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INNOVATIVE COMPRESSED AIR SOLUTIONS COMPRESSED AIR ...

INNOVATIVE COMPRESSED AIR AIR DRYERS150 2,400 SCFMHeatSinkStainless SteelHeat ExchangersIndependently Verified Performance (200-1000 scfm models) COMPRESSED AIR SOLUTIONSZEKS COMPRESSED Air SolutionsMeets The Needs Of COMPRESSED Air UsersCompressed air is a versatile energy resource, ideal for many production processes, for powering tools and equipment,and actuating valves, among other uses. For processes and devices to operate at peak efficiency, the COMPRESSED air supply must be clean and dry. Contaminants present at the intake of the air compressor can effect the operation of COMPRESSED airequipment. The compression process causes concentrations of water, compressor lubricantand airborne particulate to increase to levels that can damage tools, increase maintenancerequirements or spoil finished product. ZEKS HeatSinkTMdryers economically and reliably dry COMPRESSED air, thereby ensuring efficient operation of downstream equipment and Savings The True-CyclingTMAdvantageCommon manufacturing practices, process machinerycycling and changing production requirements all result in variable COMPRESSED air volume use.

HeatSink REFRIGERATED COMPRESSED AIR DRYERS Reliability Efficiency Innovation TM The example below calculates the annual energy savings of a HeatSinkTM dryer compared to a non-cycling design.

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Transcription of INNOVATIVE COMPRESSED AIR SOLUTIONS COMPRESSED AIR ...

1 INNOVATIVE COMPRESSED AIR AIR DRYERS150 2,400 SCFMHeatSinkStainless SteelHeat ExchangersIndependently Verified Performance (200-1000 scfm models) COMPRESSED AIR SOLUTIONSZEKS COMPRESSED Air SolutionsMeets The Needs Of COMPRESSED Air UsersCompressed air is a versatile energy resource, ideal for many production processes, for powering tools and equipment,and actuating valves, among other uses. For processes and devices to operate at peak efficiency, the COMPRESSED air supply must be clean and dry. Contaminants present at the intake of the air compressor can effect the operation of COMPRESSED airequipment. The compression process causes concentrations of water, compressor lubricantand airborne particulate to increase to levels that can damage tools, increase maintenancerequirements or spoil finished product. ZEKS HeatSinkTMdryers economically and reliably dry COMPRESSED air, thereby ensuring efficient operation of downstream equipment and Savings The True-CyclingTMAdvantageCommon manufacturing practices, process machinerycycling and changing production requirements all result in variable COMPRESSED air volume use.

2 This, combined with periods of low ambient and inlet air temperatures,results in reduced load on an air dryer . ZEKS HeatSinkTMdryers are designed to take advantage of these factors to reduce the cost of drying COMPRESSED air. HeatSinkTMdryers use a refrigeration system to cool a thermal mass,which in turn cools the COMPRESSED air that flows through the dryer . Cooling causes moisture and contaminants present in the air to condense, enabling removal in a high efficiency separator within the dryer . BecauseHeatSinkTMdryers have the capacity to store cool energy in the thermal mass fluid, the refrigeration system automatically cycles off during periods of low demand while the dryer continues to remove moisture and contaminants from the air stream. This True-CyclingTMoperation typically consumes far less energy than the equivalent non-cycling dryer that operates the refrigeration system COMPRESSED Air DryersTMThe Original Energy Saving COMPRESSED Air dryer .

3 Energy Savings As High As 80%- resulting from True-CyclingTMoperation in variable moisture load conditions (see Annual Energy Savings Chart) 99% Moisture Separation Efficiency- provided by the exclusive ZEKS moisture separator design Consistent Dew Point- dryer components are sized to enable consistent dew point at full or partial moisture loadingin all industrial environments Reliable Digital Performance Control- enhanced userinterface for dryer performance monitoring and adjustment CFX -Based Precooler/Reheater- Conditions the COMPRESSED air to minimize energy consumption and eliminate pipe sweating Rated Performance Even In Elevated AmbientTemperatures- resulting from generously sized refrigeration condenser Optimum Cycling Efficiency- from active circulationof thermal storage media Electronic Performance ControlHeatSinkTMdryer operation is automatically controlled to optimize air treatment and manage energy consumption.

