat recovery, operating pressures 1-16 bar.
  • Vertical Air Receivers: Stabilize air demand, capacities 100-10,000 liters.
  • Condensate Drains: Models include electronic and manual options.
  • Oil/Water Separators: Efficient separation, capacities 2.5-60 m3/min.
  • Industrial Chillers: Cooling capacities 0.8-365 kW.
Procedures and Recommendations
  • Heat Recovery Units: Utilize waste heat with thermostatic valve protection.
  • Condensate Management: Install ball valve and strainer to prevent air bubbles.
  • Oil/Water Separation: Emphasizes condensate management for compliance and cost reduction.
Norms and Standards
  • Vertical Air Receivers: Comply with EU directives for safety.
  • Oil/Water Separators: Meet environmental regulations.
Key Data from Tables and Charts
  • Operating Pressure Table: Lists pressures and correction factors.
  • Heat Recovery Units Table: Details dimensions and connection sizes.
  • Vertical Air Receivers Table: Provides sizes and pressures.
  • Condensate Drains Table: Includes technical data.
  • Oil/Water Separators Table: Lists model codes and capacities.
Critical Information
  • Environmental Compliance: Highlights importance of proper condensate management.
  • Energy Efficiency: Cost-saving potential of heat recovery units and separators.
  • Maintenance Recommendations: Regular service intervals for separators.
See more

Catalog excerpts

COMPRESSED AIR TREATMENT-1

COMPRESSED AIR TREATMENT • Basic Principals • Air Filters • Cyclone Separators • Refrigeration Dryers • Adsorption Dryers • Air Receiver Tanks • Condensate Drains • Oil / Water Separators • Industrial Chillers • EPL

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COMPRESSED AIR TREATMENT-2

Compressed air quality classes according to ISO 8573-1:2010 SOLID PARTICLES HUMIDITY AND LIQUID WATER OIL MAXIMUM NUMBER OF PARTICLES PER CUBIC METER CONCENTRATION OF TOTAL OIL2] CLASS PRESSURE DEW POINT (LIQUID, AEROSOL AND VAPOUR) AS A FUNCTION OF PARTICLE SIZE, D2] [ppm / w / w] [0.1 μm < d ≤ 0.5 μm] [0.5 μm < d ≤ 1.0 μm] [1.0 μm < d ≤ 5.0 μm] [°C] [°F] [mg/m3] 1] 0 As specified by the equipment user or supplier and more stringent than class 1 ≤ 20,000 ≤ 400 ≤ 10 ≤ -70 -94 ≤ 0.01 ≤ 0.008 2 ≤ 400,000 ≤ 6,000 ≤ 100 ≤ -40 -40 ≤ 0.1 ≤ 0.08 3 Not specified ≤ 90,000 ≤ 1,000 ≤ -20 -4 ≤1 ≤ 0.8 4 Not...

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COMPRESSED AIR TREATMENT-3

BASIC PRINCIPLES OF MOST TYPICAL COMPRESSED AIR APPLICATION MAX PRESS: PROD. YEAR: PROD. YEAR: PROD. YEAR: 1. Compressor: The basic working principle of an air compressor is to compress atmospheric air, which is then used as per the requirements. In the process, atmospheric air is drawn in through an intake valve; more and more air is pulled inside a limited space mechanically by means of piston, impeller, or vane. 3. Pressure vessel: Pressure vessel plays very important role in compressed air system: Since the amount of pulled atmospheric air is increased in the receiver or storage tank, volume...

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COMPRESSED AIR TREATMENT-4

Nitrogen line PROD. YEAR: PROD. YEAR: PROD. YEAR: PROD. YEAR: 5. Condensate drain: Drains are needed at all separators, filters, dryers and receivers in order to remove the liquid condensate from the compressed air system. Failed drains can allow slugs of moisture to flow downstream that can overload the air dryer and foul end use equipment. 6. Filter: Compressed air filters are used for high efficient removal of solid particles, water, oil aerosols, hydrocarbons, odour and vapours from compressed air systems. To meet the required compressed air quality appropriate filter element must be installed...

