OMEGA AIR

more than air

 Headquarters
OMEGA AIR d.o.o. Ljubljana
Slovenia

OMEGA AIR Germany GmbH

Germany

OMEGA AIR d.o.o. Ljubljana

Cesta Dolomitskega odreda 10
SI-1000 Ljubljana, Slovenia
www.omega-air.si

GPS: 46°2’27.13” 14°27’59.46” OMEGA AIR Japan

Japan

OMEGA AIR Italy s.r.l.

Italy

OMEGA AIR Zagreb d.o.o. OMEGA AIR South East Asia

Croatia Indonesia
 OMEGA AIR d.o.o. Ljubljana
Austria Hungary

OMEGA AIR d.o.o. Ljubljana HEADQUARTERS

Ljubljana, Slovenia
Head office, Production halls, Sales office, R & D Area: 6.600 m2

Slovenia

OMEGA AIR Logatec

Logatec, Slovenia Italy
Compressors and technique dept., Service centre, Welding department, Dryers production
- Land: 80.000 m2 - Facilities: 4.100 m2

Croatia

OMEGA AIR Logatec

Logatec, Slovenia
Main warehouse Area: 4.000 m2
 Air and Gas
treatment
A complete system for
every application

INDEX
4 Air and gas treatment
6 Compressed air and gas filtration
18 Condensate managent
22 Drying SYSTEM MONITORING COMPRESSOR HEAT RECOVERY UNIT AFTERCOOLER COMPRESSED AIR RECEIVER FILTRATION SYSTEM
Monitoring of system parameters Stable compressed air Reuse of waste heat Cooling Storage Air quality
36 Gas generators • pressure • wide pressure ranges • 90% of energy for air compression is • reduces the compressed air temperature • buffer effect • pre-filters 25 to 3 µm
• temperature • energy efficient transferred into heat to 10 °C above ambient temperature • eliminates pulsations from the • super fine filters down to 0,01 µm
40 Gas dryers • power consumption • contemporary machines • exploitation of up to 70% of the • reduces the water vapour dew point discharge line • activated carbon filters
• capacity • wide capacity ranges compressor energy • improved energy efficiency of the system • decreases wear and tear on the • drying filters
44 Gas purifiers • dew point • stable operation • improved energy efficiency of the compression module, control system • sterile filters
• purity • designed for continuous operation system Benefits and motor
46 Industrial water chillers • data logging • high efficiency axial fan • reducing excessive compressor cycling Pressure ranges
• ensures the maximum performance and • low, medium and high pressure
50 Pressure vessels Benefits Benefits protection of all equipment
• help to reduce dew point and
temperature spikes that follow applications
Benefits • exceptional compactness • simple upgrading • possibility to install the unit vertically or • up to 420 bar
54 Measuring equipment • reduced operating costs • high ecological sustainability • inexpensive upgrading horizontally
regeneration
• separates moisture oil and solid
• energy savings • low noise level • energy efficient system Media
58 Additional program • control of individual system branches • easy maintenance • profitable system
particles provide extra storage for
compensating surges in compressed air
• Air
• optimized operation • low operating costs • easy maintenance • Nitrogen
60 Industrial engineering • history & statistics • longer product life cycle • low operating costs
usage • Oxygen
• graphical and statistical evaluation • compact design • Methane
62 SKID and BOX units • analysis and comprehensive reports • easy installation without additional
Benefits • CO2
• reduces energy costs associated with • Argon
control on the compressor
66 Projects • upgrade regardless of compressor
excessive starting of the compressor • Helium
motor • Hydrogen
brand
68 AirSys • etc...

