THE RATIONAL ANSWER: CONDENSATE PURIFICATION SAVES DISPOSAL COSTS

Transcription

1 THE RATIONAL ANSWER: CONDENSATE PURIFICATION SAVES DISPOSAL COSTS Energy and environmental technology.

2 THE COMPLETE SOLUTION. CONDENSATE MANAGEMENT MADE BY ULTRAFILTER Content: ultramat plus tronic Automatic drain UFM-T 1 UFM-T 10 UFM-T 20 UFM-T UFM-T 20 HP Page 6 ultrasep superplus Oil/Water Separator with activated carbon UFS-SP 5 to UFS-SP 240 Page 8 Condensate management: Draining and purification For experts only The ultrafilter-engineer. Together with you he finds the solution. As an expert he ultraaqua autoclean ultrafiltration unit with automatic cleaning UFA-AC 0008 to UFA-AC 0256 Page 10 Dimensions Page 12 2 realises economic concepts. Rely on the competence of a high performance company, setting standards in the market. ultrafilter is a synonym for highest quality: The proof is the DQS-certificate since Condensate management: Draining and purification Consulting and service When we talk about condensate management we do not just mean a system of outstanding hardware. Condensate management is more: It includes a break even analysis free of charge, intensive consulting and an outstanding skilled and trained service engineer.

3 Clean solutions. From ultrafilter The system All ultrafilter units provide the best solution in every application. ultrafilter offers reliable solutions. Futureoriented products for economic and environmental oriented draining and purification of your condensate independent of quantity and separation characteristics. A system with efficiency But where is the benefit of the best and most modern drain when the condensate is still disposed of carelessly? Where is the benefit of a sophisticated condensate purification when draining is not reliable It is important for you to select a system, harmonised to your application down to the last detail. Solving your problem and saving you money. We from ultrafilter work for these goals. and not cost effective? The answer is obvious: With ultrafilter s system engineered solution you get draining and purification from one source. True condensate management. 3

4 ACT RESPONSIBLY WITH ECONOMY IN MIND The drain. Working with time-controlled drains means unnecessary costs. A level-controlled drain has a pay back period of less than one year. Action yes, but how? You drain your condensate with the reliable ultramat plus tronic without expensive air loss. This is economical and protects the environment, always. The economic facts. If a time-controlled drain with a 1 /8 opening blows off just 10 secs of air (at 7 bar) every 10 mins, the cost will be 193,-- EURO each year. And for the T1? No waste of air and 4,47 EURO for electricity! Compare this with the T1 s pricing: the advantage is obvious in every currency! 4 Airloss-calculation: Pressure Outlet (bar) () 0,4 0,8 1,6 3,2 6,4 1 3, , , , , , , , Airloss in l/min Opening time: = 1sec per minute = 1 min per hour = 24 min per day = 87 min per year of air loss. Air loss = 87 x 0,735 m 3 /min = 6438,6 m 3 /year Costs = 6438,6 m 3 /year x 0,03 EURO/m 3 = 193,15 EURO/year

5 The condensate. Oil polluted condensate produced in oil lubricated compressors is unavoidable. It is not unusual that the oil concentration exceeds today s legal limits up to 250 times. And the future: Laws will be even more restrictive. Purification from ultrafilter already meets these standards today. Restrictive legislation: Justified World-wide legislation punishes discharges of oil into the environment. Every gallon of oil has a huge damage potential. Act now: ultrafilter can help you to protect from these risks. Action yes, but how? You can collect the condensate and dispose it using disposal companies for costs up to 0 DM/m 3. A lot of money. There is one cost-saving alternative: Purification of oil/water mixtures and emulsions with ultrasep superplus or ultraaqua autoclean. Always economical, always the best for the environment, always cost-effective. 5

6 THE MOST COMPACT: UFM-T 1 / T10 / T20 / T Especially in small installations there is definitely the need for drains working without air loss. Everywhere: from compressors, air receivers, filters, dryers. Float or timecontrolled drains may stick, are sensitive to particles and cause malfunctions. Or they open too early and too long thus causing high losses of your most expensive and most valuable energy: pressurised air. The ultramat plus tronic drain condensate automatic, reliable and economical, without air loss. The function Whilst collecting the condensate the diaphragm is closed by the system pressure. As soon as the sensor detects liquid either oil or water the magnet pulls up the anchor plate. The chamber above the diaphragm deflates, the condensate is driven out by the system pressure. As soon as the magnet releases, the drain closes. Reliable operation can be that simple. And in the case of malfunction? The drain continues to work with the timing it needs for airloss free working. And as soon as the malfunction is over, it resets automatically. That s service-free operation! 6

