Air Handling Unit
The air handling unit is the main component of various types of piston cylinder air compressors and screw compressors, also known as the air-end compressor. The primary function of this device is to intake ambient air, compress it, and ultimately store the compressed air in the compressor tank.
Arman Havasazan offers air handling units for compressors in the following two main types:
- Air End for Piston Cylinder Compressors
- Air End for Screw Compressors
The part of the compressor responsible for suction and compression of air is called the air end or airend. It is considered the heart or core block of the compressor system, where its energy is supplied directly or via belt from an electric motor, diesel engine, or gasoline engine.The part of the compressor responsible for suction and compression of air is called the air end or airend. It is considered the heart or core block of the compressor system, where its energy is supplied directly or via belt from an electric motor, diesel engine, or gasoline engine.
Air Handler Unit for Piston Cylinder Air Compressor
The piston cylinder air handler unit is one type of air handler unit where the piston, driven by an electric motor or dynamo piston air handler unit, moves inside the cylinder and performs the compression of air. These units are available in models with one, two, three, or four cylinders in the market.
To enhance the strength of the air handler unit, they use a body made of suitable alloys. The smooth sound produced by the belt compressor when it is running indicates the quality of this device. Leading sellers of this product are found in major industrialized countries such as Europe, America, Italy, China, and others.
واحد هواساز کمپرسور اسکرو
The screw air handler unit is one of the main components of a screw compressor, tasked with compressing the surrounding air and transferring this compressed air to the compressor tank. The air end of the compressor consists of two helical rotors, one male and one female, which work together to compress air. The structure and operation involve air entering from one side and the rotors, driven by the necessary force generated by an electric motor, compressing the incoming air to a specified pressure (up to a maximum of 10 bar).
When selecting a suitable screw air handler unit, considerations should include the required air delivery capacity, operating pressure, and motor power. It’s important to note that larger screw air handler units typically operate at lower speeds, resulting in longer lifespan and lower wear and tear.
Air Dryers
Types of air compressor
The air compressor dryer is divided into two general categories:
- Compressor refrigeration dryer
- Compressor absorption dryer
1- Refrigeration dryer
Why should a refrigeration dryer be installed after the compressor?
The air inside the compressor tank contains a significant amount of dissolved moisture, and all compressors generate water in their tanks. This water, along with moist air, enters the air transmission lines and can damage industrial components, pneumatic tools, and solenoid valves.
To completely remove water and moisture, a refrigerated dryer or desiccant dryer must be used. These devices separate moisture, vapor, and water from the compressed air through a process of cooling and lowering the air temperature.
Installed after the compressor tank, the air entering these devices is cooled to 3 degrees Celsius. As the temperature decreases, the ability to retain moisture in the air diminishes. Consequently, at this temperature, all water particles and vapor are separated from the air and ultimately discharged from the refrigerated dryer through a timed electric drain valve.
Common brands of refrigeration dryers: Mikropor and Wise Air
Wise Air
The Wise Air brand is produced in China by adapting Dominic Hunter’s refrigeration dryer design.
BRAND Mikropor
Mikropor brand is produced in Turkey. The headquarters of this company is located in Ankara, and the office of the international unit and its sales to the American continent is located in the city of Michigan, United States of America.
Micropore dryers are usually sized with the characteristic code MKE. The number written after MkE. The maximum flow rate that can pass through the device is in cubic meters per hour.
The good feature of MKE series micropore dryers is the use of primary and secondary microfilters as a package inside the device. That is, by purchasing the MkE model dryer, there is no need to purchase a separate micro filter
The structure of the dryer body is such that the cabin doors can be easily opened and the micro filters can be easily replaced.
Features of MIKROPOR refrigeration dryer
- The lowest amount of pressure drop when the compressed air passes through the dryer (dehumidifier compressor), which improves the energy consumption of the compressor.
- Each refrigeration dryer is designed according to the capacity of the passing air to have the lowest amount of energy loss.