70 Alternative filter elements

4
AIR DRYING ACTIVATED CARBON TOWERS CONDENSATE TREATMENT AIR BUFFER GAS GENERATORS GAS BUFFER PRESSURE BOOSTER FINAL GAS STORAGE
Dryer types Air purifiers Water-oil separators Air receiver N2 and O2 generators Gas receiver Gas pressure booster Gas cylinders
• refrigeration • separating oil vapours and other • just 1 litre of used oil can contaminate 1 • accumulates purified compressed air • separating the gas from the other gases • accumulates treated compressed gas • builds up gas pressure • storage of gases at high pressures
• adsorption hydrocarbons from compressed air million litres of fresh water • reduces peak consumption in the compressed air • reduces peak consumption • safe storage
• membrane • based on adsorption process • one of the most effective and • pressure swing adsorption (PSA) Benefits
• large adsorption surface area economical separating solutions Benefits • membrane separation Benefits • on-site production Benefits
Dew points • multi-stage separation process using • storage: constant supply of purified air • reliable supply of prepared gas • independence from suppliers of • easy transportation of compressed
• +15 to -70°C Benefits oleophilic filters and activated carbon • no production errors Benefits • no production errors cylinders or liquefied gas gases
• high quality compressed air without oil • constant compressed air quality • stable reliable supply of generated gas • constant compressed gas quality • assures sufficient gas supply during
Pressure ranges presence Benefits • gas produced directly at the site of use peak consumption.
• low, medium and high pressure • safety of end product • ensures exceptional performance • constant compressed gas quality • allows installation of smaller gas
applications • trouble free operation • the manufacturing company is generator & compressor
• up to 420 bar • no complex sizing required independent from suppliers of cylinders
• simple to install or liquefied gas
• works with any type od cond. drain
• can handle and separate any type of oil
• oil residue value is less than 10 ppm
• easy maintaining
• no condensate settling tank is required
(no bacteria build-up)
• unique, cartridge-like solutions for lower
flows
• test valve and test set included for
sampling purposes

OMEGA AIR
more than air
5
 Compressed Air
and Gas Filtration
Basics Compressed air and gas filters are used to remove
contaminants such as dirt, oil, water, and other
particulates from compressed air or gas systems.
They typically consist of a housing or vessel COMPRESSED AIR AND GAS FILTERS
that contains a filter element or cartridge. The AAF Aluminium compressed air filters 20 bar 10 - 2.760 Nm3/h
filter element is designed to trap contaminants BF Welded carbon steel compressed air filters 16 bar 1.680 - 31.400 Nm3/h
as the compressed air or gas flows through it. CS/CS SS Welded condensate separators 16/13 bar 840 - 14.280 Nm3/h
Filters can be classified based on their filtration
efficiency, filtration rating, and filtration media. It is SFH/SFH SS Welded condensate separators 16/13 bar 1.760 - 12.550 Nm3/h
important to select the correct filter for the specific AAFs Silicone free compressed air filters 20 bar 10 - 2.760 Nm3/h
application, as well as to maintain and replace AAF HT Aluminium high temperature compressed air filters 10 (13)bar 10 - 2.760 Nm3/h
filters on a regular basis to ensure optimal system
AAF O2 Aluminium compressed gas filters for Oxygen 20 bar 10 - 2.760 Nm3/h
performance and efficiency.
P-VAC Vacuum pump protection filters 20-2.000 mbar (abs) 1,25 - 345 Nm3/h
M-VAC Medical vacuum filters 20-2.000 mbar (abs) 1,25 - 345 Nm3/h
PRESSURE
BF HP High pressure welded carbon steel compressed air filters 25 bar 1.680 - 31.400 Nm3/h
Low 16 bar
SFH HP Welded high pressure condensate separators 25 bar 1.760 - 12.550 Nm3/h
Medium 50 bar
HF Cast aluminium high pressure compressed air filters 50 bar 71 - 2.760 Nm3/h
High 420 bar
HF O2 Cast aluminium high pressure filters for Oxygen 50 bar 71 - 2.760 Nm3/h
CHP Carbon steel high pressure compressed air filters 100, 250, 420 bar 40 - 715 Nm3/h
FILTRATION
IHP Stainless steel high pressure compressed air filters 100, 250, 420 bar 40 - 715 Nm3/h
Pre-filters 25 to 3 µm
WFIT Welded stainless steel comp. air filters - threaded connections 14/25 bar 75 - 3.600 Nm3/h
Super fine filters down to 0,01 µm
WFIW Welded stainless steel comp. air filters - welding end connections 14/25 bar 75 - 3.600 Nm3/h
Sterile filters
WFIF Welded stainless steel comp. air filters - flanged connections 10/14 bar 150 - 21.120 Nm3/h
MEDIA WHFIT High pressure stainless steel process compressed air filters 50 bar 150 - 2.400 Nm3/h