7 The construction The UFM-T s. This means compact dimensions and well estimated details, e.g. coated housing, membrane and o-rings of VITON for condensate of oilfree compressors. The whole ultrafilter know-how of our construction team results in this drain: easy to install and easy to service. Sensors without moving parts. Safe function without sticking or blocking means safe working without air loss. Condensate entry from the top and rear side. Enables fitting in even narrow spaces, e.g. under vessels or small compressors. Installation without additional fittings makes installation work quick and easy. Cable at the backside and sloped display. Easy reading from every position. Voltage range from 24V to 230V alternating or dual voltage, automatically self adjusting. Sophisticated electronic control. A continuously self-monitoring electronic, a potential free malfunction contact and automatic routines ensure long-term reliable function. The options BSP- or NPT bolt connections Thermostatically controlled heater 7

8 FOR OIL/WATER MIXTURES ULTRASEP SUPERPLUS UFS-SP 5 TO UFS-SP 240 A practical decision: Waste purification on your own with a powerful oil/water separator fulfilling legal demands. Working so effectively and producing water so clean that it may be drained directly always of course provided that the unit is serviced periodically and runs exclusively with mixtures and not with emulsions (see page 5). certified The function A pressure-relief chamber separates condensate and expanding air. The condensate then passes a sedimentation compartment - easy to remove thus easy to clean. The next step is the coalescing foam with its additional oil separation effect. Free floating oil is siphoned off into an oil can. The water is purified in the activated carbon adsorber from the last oil droplets. Pure water leaves the unit ready to be drained. 8

9 The construction The range of ultrasep superplus : There are 7 sizes, the smallest up to 120 m 3 /h, the largest up to 7. m 3 /h to allow perfect match to your compressor room. Best match best economy for your benefit. And the safety? The activated carbon is protected by a pre-adsorbent ultrasorb and a bright yellow floater warns about the beginning of a blockage of the carbon by oil sludge and the water quality is visibly checked with a simple turbidity comparison and... Details? An incorporated oil can which can only be changed if the oil flow is interrupted or the water exit at the unit s rearside or a coalescing foam for additional oil separation or... The service The water s quality can only be as good as the activated carbon s performance. The service label on the unit s lid demonstrates what to do: take out the little glass and the sample bottle, take a sample and compare. And then? Either the water is safe to be drained. Or you have to replace the adsorber. How? Is indicated on the lid with a permanent servicelabel. 9

10 FOR OIL/WATER EMULSIONS ULTRAAQUA AUTOCLEAN Your expectations: long service intervals, an automatic unit constructed according to the strict quality demands of company being certified since 1991, a separation technology with a filtrate quality guarantee of less than 5 mg/l. ultraaqua autoclean : ultraaqua means ultrafiltration, a separation technology without adding chemicals; a virtually indestructible ceramic membrane, a membrane with a ph resistance from 1 to 11 and a temperature range up to 80 C; autoclean is a synonym for a revolutionary adaptive performance control of the filtration process. 10 The function Condensate and expanding air are separated in the pressure relief section (1). The sedimentation and the coalescing filter following can easily be removed to be serviced. Free floating oil is removed by an overflow (2). Between gravity separation (5) and buffer tank (7) there is a second coalescing foam. The internal feed pump (8) pumps the pre-separated condensate into the process tank (9). Process pump (10) pumps the condensate through the membrane module (11). Clean filtrate passes the membrane and leaves the unit by V2, ready to be drained. V1 pulses back periodically filtrate by means on compressed air. This repeated automatic backflush extends significantly the cleaning intervals. Oil and water is fed into the process tank only pure water is discharged. Consequently the oil concentration raises continuously thus reducing the filtrate flow. Therefore, this so called concentrate must be expelled before an (automatic) cleaning cycle by V4. Due to autoclean this is done at the latest possible and therefore most economic moment. Then water (V3) and cleaning agent (with metering pump 13) are added into the processtank. After the cleaning the agent may be expelled by V5. The unit starts the next filtration cycles with a regenerated membrane.

