OC Industrial Group AG designs heat exchangers and impurities filtration systems for the refrigeration industry. These exchangers are the heart of refrigerated air dryers and it was only a short step to designing the whole package. Heat exchangers are produced from stainless steel and or aluminum.
After the compression process the air is saturated with moisture including dust particles and oil. These particles represent a serious danger for the end device where it could cause dysfunction, damage or influence proper operation.
Zephyr dryer has specifically designed compact exchanger modules with a cross flow system of the air and refrigerant. Hot and saturated air enters the unit for precooling. The air is cooled down by outgoing dried compressed air and this process decreases the heat load on the exchanger. It has a positive influence on the operating cost by about 30%. The cooled saturated air enters the exchanger where it reaches the required pressure dew point (PDP). The air is cooled in the exchanger and subsequently the condensed moisture is collected and drained out. The dried and cooled air then flows through the cross flow exchanger where it is heated by the incoming compressed air.
OC Industrial Group AG uses only environmentally friendly coolant.
Standard refrigerated air dryers are constructed to withhold 15barg and on demand it is possible to increase the pressure to 50barg. Zephyr refrigerated dryers are designed for the inlet air temperature of 38°C and the maximum allowed inlet temperature is 60°C. The capacity of the refrigerated dryers are in the range of 0,6 to 300m3/min.
Zephyr refrigerated air dryers are available in air or water cooled versions.
Bypass valve
It can ensure the temperature of refrigerant into evaporator at the range of 0-1 °C, which not only can stabilize the PDP at 3 °C, but also can avoid the ice block in the heat exchanger.
Compressor
In the gas circuit is working reliable compressor from established producers as are Copeland, Sanyo or Maneurop. Compressors have high performance, low noise level and build-in overheat protection.
Compact Heat Exchanger
The unique design of the precooler makes efficient heat transfer, reduces the evaporator load and the power consumption of the dryer is lower about 30%. Moisture flows directly to the timer controlled drain. The dried and cool air then flows through the cross flow exchanger where it’s heated by the incoming compressed air.
Technical specification of the Zephyr refrigerated dryers:
| Model | Capacity | Power | Connection | Dimensions, mm | Weight | ||
|---|---|---|---|---|---|---|---|
| m3/min | kW | l | w | h | kg | ||
| ZD-24 | 2.4 | 0.47 | G 3/4 | 750 | 360 | 550 | 50 |
| ZD-30 | 3.0 | 0.49 | G 3/4 | 750 | 360 | 550 | 50 |
| ZD-40 | 4.0 | 0.65 | G 3/4 | 750 | 360 | 550 | 55 |
| ZD-80 | 8.0 | 1.4 | G1 1/2 | 750 | 550 | 880 | 80 |
| ZD-100 | 10.0 | 1.85 | G1 1/2 | 750 | 550 | 880 | 85 |
| ZD-120 | 12.0 | 2.3 | G2 | 1000 | 670 | 1030 | 130 |
| ZD-150 | 15.0 | 3.03 | G2 | 1000 | 670 | 1030 | 140 |
| ZD-200 | 20.0 | 3.1 | G2 | 1000 | 670 | 1030 | 150 |
| ZD-250 | 25.0 | 3.63 | G2 1/2 | 1000 | 820 | 1600 | 250 |
| ZD-300 | 30.0 | 4.4 | G2 1/2 | 1000 | 820 | 1600 | 260 |
| ZD-350 | 35.0 | 5.1 | G2 1/2 | 1000 | 820 | 1600 | 270 |
| ZD-400 | 40.0 | 6.13 | DN 100 | 1150 | 1120 | 1750 | 500 |
| ZD-500 | 50.0 | 6.9 | DN 100 | 1150 | 1120 | 1750 | 510 |
| ZD-600 | 60.0 | 8.34 | DN 100 | 1150 | 1120 | 1750 | 550 |
| ZD-700 | 70.0 | 9.81 | DN 125 | 1150 | 1120 | 1750 | 580 |
| ZD-800 | 80.0 | 11.9 | DN 150 | 1850 | 1200 | 2350 | 800 |
| ZD-900 | 90.0 | 13.1 | DN 150 | 1850 | 1200 | 2350 | 810 |
| ZD-1000 | 100.0 | 16.7 | DN 150 | 1850 | 1200 | 2350 | 850 |
| Limited working conditions | |
|---|---|
| Min/Max parameters | |
| Working pressure | 3/20 barg |
| Inlet temperature | 5/60 °C |
| Ambient temperature | 5/60 °C |
| Correction factors of the Zephyr dryers | |||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| To ensure real capacity according to operation conditions multiply nominal capacity of dryer by correction factors x KA x KB x KC | |||||||||||||||||||
| Working pressure factors | |||||||||||||||||||
| Inlet pressure | barg | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 |
| Correction factor | KA | 0.76 | 0.86 | 0.92 | 0.96 | 1 | 1.04 | 1.08 | 1.11 | 1.15 | 1.18 | 1.22 | 1.25 | 1.28 | 1.30 | 1.31 | 1.32 | 1.32 | 1.33 |
| Inlet temperature factors | |||||||||||||||||||
| Inlet temperature | °C | 27 | 30 | 35 | 38 | 40 | 43 | 46 | 49 | 54 | 60 | ||||||||
| Correction factor | KB | 1.5 | 1.36 | 1.11 | 1 | 0.92 | 0.83 | 0.76 | 0.69 | 0.56 | 0.46 | ||||||||
| Ambient temperature factors | |||||||||||||||||||
| Ambient temperature | °C | 20 | 25 | 30 | 35 | 38 | 40 | 45 | 50 | ||||||||||
| Correction factor | KC | 1.21 | 1.15 | 1.1 | 1.02 | 1 | 0.89 | 0.79 | 0.69 | ||||||||||