- Air PF Stainless steel process compressed air filters 14 bar 75 - 21.120 Nm3/h
GAS
- Nitrogen SPF Stainless steel sterile compressed air filters 14 bar 75 - 3.600 Nm3/h
- Oxygen
- Methane SF Stainless steel sterile compressed air filters 10 bar 75 - 21.120 Nm3/h
- Biogas
- CO2 HPF High pressure stainless steel process filters 50 bar 150 - 2.400 l/min
- Argon
- Helium AV Stainless steel air venting filters 9 - 310 Nm3/h
- Hydrogen MSS Mobile steam sterilizer 1 to 3,6 bar -

6
Airborne particles, water vapour, microbes, and chemical gases
enter compressors. After compression has taken place these
contaminants become concentrated and more destructive.

Compressed air and gas quality is essential to all modern

production facilities. Compressed air filters, often referred to
as line filters, are used to remove these contaminates from
compressed air. Clean and dry air protects the compressed
air system, reduces maintenance costs and increases finished
product quality.

Types of filters vary depending on the application, the pressure

level and type of contaminants.
Flow rate
Industrial filters Determine the required flow rate for the compressed
Industrial filters are used in typical industrial low pressure air or gas system to ensure that the filter is capable of
applications. They are typically made of cast aluminium for lower handling the required volume.
air flows, and of carbon steel for higher flows. They all have
anticorrosion protection. Pressure and temperature
Identify the operating pressure and temperature of the
High pressure filters compressed air or gas system. This will help determine
Demanding technical construction calculations according to PED the appropriate filter housing material, as well as the
and ASME ensure the safe operation of the filters even at high filter element material.
pressures.
Application
Sterile filters Consider the specific application of the compressed air
The rugged stainless steel housing allows the sterilization process or gas system, as this may require additional features
in the demanding pharmaceutical, food and similar applications. such as coalescing filters for removing oil or activated
carbon filters for removing odors.
Filters for special applications
Different types of filters are available for special applications. Maintenance
Determine the maintenance requirements for the
filter, including the frequency of filter replacements or
To select the right compressed air or gas filter for a specific cleaning.
application, the following factors should be considered:
By considering these factors, you can select the
Contaminant type and size right compressed air or gas filter for your specific
Identify the type of contaminants that are present in the application. It is important to consult with a
compressed air or gas system and their size. This will help qualified professional or refer to the manufacturer’s
determine the appropriate filtration media, filtration rating, and specifications to ensure proper selection and
filtration efficiency needed to remove these contaminants. installation of the filter.
OMEGA AIR
more than air
7
 Compressed Air AAF BF CS
and Gas Filtration Aluminium filters Welded carbon steel filters Welded carbon steel condensate separators

Filter housings

Oper. pressure 20 bar Oper. pressure 16 bar Oper. pressure 16 bar

Capacity 10 - 2.760 Nm3/h Capacity 1.680 - 31.400 Nm3/h Capacity 840 - 14.280 Nm3/h

SFH SFH SS AAFs

Welded carbon steel condensate separators Welded stainless steel conden. separators Aluminium silicone free filters