11 autoclean autoclean detects fluctuation in the day/night or seasonal flow of condensate. autoclean compares the condensate flow with the unit s performance : Automatic cleaning is not initiated before the input exceeds the output. Standard: The freezing of the membrane is prevented by a sensor-controlled heater system. So autoclean adapts the unit s performance to the varying demands: large quantities in suer, small quantities in winter do require a flexible and adaptive control. And a self adapting unit is the The large LC-display shows all necessary information, making operation very easy: just follow the unit s instructions. most safe and economic that can be imagined. Environmental protection in detail: An all-round border catches small fluid spillages. 11

12 ALL AT A GLANCE ultramat plus tronic superplus A B Dimensions max. Performance max. Temp. C pressure range C D E F compr. Dryer m 3 /min m 3 /min condensat ambient bar drain volume UFM-T1 UFM-T10 UFM-T20 UFM-T / 2 1 / 2 3 / 4 G 3 / 4 G 3 / 4 G 3 / 4 G ,8 16 0,8 16 0,8 16 0,8 16 0,10 0,11 0,22 0,58 UFM-T20HP / 4 G ,2 40 0,32 ultrasep superplus Max. compressor performance Dimensions Condensate entry Water exit Clearance required Tank volume Nm 3 /h* max. Height (A) Width (B) Depth (C) D E F G H l UFS-SP 5 UFS-SP 10 UFS-SP 15 UFS-SP 30 UFS-SP UFS-SP 120 UFS-SP * Not suitable for stable emulsions, specific performance depends on type of compressor and lubricant / / ultraaqua autoclean Max. filtrate quantity Dimensions l/h Height (A) Width (B) Depth (C) D E F G UFA-AC 0008 UFA-AC 0016 UFA-AC 0032 UFA-AC 0064 UFA-AC 0096 UFA-AC 0128 UFA-AC 0192 UFA-AC

13 weight Power Supply D kg 0,9 1,0 1,2 3,5 V/Hz 24 V DC ~ 230 V AC 24 V DC ~ 230 V AC 24 V DC ~ 230 V AC 110 ~ 230V 50 Hz altern. 24 V DC A UFM-T1 E - T B C F 3,3 110 ~ 230V 50 Hz altern. 24 V DC effective carbon volume Pre-adsorber ultrasorp volume Oil tank volume l l l , ,5 17,5 2x 17,5 2x 17,5 UFS-SP L e n Total volume Tank l Max. filtrate quantity Processpump kva* 0,75 0,75 1,50 1,85 3,00 4,00 5,50 7,50 Electr. Heater kva* 1,0 1,0 1,6 1,6 2,0 2,0 2,0 3,0 * 3 x 400 V/50 Hz, altern. 3 x 440 V/ Hz Connection for: electricity, water, air, filtrate UFA-AC g t h 13

14 ULTRAFILTER. AND MORE THAN THAT. COMPRESSED AIR FILTER DIVISION COMPRESSED AIR DRYER DIVISION COMPRESSED AIR FRIDGE DRYER DIVISION PROCESS DIVISION Applications profile Filtration of compressed air. Wherever compressed air is used as a source of production energy. Treatment target: clean compressed air at qualities defined by specifications. And clean compressed air means: free of oil, water, dirt and particulates. Product profile ultrafilter supplies the following products for this purpose: Water separators Prefilters High-performance filters Adsorption filters Filter housings Product features High flow rates Constant high efficiency Better-than-average dirt retention capacity Minimal pressure drop Guaranteed long service life Maximum operational reliability Success profile Maximum cost-effectiveness thanks to price, performance and permanent reduction of operating costs. Applications profile Cleaning and drying of compressed air in all areas of production in which compressed air is used as an energy source. Target: clean and dry compressed air at a quality defined by the application. Clean and dry means here, in particular: compressed air free of condensate, water, vapours and gases. Product profile ultrafilter supplies the following products for this purpose: Fridge dryer system Adsorption dryers - Heat-regenerated - Heatless-regenerated - Electrical - Pneumatic Oil vapour adsorbers Breathing air systems Complete packages for the purification of compressed air Product features Ease and flexibility of use Low-maintenance, always reliable Ultramodern, highly efficient process design Correct function guarantee Success profile Highly efficient and costeffective thanks to significant cuts in operating costs. Applications profile Cleaning and drying of compressed air. Target: basic purification of compressed air dry, free of condensate and particles. Product profile Fridge dryer water cooled air cooled processor controlled high pressure complete plants for purification of compressed air Product features easy and flexible in use low-maintenance, always reliable ultra-modern, highly efficient process design and environmental friendly Success profile Constant performance and additional reduction of running costs by efficient purification. Applications profile Filtration of gases and liquids wherever they come into contact with the product during manufacture. The target: maximum purity standards up to and including sterilisation where quality requirements are exceptionally high. Gases and liquids free of impurities, aggressive dirt particles, oil vapours, bacteria, viruses and hydrocarbons. Product profile ultrafilter supplies the following products for this purpose: Pre- and submicrofiltration of liquids Sterile filtration of compressed air, gases and liquids Vent filters Ultrapure gas filters Sterile air systems Product features High performance and low pressure drop Maximum safety standards Guaranteed quality Validated and certified performance Success profile Cost-effective performance at maximum purity level. 14