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COMPRESSED AIR TREATMENT-5

CHF SERIES ALUMINUM COMPRESSED AIR FILTERS • General industrial applications At a glance… Operating Pressure 17 bar Connections 3/8″ - 3″ Flow Rate 18 - 18247 cfm The reliability of compressed air filtration is paramount to the ongoing fight against problems caused through contamination entering the air system. Contamination in the form of dirt, oil and water can lead to: • Pipescale and corrosion within pressure vessels • Damage to production equipment, air motors, air tools, valves and cylinders • Premature and unplanned desiccant replacement for adsorption dryers • Spoiled product The Champion...

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COMPRESSED AIR TREATMENT-6

Compressed Air Purification - The perfect choice! Water Separation – The CHF Range of water separators Filtration – The CHF Range of compressed air filters The CHF-range of water separators provide bulk condensed water and liquid oil removal and are used to protect coalescing filters against bulk liquid contamination. The CHF-range of filters efficiently removes water and oil aerosols, atmospheric dirt and solid particles, rust, pipescale and micro-organisms. Compressed air contamination will ultimately lead to: t Inefficient production processes S t poiled, damaged or reworked products R t educed...

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COMPRESSED AIR TREATMENT-7

Superior Filtration Technology A Patented dual indicator (optional accessory) shows differential pressure drop and economical operating efficiency B Patented smooth bore flow insert directs air into the filter element, minimising turbulence and pressure losses C All-aluminum, precision die cast body suitable for 80°C and 17 bar g maximum working pressure applications Filter element with stainless steel mesh withstands high differential pressure while minimizing flow restriction through the element High-efficiency drainage layer improves liquid drainage properties and enhances chemical compatibility...

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COMPRESSED AIR TREATMENT-8

Technical Data - Compressed Air Condensate Separators - CHF Series SEPARATOR MODEL CHF005W CHF007W CHF018W CHF040W CHF085W CHF170W CHF380W

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COMPRESSED AIR TREATMENT-10

Grade M - General Purpose Protection Grade A - Activated Carbon Filtration Particle removal down to 0.1 micron including coalesced liquid, water and oil, Oil vapor and hydrocarbon odor removal, providing a maximum remaining oil providing a maximum remaining oil aerosol content of 0.03 mg/m3 @ 21°C content of <0.003 mg/m³ (<0.003 ppm) @ 21°C (Precede with Grade S filter) Grade S - High Efficiency Oil Removal Filtration Grade R - General Purpose Dust Filtration Particle removal down to 0.01 micron including water and oil aerosols, providing a Dust particle removal down to 1 micron maximum remaining...

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COMPRESSED AIR TREATMENT-11

FILTER ELEMENTS Technical Data - Compressed Air Filter Elements CHF Series - Grade M Technical Data - Compressed Air Filter Elements CHF Series - Grade A

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COMPRESSED AIR TREATMENT-13

REFRIGERATION COMPRESSED AIR DRYERS CHR SERIES REFRIGERATION AIR DRYERS Applications • Compressed air systems At a glance… Operating Pressure 16/14 bar g The advanced design and innovative technology offered by CHR Series refrigeration dryers provides an optimised performance alongside a more efficient mode of management. The electronic controller, complete with user-friendly interface, has been simplified to focus on the essential functions of operation and regulation, including the unique fan control (CHR6 – CHR167). Simplicity in design, unrivalled reliability, and extraordinary value for...

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COMPRESSED AIR TREATMENT-14

For higher capacities up to 45 m3/min (2,700 m3/h) please contact the Champion Sales Team DRYER ABSORBED POWER POWER SUPPLY Timer drain as standard, electronic no loss drain option on request on Models CHR6 - CHR217. Integrated zero loss drain as standard on Models CHR333 and CHR417. OPERATING PRESSURE [bar] CORRECTION FACTOR FC1 Calculation for correct Dryer Air flow = Nominal Dryer Air Flow x FC1 x FC2 x FC3

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.