Oper. pressure 16 bar Oper. pressure 13 bar Oper. pressure 20 bar

Capacity 1.760 - 12.550 Nm3/h Capacity 1.760 - 12.550 Nm3/h Capacity 10 - 2.760 Nm3/h

AAF O2 P-VAC M-VAC

Aluminium filters for Oxygen Vacuum pump protection filters Medical vacuum filters

Oper. pressure 20 bar Oper. pressure 20-2.000 mbar (abs) Oper. pressure 20-2.000 mbar (abs)
Capacity 10 - 2.760 Nm3/h Capacity 1,25 - 345 Nm3/h Capacity 1,25 - 345 Nm3/h

8
 CS SS SFH HP HF HF O2 CHP IHP
Welded stainless steel conden. separators Welded high pressure cond. separators Cast aluminium high pressure filters Cast aluminium high pressure oxygen filters Carbon steel high pressure filters Stainless steel high pressure filters

Oper. pressure 13 bar Oper. pressure 25 bar Oper. pressure 50 bar Oper. pressure 50 bar Oper. pressure 100, 250, 420 bar Oper. pressure 100, 250, 420 bar
Capacity 840 - 14.280 Nm3/h Capacity 1.760 - 12.550 Nm3/h Capacity 71 - 2.760 Nm3/h Capacity 71 - 2.760 Nm3/h Capacity 40 - 715 Nm3/h Capacity 40 - 715 Nm3/h

AAF HT WFIT WFIW WFIF WHFIT PF

Aluminium high temperature filters Welded stainless steel filters - threaded con. Welded stainless steel filters - welded conn. Welded stainless steel filters - flanged conn. High pressure stainless steel process filters Stainless steel process filters

Oper. pressure 10/13 bar Oper. pressure 14/25 bar Oper. pressure 14/25 bar Oper. pressure 10/14/25 bar Oper. pressure 50 bar Oper. pressure 14 bar
Capacity 10 - 2.760 Nm3/h Capacity 75 - 3.600 Nm3/h Capacity 75 - 3.600 Nm3/h Capacity 150 - 21.120 Nm3/h Capacity 150 - 2.400 Nm3/h Capacity 75 - 21.120 Nm3/h

BF HP SPF SF HPF AV MSS

High pressure welded carbon steel filters Stainless steel sterile filters Stainless steel sterile filters High pressure stainless steel process filters Stainless steel air venting filters Mobile steam sterilizer

Oper. pressure 50 bar Oper. pressure 14 bar Oper. pressure 10 bar Oper. pressure 50 bar Oper. pressure Oper. pressure 1 to 3,6 bar
Capacity 1.680 - 31.400 Nm3/h Capacity 75 - 3.600 Nm3/h Capacity 75 - 21.120 Nm3/h Capacity 150 - 2.400 Nm3/h Capacity 9 - 310 Nm3/h Capacity
OMEGA AIR
more than air
9
 Compressed Air
and Gas Filtration COMPRESSED AIR QUALITY CLASSES ACCORDING TO ISO 8573-1
SOLID PARTICLES HUMIDITY AND LIQUID WATER OIL