15 CONDENSATE TREATMENT DIVISION WATER CHILLER DIVISION SPECIAL PLANTS SERVICE DIVISION Applications profile Discharge and treatment of oil-saturated compressed air condensates wherever they occur in production. Separation of water and oil where compressed air condensates are not to be disposed of but instead recycled in accordance with legal requirements. Product profile ultrafilter supplies the following products for this purpose: Condensate drains Condensate processors (oil/water separation systems for stable and non-stable condensate) Complete systems for condensate treatment Product features Fulfils legal requirements (Germany s Water Management Act) Maximum operational reliability Modern user-friendly technology Compact, robust and functional Intelligent automatic control system Economical and therefore cost-effective in service Exceptionally easy to maintain Success profile In-house condensate purification. To protect the environment and achieve permanent cuts in operating costs. Application Profile In many production processes cooling water needs to be chilled. Required are chillers which cool the process water economically and sercurily down to required temperatures. Product Profile ultrafilter offers the following products: ultracool mini ultracool midi ultracool maxi Product Features environmental-friendly refrigerant R 134a high security in operation modern, application-oriented technology high efficiency of fridge circuit intelligent control easy to service and to maintain Success Profile ultracool water chiller reduce production cycles, increase productivity and reduce manufacturing costs. Application profile Custom-sized systems for purification of compressed air, technical gases (CO, CO 2, N 2, H 2, O 2 ) and fluids. Complete solutions designed for the individual customer requirements. Product profile System solutions, based on adsorption technique: drying multi-components adsorption substance diversification Individual solutions, which extend the standard prograe. With conclusive advantages highest consulting quality by trained and experienced ultrafilter-engineers complete service prograe (from energy consulting to analysis of working expenses and profitability, to planing, project management and service. Success profile System engineered solution. Reliable and economic solutions for individual applications. Service profile Complete range of engineering services and on-the-spot expert technical advice, ideal pre-sales consultation and aftersales services. An allround service to ensure that your customers know they are getting the right advice every time. Range of services Services (profitability and operating cost analyses, project planning and design) After-sales service (coissioning, inspection, repair and maintenance) Measuring and analysis (quality, flow and energy measurements, determination of residual oil content) Financing of sales (instalment purchasing, coercial leasing, procurement of financing, part-exchange of used equipment) Training (seminars tailored specifically to customer, industry, product and application) Disposal (both ultrafilter and competitors elements, adsorbents and activated carbon) Success profile Services which stand for maximum quality and customer counication. Services that the customer can rely on. 15