- Controller with touch keyboard
- The possibility of replacing the internal element of the refrigeration dryer in the compressed air dryer
- Display the amount of energy consumption reduction on the screen
- Error reporting system
- Show operating hours
- Ability to choose temperature in Celsius and Fahrenheit units
- Capacity 23 cubic meters per hour to 12500 cubic meters per hour
- Maximum working pressure 16 bar
- Placement of standard aluminum plate heat exchanger according to dryer capacity
- It has an efficient scroll compressor that consumes less energy than other brands of air pump dehumidifier refrigeration dryers.
- Compact design and fit in a small space
- All Micropor products have a 12-month warranty if standard principles are followed during installation.
2- Absorption dryer
The compressed air produced by the compressed air compressor carries a significant amount of water, oil and other impurities. If water vapor enters the compressed air lines, the condensed vapor causes oxidation, corrosion and destruction of production line equipment.
The maximum condensation point of water vapor in any gas depends on its temperature and pressure. When the density of water reaches a certain temperature and working pressure, that temperature indicates the dew point. That is, if the coldness of the air reaches below the dew point, the water vapor in the air will show itself in the form of water droplets, which will cause problems in the production line. The dew point of diskant dryers is -20 to -70 degrees Celsius.
How absorption dryer works:
The air first enters a tower and is dried. For a certain period of time, water is transferred to the desiccant material until the water pressure in the air is equal to the pressure on the surface of the material. At this time, the control system directs the air to the second tower to continue the dehumidification operation. The desiccant materials in the first tower have a chance to regenerate. In this process, the intelligent PLC system manages solenoid valves and timers
Unloader
What is the use of unloader?
The screw compressor unloader is a mechanical valve that can control the air entering the screw compressor air unit by opening and closing. This part is installed on the screw compressor and reduces energy consumption and increases the life of the electric motor and compressor. The type of unloader is determined based on the pressure and flow rate of the compressor.
Technical specifications of screw compressor unloader
An electric valve is installed on the unloader, whose task is to open and close the unloader to determine the amount of air pressure entering the air conditioner unit. The electric valve installed on the unloader is controlled from the electrical panel and the air pressure is determined according to the changes in the system and the opening and closing of the unloader. Of course, the opening of the unloader is closed under normal conditions and it returns during the flow so that the air suction action is performed by the airend and then the air compression takes place.
Types of screw compressor unloaders
Unloaders are generally designed in three types: diaphragm, reciprocating and rotating, which are usually produced in two vertical and horizontal modes. In general, the type of unloader is determined based on the pressure and flow rate of the compressor.
Another type of classification of unloaders is determined according to the opening and closing of their openings, which are classified into two types: normally open and normally closed. In normal open condition, the air passage is open and after passing a certain amount of air, the unloader valve is closed, and in normal closed condition, the unloader valve is opened after turning on the compressor, and in normal condition, the valve is closed.
Unloaders in different Chinese, Italian, Iranian brands in the RB, R, C, etc. series are available in the market.
Screw compressor unloader duties
When the compressor pressure reaches the maximum working pressure and the compressor tank is completely filled, the pressure level is determined by the transmitter and the air intake is stopped by the air compressor unloader, then the unloader opening is closed and prevents air from entering the airend. Also, when the compressor pressure decreases and reaches its minimum level, the unloader opening opens and directs the surrounding air into the air conditioning unit. This process continues until the pressure of the device increases and reaches its maximum value. In fact, it can be said that the unloader works like a mechanical valve and its main task is to determine the amount of air entering the airend.
Screw compressor unloader duties
When the compressor pressure reaches the maximum working pressure and the compressor tank is completely filled, the pressure level is determined by the transmitter and the air intake is stopped by the air compressor unloader, then the unloader opening is closed and prevents air from entering the airend. Also, when the compressor pressure decreases and reaches its minimum level, the unloader opening opens and directs the surrounding air into the air conditioning unit. This process continues until the pressure of the device increases and reaches its maximum value. In fact, it can be said that the unloader works like a mechanical valve and its main task is to determine the amount of air entering the airend.
- Unloader causes tank pressure to be discharged.
- Control the amount of air into the air conditioner
- Adjusting the compressor pressure and draining the internal pressure of the compressor tank
- Prevent oil return, prevent problems when restarting
- Air discharge in the separator tank
Advantages of using a screw compressor unloader
- Reducing energy consumption
- Extending the life of the compressor
- Ability to control the compressor capacity
- Increasing the life of the electric motor and reducing the number of times it is turned on and off
Electric Motor
What is an electric motor?