CLASS Maximum number of particles per cubic meter as a Concentration of total oil(1)
Pressure dew point
Modern production companies need expensive function of particle size, d(1) (liquid, aerosol and vapor)
Filtration principles and complex production equipment to 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 ppm/w/w
meet the demands of the modern market. 0 As specified by the equipment user or supplier and more stringent than class 1
Equipment and machines which are powered 1 ≤ 20.000 ≤ 400 ≤ 10 ≤ -70 -94 ≤ 0,01 ≤ 0,008
by compressed air are worth nothing, if the 2 ≤ 400.000 ≤ 6.000 ≤ 100 ≤ -40 -40 ≤ 0,1 ≤ 0,08
quality of compressed air is poor. Downtime 3 Not specified ≤ 90.000 ≤ 1.000 ≤ -20 -4 ≤1 ≤ 0,8
and unreliability are not acceptable.
4 Not specified Not specified ≤ 10.000 ≤ +3 38 ≤5 ≤4
5 Not specified Not specified ≤ 100.000 ≤ +7 45 Not specified Not specified
Compressed air contamination is a real
6 ≤ ±10 50
problem, which cannot be ignored. Even the
most simple and basic use of compressed air Mass concentration(1)-Cp LIQUID WATER CONTENT(1) - CW
requires a minimum treatment, comprising the mg/m3 g/m3
elimination of water, oil and solids. 6 0 < Cp ≤ 5 Not specified Not specified
7 5 < Cp ≤ 10 CW ≤ 0,5 Not specified Not specified
To guarantee maximum performance and 8 Not specified 0,5 ≤ CW ≤ 5 Not specified Not specified
reliability, clean, dry, reliable compressed air 9 Not specified Not specified Not specified
supply is essential to maintain efficient and X Cp > 10 >5 >4
cost effective production. The key factor in (1)
At reference conditions: air temperature of 20° C, absolute air pressure of 100 kPa (1 bar), 0 relative water vapour pressure.
planning an efficient compressed air system is
to know all sources and types of compressed
air contaminants and the required maximum
levels of certain contaminants.
CKL grade N grade 25/5 µm I grade 20/1 µm B grade 15 µm
cyclone separator prefilter prefilter prefilter
Contaminants come to compressed air and
gas system from different sources:
- Atmospheric air, containing water vapour,
dust, oil vapours and microorganisms. centrifugal
force

- Air compressor generates oil contaminants gravity

in liquid, aerosol and vapour phase.

- Air receivers (pressure vessels) and
distribution systems generates corrosion and
scales. quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1)
solids, oil - solids - solids - solids 7
The degree of purification of individual water 8 oils - oils - oils -
contaminants must be consistent with the material material material material
needs of the application and the requirements
- sintered stainless
of ISO 8573-1, which prescribes compressed air - stainless steel mesh - sintered brass
steel 1.4404
quality classes.

10
Condensate separators Catalyst filters
Cyclone condensate separators use centrifugal motion to force material based on glass fibers. These materials enables the Two stage catalyst filter elements are used for a highly efficient from the air and in the second stage the depth fiber filter media
condensate out of compressed air. The spinning causes the formation of oil drops, which are forced to the outside of the reduction of carbon monoxide as well as some other substances intercepts all dust particles. The molecular sieve filtration grade
condensate to gather on walls of the centrifugal separators. filter by air flow. When it reaches the exterior of the filter from compressed breathing air. In the first stage the Hopcalite is suitable for point of use applications. It is important that
When the condensate gains enough mass it moves to the material, it is stopped in a porous foam material, which catalyst reduces the level of these substances from the air and inlet air is free of liquid water and oil aerosols.
bottom of the separator bowl where the blind plate calms the covers the filter element, and then runs down to the bottom in the second stage the depth fiber filter media intercepts all
air flow and prevents the condensate from being sucked to of the filter housing. The oil is discharged by the automatic Hopcalite dust particles.
the outlet. Condensate is removed out of the system by the condensate drain.
Sterile filters
condensate drain. It is essential that coalescing filter element is installed as a
pre-filter to the Catalyst grade filter and that relative humidity Sterile filters eliminate micro-organisms from compressed
Activated carbon filters is sufficiently low. air and they are used and are used in processes and systems
General purpose filters which require the highest air quality. Sterile filters are made of
Activated carbon filters are two stage filter elements. They are materials that enable high temperature steam sterilization.
Pre-filter elements are designed for efficient removal of coarse required in applications, where the air is required for breathing; Molecular sieve filters The sterile filter element is used for highly efficient sterile
solid particles and bulk liquids from compressed air. This type mixing with food, pharmaceutical products or other similar filtration of compressed air, processed air and technical gasses.
of filter is generally used as a pre-filter for the coalescing applications. Activated carbon filter elements are designed for A molecular sieve filters are two stage filter elements. Molecular
filter. They are required by non-lubricated and lubricated highly efficient removal of oil, hydrocarbons, vapors and odours sieve is material with pores (very small holes) of uniform size. The depth filter medium made of borosilicate glass microfibers
compressors. from compressed air. Activated carbon is an excellent adsorbent These pores match the dimesions of small molecules, thereby ensures highly efficient removal of submicron particles down to
for oil vapors and a medium suitable for the purification of preventing the adsorption of large molecules and only allowing 0,01 µm including microorganisms (bacteria). The filter medium
compressed air. It must be in fine granulated form to generate the passage of smaller molecules. supported with NOMEX is rigidly held between two stainless
Oil removal filters a large surface on which the adsorption can occur. It is essential steel cylinders and encapsulated between stainless steel
that the coalescing filter element is installed as a pre-filter Molecular sieve filter elements are used for separating water end-caps. This results in exceptionally strong filter element that
Coalescing filter elements are used for a highly efficient removal vapor from small flows of compressed air and therefore for air ensures highly efficient filtration and allows a large number of
upstream to the activated carbon filter.
of solid particles, oil aerosols and water from compressed air. drying. In the first stage, the desiccant adsorbs water vapor sterilization cycles.
Oil removal filters are usually made of special coalescence