4 In addition, both the CompustatTMand DPCTM controllersenable the user to adjust the operating parameters based on specific application requirements, optimizing energy Digital controller standard on 200-800 models. Includes LED display to communicate operating status and energy Optional on 150 models. Enhanced version standard on 1000-2400 models. Includes backlit LCD to communicateoperating status and refrigeration system Controller Optional on 200-2400 models. Provides all thefeatures of the DPCTMC ontroller, with the addition of air temperature and pressure ModelDisplay of:150200-8001000-2400 Chiller TemperatureOSS % Energy SavingsOSS Refrigerant Suction PressureS(Gauge)+S Refrigerant Suction TemperatureNA+S Refrigerant Discharge PressureNA+S dryer Compressor Running TimeO+S dryer Running TimeO+S Diagnostic MemoryO+S Inlet Air PressureNA++ Outlet Air PressureNA++ Inlet Air TemperatureNA++ Outlet Air TemperatureNA++Condensate Drain Time AdjustmentOS SAutomatic dryer RESTARTOS SRemote START/STOP-ReadyOS SRemote Alarm ContactOS SMODBUS Communication-ReadyO+SS - Standard feature with either CompustatTMor DPCTMO - Option provided by DPCTMNA - Not Applicable+- Included with DPCTMPlus OptionThe Standard of Excellence For Heat Exchanger DesignZEKS patented CFX stainless steel heat exchangers, engineered exclusively for COMPRESSED air drying, include industry-leading low pressure drop and a high heat transfer coefficient.

5 A multi-path flow area that is 3 5 times that of the equivalent copper tube exchanger combined with continuous self-cleaning action minimizefouling potential. All-welded CFX Corrugated, Folded heat eXchangers provide durability in environments where copper or other metals are not suitable. 100% Stainless Steel Construction- Resists corrosion andprovides long-lasting durability Industry - Leading Low Pressure Drop- Minimizes energyconsumption and the need for more air compressor horsepower Less Prone To Fouling Than Copper Or AluminumExchangers- Maintains optimal performance ZEKS Exclusive 10-Year Warranty-A testament to the durability and efficiency of this robust component DPCTM- Standard on 1000-2400,optional on 150 CompustatTM- Standard on 200-800 Protected under PatentNos. 6,186,223 and 6,244,333 Standard Features: Stainless Steel CFX Heat Exchangers Fully Hermetic Refrigeration Compressor High Efficiency Moisture Separator Electronic Performance Control (optional on 150) Timed Electric Condensate Drain Water-Cooled or Air-Cooled Condensers(air-cooled only on 150) Environmentally Friendly R-404 Refrigerant Thermal Mass Circulation Pump NEMA 1 Electrics Full Powder-Coated Cabinet Galvanized Internal StructureOptional Features.

6 Digital Display of COMPRESSED Air Inlet and Outlet Temperatures and Pressures (200-2400 only) Complete Stainless Steel Air Circuit Prefilter and Afterfilter To Meet Application Needs CMETMCold Mist Eliminator 99% removal of air compressor lubricant carryover (available on 200-400) High Condensate Level Alarm (200-2400 only) Refrigeration Condenser Filter NEMA 4/12 Electrics No Air Loss Drain Exclusive WarrantyIn addition to the standard warranty on all HeatSinkTMdryers, the refrigeration compressor is warranted for fiveyears and the CFX Heat Exchangers for ten to ZEKS Product Warranty Policies and Verified Performance!Through participation in the COMPRESSED Air and Gas Institute (CAGI) Performance Verification Program, actual performance and energy c onsumption of 200-1000 scfm ZEKS HeatSinkTMdryers have been independently validated against CAGI Data to view ZEKS refrigerated dryer Data Sheets.

7 COMPRESSED AIR COMPRESSED AIR DRYERS150 2,400 scfmReliability. Efficiency. H e a t S i n kREFRIGERATED COMPRESSED AIR DRYERSR eliabilityEfficiencyInnovationTMThe example below calculates the annual energy savings of a HeatSinkTMdryer compared to a non-cycling design. The factors can be replaced with those of any COMPRESSED air Maximum Capacity of The DryerAssume a maximum capacity of 1,000 scfm for this Weekly COMPRESSED Air VolumeMultiply the number of hours worked per week on all shifts times the COMPRESSED air volume (scfm x 60 min.) used on each shift. Total all shift numbers to determine the actual COMPRESSED air volume used per week:ShiftHours(60 min.)scfmAir VolumeFIRST35x 60x800=1,680,000 SECOND35x60x600=1,260,000 THIRD35x 60x400=840,000 SATURDAY7x 60x200=84,000 Weekly COMPRESSED Air Volume3,864,000 Calculate Weekly Air Treatment Potential of The DryerMultiply the total number of hours per week (168 assuming the equipment is ON, 24/7) times the maximum capacity of the dryer :Weekly Air Treatment Potential = 168 hrs.