16 EUROPE ultrafilter gmbh Büssingstraße 1 D Haan Tel.: Fax: info@ultrafilter.de Niederlassung Nord Am Markt 4 D Stadthagen Tel.: Fax: info@ultrafilter.de Niederlassung Süd Hauptstraße 18 D Senden Tel.: Fax: info@ultrafilter.de Niederlassung Ost Greifswalder Str. 80a D Berlin Tel.: Fax: info@ultrafilter.de ultrafilter s.r.l. Via Cesare Pavese 5 I-90 Opera MI (Milano) Tel.: Fax: ultrafilter@iol.it ultrafilter s.a. B.P. 12 6, rue de la Croix Jacquebot F Vigny Tel.: Fax: info@ultrafilter.fr ultrafilter s.a. c./colom II. no. 6 E-Terrassa (Barcelona) Tel.: Fax: ultrafilter@ultrafilter.es ultrafilter b.v. Zoomstede 16 NL-3431 HL Nieuwegein Tel.: Fax: ufnl@euronet.nl ultrafilter gesmbh Lamezanstraße 5 A-1232 Wien Tel.: Fax: ultrafilter@e4n.at ultrafilter ag Thurgauer Str. 74 CH-8050 Zürich Tel.: Fax: verkauf@ultrafilter.ch ultrafilter ltd. Pebble Close, Tamworth Business Park, Amington GB-Tamworth Staffs B77 4RP Tel.: Fax: info@ultrafilter.com ultrafilter A/B Sweden ultrafilter a/s Strudsbergsvej 6 DK-4 Slagelse Tel.: Fax: ultrafilter@ultrafilter.dk ultrafilter a.s. Solgaard Skog 4, N-1539 Moss P.O. box 744, N-1509 Moss Tel.: Fax: ultrafilter@ultrafilter.no ultrafilter sp. z o.o. ul. Genewska 18 a PL Warszawa Tel.: Fax: info@ultrafilter.com.pl ultrafilter s.r.o. Konevova 139 CZ Praha 3 Tel.: Fax: ultrafilter@bitis.cz ultrafilter spol. s.r.o. Púchovská 8 SK Bratislava 35 Tel.: Fax: info@ultrafilter.sk ultrafilter kft. Karolina ut. 65 H-1113 Budapest Tel.: Fax: ultrafilter@matavnet.hu ultrafilter s.r.l. Calea Mosilor nr. 274, Bl. 18, Sc. A, Et. 3, Apt.12 Bucaresti - Sector 2, Romania Tel.: Fax: ultrafilter@xnet.ro ultrafilter San. ve Tic. a.s Turkey AO ultrafilter Russia AMERICAS ultrafilter inc. 35 Engineering Drive Atlanta Technology Park USA-Norcross, GA Tel.: Fax: Tollfree: info@ultrafilter-us.com ultrafilter inc Millcreek Drive, Unit 7 Mississauga, Ontario L5N 5R8 Tel.: Fax: Tollfree: info@ultrafilter-ca.com ultrafilter Ltda. Brazil ASIA ultrafilter k. k Shiba, Minato-ku Tokyo , Japan Tel.: Fax: ultrafilter@syd.odn.ne.jp ultrafilter co. ltd. #911 Kwachon officetel, 1-14 Byulyang-dong, Kwachon Kyunggido Korea Tel.: Fax: info@ultrafilter.co.kr ultrafilter pte. ltd. 25 International Business Park #02-65/67 German Centre, Singapore 22 Tel.: Fax: info.asia@ultrafilter.com.sg ultrafilter inc. 24th floor, Pacific Star Building Makati Avenue Makati City 1, Philippines Tel.: Fax: jclcorpuz@yahoo.com ultrafilter co. ltd. 96/18 Rattanathibet Rd. Bangkarsoe, Muang Nonthaburi 10 Thailand Tel.: (hunting 10 lines) Fax: and ufthai@asiaaccess.net.th ultrafilter sdn. bhd. No 21, Jalan Pengacara U1/48, Temasya Industrial Park Shah Alam, Selangor Darul Ehsan, Malaysia Tel.: Fax: ultrafilter pt. Cilandak Coercial Estate 101 JI. Cilandak KKO, Jakarta 12075, Indonesia Tel.: Fax: info@ultrafilter.co.id ultrafilter pte. ltd Nan Zheng Building 580, Nanjing Road West Shanghai 041 China Tel.: Fax: ultrasha@public7.sta.net.cn ultrafilter co. ltd. 10F-1, No. 79, Hsin-Tai Wu Road, Sec. 1 Hsi-Chih City, Taipei Hsien, Taiwan R.O.C. Tel.: Fax: epoch908@seed.net.tw ultrafilter international AG 334, 14th Main Road Rajmahal Vilas Extension Bangalore India Tel.: Fax: ufiag@vsnl.net AUSTRALIA ultrafilter pty. ltd Norcal Road, Unit 29 Nunawading, Victoria 3131 Tel.: Fax: Mobile: sales@ultrafilter.com.au ultrafilter pty. ltd. 72a Raleigh Street Cambridge Neuseeland Tel Fax: AFRICA ultrafilter pty. ltd. PO Box 1991 Cramerview 20 South Africa Tel.: /7/8, Fax: ultrafil@global.co.za ultrafilter manufacturing Co. Büssingstrasse 1 D Haan Tel.: Fax: info@ultrafilter.de ultratroc gmbh Ochsenweg 73 D Flensburg Tel.: Fax: info@ultratroc.com AG ultrafilter s.a. Oc./Colom II. no. 6 E-Terrassa (Barcelona) Tel.: Fax: ultrafilter@ultrafilter.es ultrafilter inc. 35 Engineering Drive Atlanta Technology Park USA-Norcross, GA Tel.: Fax: Tollfree: info@ultrafilter-us.com 21/03/2