P grade 3 µm XR grade 1 µm XM grade 0,1 µm XS grade 0,01 µm A grade A2 grade H2 grade MS2 grade VSF grade
prefilter prefilter microfilter microfilter activated carbon adsorption catalyst molecular sieve sterile

quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1) quality class (ISO 8573-1)
solids 6 solids 3 solids 2 solids 1 solids 1 solids 1 solids 1 solids 1 solids 1
oils - oils - oils 2 oils 1 oils 1 oils 0/1 oils - oils - oils -
material material material material material material material material material

- acrylic fibres - activated carbon - activated carbon - hopcalite - molecular sieve - borosilicate micro fibres
- borosilicate micro fibres - borosilicate micro fibres - borosilicate micro fibres
- cellulose - borosilicate micro fibres - borosilicate micro fibres - borosilicate micro fibres - borosilicate micro fibres - Nomex™

OMEGA AIR
more than air
11
 Compressed Air
and Gas Filtration
Filter elements FILTER ELEMENTS AND FILTER HOUSING COMPATIBILITY
Filter element type CKL N25 I IW B N5 P XR XM XS A A2 H2 MS2 CKL VSF AVF
acivated acivated water
filtration grade 25 µm 20, 1µm 20, 1µm 15 µm 5 µm 3 µm 1 µm 0,1 µm 0,01 µm carbon carbon catalyst adsorption separation sterile vent
AAF Aluminium compressed air filters  - - -  -          - -
BF Welded carbon steel compressed air filters - - - -  -      - - - - - -
CS/CS SS Welded condensate separators - - - - - - - - - - - - - - - - -
SFH/SFH SS Welded condensate separators - - - - - - - - - - - - - - - - -
AAFs Silicone free compressed air filters - - - - - -      - - - - - -
AAF HT Aluminium high temperature compressed air filters   - -   -    - - - -  - -
AAF O2 Aluminium compressed gas filters for Oxygen - - - - - - -    - - - - - - -
P-VAC Vacuum pump protection filters - - - - - -  -  - - - - - - - -
M-VAC Medical vacuum filters - - - - - - - - - - - - - - - - -
BF HP High pressure welded carbon steel compressed air filters - - - -  -      - - - - - -
SFH HP Welded high pressure condensate separators - - - - - - - - - - - - - - - - -
HF Cast aluminium high pressure compressed air filters  - - -  -      - - - - - -
HF O2 Cast aluminium high pressure filters for Oxygen - - - - - - -    - - - - - - -
CHP Carbon steel high pressure compressed air filters  - - -  -      - - -  - -
IHP Stainless steel high pressure compressed air filters   - - -  -     - - -  - -
WFIT Welded stainless steel comp. air filters - threaded connections     -       - - -  - -
WFIW Welded stainless steel comp. air filters - welding end connections     -       - - -  - -
WFIF Welded stainless steel comp. air filters - flanged connections     -       - - -  - -
WHFIT High pressure stainless steel process compressed air filters     -       - - -  - -
PF Stainless steel process compressed air filters -    -       - - -   -
SPF Stainless steel sterile compressed air filters -    -       - - -   -
SF Stainless steel sterile compressed air filters - - - - - - - - - - - - - - -  -
HPF High pressure stainless steel process filters -    -       - - -   -
AV Stainless steel air venting filters - - - - - - - - - - - - - - - - 
MSS Mobile steam sterilizer - - - - - - - - - - - - - - - - -