It is a type of machine that converts electrical energy into mechanical motion. The general idea is based on the fact that when a current-carrying conductor is subjected to a magnetic field, a force is exerted on that current-carrying conductor by the magnetic field. Most electric motors are rotary. But there are also linear motors.
Every rotating electric motor consists of two moving parts and a driver. The moving part is the rotor and the fixed part that is usually located inside the motor is also called the stator. In an electric motor, the rotor rotates around its axis due to the torque caused by the force created by the magnetic field in the stator. According to its structure, each electric motor is powered by direct current DC or alternating current AC.
Compressor oil cooling radiator
Compressor oil cooling radiator
One of the components of the screw compressor is the oil and air cooling radiator. In the air compression process, in the screw compressor, the temperature of oil and air rises sharply. Therefore, the oil and air temperature should be reduced, which is done by the radiator
The radiators in the screw compressor have two parts. One part is for cooling the air and the other part is for cooling the oil.
Control system
This system can be provided to one of the following two systems according to the customer's order.
Both systems are easily controllable.
1- Intelligent system (micropressor)
2- Automatic analog system
General advantages of intelligent system (micro-pressor PLC)
One of the components of the screw compressor is the oil and air cooling radiator. In the air compression process, in the screw compressor, the temperature of oil and air rises sharply. Therefore, the oil and air temperature should be reduced, which is done by the radiator
The radiators in the screw compressor have two parts. One part is for cooling the air and the other part is for cooling the oil.
- Display the total operating time
- Display time under load
- Show compressor idle time
- Announcing the service time of the device at the same time as it is displayed on the screen
- Automatic start after disconnection and connection of electricity
- Oil temperature display
- Display the pressure of the main tank and separator
- Display system errors and messages
The exclusive advantages of the intelligent system (Micropressor PLC)
- The capabilities of the system to be compatible with PLCs of its kind.
- Ability to display pressure with BAR and PSI units
- Ability to display system temperature in Celsius or Fahrenheit
- The ability to schedule the compressor to turn on or off at a specified time
- Controlling the operation of the compressor through the computer in the office
- The ability to use several compressors in sequence
Microfilter
What is a microfilter?
The air that is compressed in the compressor usually has a significant percentage of pollution due to environmental factors and the working conditions of the compressor itself. In order to increase the efficiency and also to protect the compressed air consuming devices in the industries, it is necessary to obtain completely clean air free of pollutants and for this reason the importance of using a micro filter (compressor air filter) in the compressor is clearly evident.
MIKROPOR Turkey is known as one of the main producers of compressor air purification units at the international level, and due to its quality and reasonable price, Mikropor microfilter (compressor oil filter) is the best option for filtering compressed air in industries. is.
MIKROPOR company of Türkiye
MIKROPOR Turkey is known as one of the main producers of compressor air purification units at the international level, and due to its quality and reasonable price, Mikropor microfilter (compressor oil filter) is the best option for filtering compressed air in industries. is.
- With replaceable element
- The body is made of aluminum alloy with an epoxy powder coating that is resistant to corrosion
- Removal of dust and oil particles up to 0.01 micron
- It has a standard protected float (diaphragm 2 mm) for automatic discharge of liquid particles
- Connection size from ¼ inch to 3 inches
- Flow capacity from 20 cubic meters per hour to 26,000 cubic meters per hour
- Equipped with a filter life indicator
- All filters are suitable for mineral and synthetic oil absorption.