8 X 1,000 scfm x 60 min. = 10,080,000 Calculate The Plant Operation FactorDivide the total COMPRESSED air volume used per week by the total weekly air treatment potential to determine the plant operation factor:Plant Operation Factor = = .383 Select Ambient Air Temperature Reduction FactorThe factor varies based on geographic location and takes into account the impact of lower ambient temperatures on energy consumption. Typical factors are:Northern US Climate .24 Central US Climate .31 Southern US Climate .34 Calculate Utilization FactorThis incorporates all of the above:Plant Operation Factor x Ambient Air Temperature Reduction FactorIf we assume the plant is in the Southern US, the Utilization Factor will be:Utilization Factor = .383 x .34 = .13 (13%)Estimate Annual SavingsRefer to the following table for a 1,000 scfm dryer and interpolate between a 10% and 20% utilization factor:Annual Energy Savings3,864,00010,080,000 Estimated Annual Savings ($) From True-Cycling Operation*(Based on $.)

9 10/kWh) dryer SizeUtilization Factor(scfm)10%20%30%40%50%60%150 HSG1000887774661548434200 HSG139312091025841657473250 HSG13751174972771569368300 HSG1857161213671121876631400 HSG286525752286199717081419500 HSF28032365192714891051613600 HSF359231542716227818401402700 HSF463441003565303124971962800 HSF4581399534082821223416471000 HSF5703492341433364258418051200 HSF7402648255634643372328031600 HSF8751760464565309416130132000 HSF10906972485417358617649932400 HSF128071142310039865572715887*Consult factory for calculation details Results shown for air-cooled modelsHeat load on a refrigerated compressedair dryer is based on the combination of inlet air flow volume, inlet air temperature, ambient air temperature,and COMPRESSED air pressure. Of these,inlet air flow volume (scfm) and inlet airtemperature have the greatest a slight reduction of inlet air temperature will greatly reduce theheat load on the dryer .

10 dryer modelselection is based on capacity sufficientto handle the heat load during thehottest months of the year. Cyclingoperation provides the greatest way to realize energy savings as inlet airtemperature COMPRESSED AIR Goshen ParkwayWest Chester, PA 19380 Phone: 610-692-9100 800-888-2323 Fax:610-692-9192 , illustrative materials and descriptions contained herein were as accurate as known at the time this publication wasapproved for printing. The company reserves the right to change specifications, discontinue models, equipment or design withoutnotice and without incurring obligation. The information set out in this brochure is for preliminary information only and is not intendedto constitute any representation or warranty by ZEKS to potential customers or to form the basis of a contract with any customer. 2017 ZEKS COMPRESSED Air SOLUTIONS HS 150-2400 0417 HeatSinkREFRIGERATED COMPRESSED AIR DRYERSTMT echnical SpecificationsCAPACITY*DIMENSIONSSHIP COMPOPERATING MAXSCFMPRESSUREWDHAIR-COOLWATER-COOLCONN ECTDRAINAIR-COOLWATER-COOLKW**REFRIGWORK INGMODEL38 OFDROP** MPT1/4 404300 MPT1/4 404300 MPT1/4 404300 MPT1/4 404300 MPT1/4 404300 MPT1/4 404300 MPT 1/4 404300 MPT1/4 404300 MPT1/4 404300 psig1000 HSF1, FLG1/4 404220 psig1200 HSF1, FLG1/4 404220 psig1600 HSF1, FLG1/4 404220 psig2000 HSF2, 392539256 FLG1/4 404220 psig2400 HSF2, 415040156 FLG1/4 404220 psig* Performance data obtained as per ISO 7183, Table 2, Option dew point at 100 psig inlet air pressure, 100oF inlet air temperature, 100oF ambient air temperature.


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