12
CKL N 25; 5 µm I 20; 1 µm IW 20; 1 µm B 15 µm P 3 µm XR 1 µm XM 0,1 µm
condensate separator prefilter prefilter prefilter prefilter prefilter prefilter general purpose filter

Construction: Layers: Layers: Layers: Layers: Layers: Layers: Layers:

- stainless steel construction - stainless steel expanded mesh - sintered stainless steel 1.4404 - sintered stainless steel 1.4404 - sintered brass - stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh
- abs plastic insert 1.4301 - nonwoven layer - nonwoven layer - nonwoven layer
- stainless steel filtration mesh - acrile fibres, cellulose - acrile fibres, cellulose - depth fiber filter layer
- stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh (borosilicate micro fibers)
1.4301 - needle felt - coalescing layer (borosilicate
micro fibers)
- stainless steel expanded mesh
- needle felt

XS 0,01 µm A adsorption A2 adsorption H2 MS2 VSF

super fine filter activated carbon activated carbon catalyst molecular sieve sterile

Layers: Layers: Layers: Layers: Layers: Layers:

- stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh
- nonwoven layer - nonwoven layer - activated carbon media - hopcalite - molecular sieve - carrier layer
- depth fiber filter layer - activated carbon media - nonwoven layer - nonwoven layer - nonwoven layer - depth fiber filter layer
(borosilicate micro fibers) - depth fiber filter layer - depth fiber filter layer - depth fiber filter layer - depth fiber filter layer (borosilicate micro fibers)
- coalescing layer (borosilicate (borosilicate micro fibers) (borosilicate micro fibers) (borosilicate micro fibers) (borosilicate micro fibers) - stainless steel expanded mesh
micro fibers) - stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh - stainless steel expanded mesh -Nomex™
- stainless steel expanded mesh
- needle felt
OMEGA AIR
more than air
13
 Compressed Air
and Gas Filtration
System pressure drop Knowing the pressure drop level is important!
1 bar of pressure drop = 7-8%
of additional compressor energy !!!

8 bar

7,5 bar

7 bar
ADDITIONAL PRESSURE DROP
DUE TO CLOGGED
6,5 bar
FILTER ELEMENTS

6 bar

5,5 bar

14
 CHANGE THE FILTER ELEMENTS REGULARLY !

The filtering efficiency of the saturated filter is much higher,

since the pores of the filtering medium are narrower.
However, this significantly increases the pressure drop in the
system. 1 bar of pressure drop, causes the request for 7 to
Pressure drop in compressed air system 8% of additional energy to drive the compressor.

Pressure drop is a huge problem in compressed air system. Every additional Omega Air products have a very low pressure drop. For
obstruction of compressed air flow requires additional power to drive the instance, when first installed in the housing, the pressure drop
compressor. of the pre-filter cartridge of 3 microns is as low as 10 mbar.
Control pressure drop at any time with any of our pressure
Compressed air system pipeline has fixed pressure drop, which has already drop indicators.
been taken into account in the phase of compressor dimensioning. This
pressure drop generally can’t be changed.