- Maximum working pressure 20 bar
Water trap
Mikropor compressor water trap for sale
To remove water vapor and oil particles that are present in the compressed air coming out of the compressor, a water trap filter or water trap is used. The wind compressor water trap is used to absorb coarse water particles up to 20 microns in size, and its structure is in the form of a hollow cylinder, which separates water and oil particles from compressed air by swirling the flow in the inner shell and using a centrifugal method. Hyper Sanat Famco provides Mikrotik water traps in the form of the following models:
Mikropor compressor water trap
- Micropore GWS wind compressor water trap (up to 16 bar pressure and connection size ½ to 3 inches)
- Micropore brand HGWS high pressure water trap (pressure up to 50 bar with connection size ½ to ½ inch)
- Micropore FWS brand wind compressor flange water trap (pressure tolerance up to 14 bar and connection size from DN80 to DN350)
Technical specifications of the Mikropor GWS trap
- Micropore GWS wind compressor water trap (up to 16 bar pressure and connection size ½ to 3 inches)
- Micropore brand HGWS high pressure water trap (pressure up to 50 bar with connection size ½ to ½ inch)
- Micropore FWS brand wind compressor flange water trap (pressure tolerance up to 14 bar and connection size from DN80 to DN350)
The GWS series micropore water trap is designed to absorb a large volume of water, moisture and oil particles in the compressed air coming out of the air compressor.
The operation of the micropore water trap is centrifugal, which separates moisture and oil particles from the compressed air by swirling the flow inside the housing, which causes more efficiency, less energy consumption, and the lowest pressure drop in the compressed air system. becomes
Micropore GWS water trap is available in different connection sizes (from 1/4 inch to 3 inches) and the ability to pass compressed air (from 25 cubic meters per hour to 2200 cubic meters per hour), which is why the Micropore water trap find a special place in the industry.
Among other features of the Micropore trap, we can mention the presence of an automatic drain valve (auto-drain), which is installed as a standard at the end of the trap, and the presence of electrostatic powder paint that covers the inside and outside of the body.
Technical specifications of Mikropor FWS flanged water trap
- Micropore GWS wind compressor water trap (up to 16 bar pressure and connection size ½ to 3 inches)
- Micropore brand HGWS high pressure water trap (pressure up to 50 bar with connection size ½ to ½ inch)
- Micropore FWS brand wind compressor flange water trap (pressure tolerance up to 14 bar and connection size from DN80 to DN350)
Micropore HGWS high pressure water trap
Mikropur company has also found a solution to remove the water moisture in the compressed air coming out of high pressure compressors and booster compressors and has presented its high pressure water traps to the market under the name of HGWS series water traps. Micropore’s high pressure water trap, which is also known as water trap or water separator, can be placed before the tank and after the high pressure dryer and perform the removal and removal of existing water moisture. The material of the body shell of the micropore high pressure water trap is made of aluminum alloy and supports a capacity of 4 to 50 cubic meters per minute. The working pressure range of Micropore high pressure water trap is between 16 and 50 bar.
Technical specifications of Mikropor FWS flanged water trap
The FWS series micropore flanged water trap is designed to eliminate water and oil particles in the compressed air coming out of piston and screw air compressors with different capacities, which acts centrifugally and increases efficiency. system and prevent pressure drop in the compressed air system.
MIKROPOR flanged water trap is available in flange sizes DN80 to DN200 and with the ability to pass compressed air in different capacities (2500 cubic meters per hour to 14000 cubic meters per hour), which has made this type of water trap MIKROPOR company has a special position in various industries.
Separator filter
The separator filter is used as an air and oil separator in industrial systems. For this purpose, microfiber glass fibers are generally used in separator filter papers.
The design of this fiber is in a way that allows the passage of air molecules and does not allow the passage of oil molecules, and in fact molecules with gas phase pass and molecules with liquid phase do not pass. They have a substitute. The working time of the separator filter depends on factors such as the type of oil, working pressure, working temperature, etc., and the replacement time of the filter is determined by the filter pressure difference item, which is usually around 4000 hours.
Filter separators are available in the following three general types
- Outer bowl (Standard wrap element)
- Inner bowl (Depth Separator Elements)
- Air/Oil Separator Boxes
- Outer bowl separator filter (Standard wrap element)
Design and performance
This product is suitable for flow from outside to inside and can be used for all flow ranges of screw and vane compressors. These types of separators are generally not sensitive to design changes and give optimal results considering the working time and separation efficiency.
pressure drop
The pressure drop in the rated flow and working pressure is 7bar (0.7MPa) when the new filter is installed, it is 0.17bar (17KPa). If there is more resistance, the volumetric flow can be doubled without negatively affecting the performance of the system.
Separation quality
This product is designed for differential pressures of at least 5 bar (0.5 MPa).
Pressure resistance
This product is designed for differential pressures of at least 5 bar (0.5 MPa).
Separation quality
The remaining oil in the nominal flow and working pressure of 7 bar (0.7 MPa) is approximately between 1 and 3 mg/m3.
Service life (life service) working hours
The increase in resistance to the current and subsequently the service life directly depends on the cleanliness of the oil and the quality of the air filter. The service life of separator filter is mainly between 1500 and 6000 hours, which directly depends on the quality of the filter and the proper functioning of the system.
Design and performance
Design and performance
This product occupies little space and is used for all flow ranges of screw and vane compressors. In this type of separator filter, the oil flow is from outside to inside.
pressure drop
The pressure drop in the rated flow and working pressure is 7bar (0.7MPa) when the new filter is installed, it is approximately 0.2Kpa. In case of more resistance, the volumetric flow can be up to 1.5 times the rated flow without negatively affecting the system performance. to increase
Pressure resistance
This product is designed for differential pressures of at least 5bar (0.5MPa).
Separation quality
The remaining oil in the nominal flow and working pressure of 7bar (0.7 Mpa) is approximately between 1 and 3 mg/m3.
Life service
The increase in resistance to flow and service life directly depends on the cleanliness of the oil and the quality of the air filter. Reaching several thousand hours of operations can be realized if the system is working properly.
explanations
Internal bowl separator filter is available in different sizes. The proper performance of these products is only if there is no water leakage between the wet and dry parts. The air should be directed in such a way as to prevent the direct contact of the oil/air flow with the filter surface.
Screw separators (Air/oil Separator boxes)
flow
Screw separators can be used for nominal flows from 1 m3/min to 5.5 m3/min at a working pressure of 7 bar (0.7 Mpa).
pressure drop
The pressure drop in the nominal flow and pressure of 7bar (0.7MPa) when the new filter is installed is approximately 0.25bar (25KPa).
Pressure resistance
The housing housing of the screw separators is designed to work with pressures of up to 20 bar (2 MPa) or up to 14 bar (1/4 MPa). The components of this filter are suitable for working in a pressure differential of more than 5bar (0.5MPa).
Separation quality
The remaining oil in nominal flow and working pressure of 7bar (0.7 MPa) is approximately 1 to 3 mg/m3.
Service life (life service) working hours
The increase in resistance to the flow and subsequently the service life directly depends on the cleanliness of the oil and the quality of the air filter. Reaching several thousand hours of operation can be realized if the system is working properly.
Installation recommendations
The filter of screw separators is installed vertically and by hand on a head. This place is usually chosen according to the serviceability of the system.
Repair and maintenance
Screw separators need to be replaced if the air flow resistance reaches 1 bar (0.1 MPa). The separator filter must be replaced after the system is depressurized. This replacement is done by a suitable belt wrench. The separator filter is usually closed in place by hand.
Separator filter: for more productivity, it is recommended to use separator filters with a lifespan of 4000 hours to 6000 hours, it is necessary to explain that the manufacturers of separator filters in Iran do not apply the necessary precision in manufacturing, and Iranian separator filters last between 700 hours and They will work for 1,200 hours, of course, we hope that Iranian filter makers will use better paper in the future.
Compressor booster
As the name suggests, booster compressor means pressure booster. Standard systems used for air compression in industrial facilities are typically designed for pressures of 80 to 190 psi (5 to 13 bar). But some equipment needs higher pressures up to 40 bar and even up to 350 bar in some applications. It is not possible to achieve this high pressure normally.
booster
Booster compressors condense the pre-compressed air in the compressor to higher pressures. The duty of the booster compressor is to raise the pressure from 10 bar to 40 bar. The 40-bar air produced with a high volume is directed to the high-pressure storage tank and is ready for use by 40-bar consumers after the completion of the filtration process.
Air boosters often start by receiving pre-compressed air, so they use much less energy than using a high-pressure compressor. Therefore, if higher pressures are needed, using the air produced from the compressor by the air compressor booster is a very effective way to achieve the desired higher pressure. Booster compressor is usually used to increase the pressure in the compressed air system, or in some cases, it is used to compensate for the pressure that has dropped along the long pipelines. Compression in booster compressors may be single or multi-stage or dynamic or displacement type.