Filter element pressure drop is variable factor of compressed air system.

Despite the fact that the filter element play a useful role in the removal Economical filter element changing
of compressed air pollutants, it’s saturation could be a problem since it Pressure drop
will increase in time. The result is an increase of pressure drop, additional
compressor power, which means the significantly rising of operating costs.
Economical point of filter Pressure
element replacement drop costs
For this reason the pressure drop in filter element must be monitored and
controlled.
Economical
Omega Air produces several types of products for this purpose. There operating zone
are indicators of pressure drop with an analogue or digital display of
saturation level of the filter element, some of them with output for remote Time
monitoring.
OMEGA AIR
more than air
15
 Compressed Air
and Gas Filtration
Indicators

INDICATORS
PDI 16 Differential pressure indicator 16 bar
MDM 40 Differential pressure indicators 20 bar
MDA 60 Differential pressure indicators 20 bar
VPG 40 Differential pressure indicators 20-2000 mbar
EPG 60 Electronic pressure gauge 16 bar
MDH 200 Differential high pressure indicators 200 bar
MDH 420 Differential high pressure indicators 420 bar
MDHI 50 Differential high pressure stainless steel indicator 50 bar
OCI Oil content indicator 0,68 - 16 bar
CHI Humidity indicator 20 bar

16
 PDI 16 MDM 40 MDA 60 VPG 40
Differential pressure indicators Differential pressure indicators Differential pressure indicators Differential pressure indicators

Maintaining pressure drop is an important way to make the compressed air system
energy efficient. Pressure drop is the difference between the compressor discharge
pressure and pressure that comes to the actual user of the compressed air, for
example, the laser cutting machine. Pressure drop is thus undesirable and is an
indirect cost that results in higher electricity bill and higher production price of the
end goods.

It occurs due to improper sizing of air treatment equipment and due to insufficient
maintenance of the equipment. According to the rules of good practice, a properly
Oper. pressure 16 bar Oper. pressure 20 bar Oper. pressure 20 bar Oper. pressure 20-2000 mbar
designed system should have a pressure drop less than 10% compared to the
compressor’s discharge pressure, measured from the receiver tank output to the
user (machine or tool). EPG 60 MDH 200 MDH 420 MDHI 50
Electronic pressure gauge Differential high pressure indicators Differential high pressure indicators Diff. high pressure stainless steel indicators
The problem with pressure drop is even worse during times when the airflow and
temperature are at highest. With higher temperatures in the summer months and
increased humidity, more water comes into the compressed air system. Filters are
affected by this additional moisture and when pressure drop rises compressor
running costs are higher. Therefore, it is advisable to replace the filter elements at
that time.

Select correct filters and separators

• When selecting filters please remember that they will gradually saturate. For your
convenience we provide the information about pressure drop when the element is Oper. pressure 16 bar Oper. pressure 200 bar Oper. pressure 420 bar Oper. pressure 50 bar
dry and when it is wet. Please check our product data sheets for this information.
• The pressure drop of our 3 micron cartridges marked P or /P is just 10 mbar in dry OCI CHI
condition, making it very effective and energy saving. Oil content indicator Humidity indicator

Maintain filtering and drying level

• Wet conditions are undesirable for compressed air systems. Not only corrosion but
also higher pressure drop appears. Thoughtful choice of drying technology further
depends on the required dew point. For many applications, refrigeration dryer is
enough.
• For stable quality and low cost filtration it is recommended to replace the filter
element after 12 month of operation (6 months for A element) or when pressure
drop exceeds 350 mbar. Oper. pressure 0,68 - 16 bar Oper. pressure 20 bar
OMEGA AIR
more than air
17
 Condensate
management
Basics

CLEAN WATER OUTLET

residual oil content <10 ppm

Compressing is a process, where atmospheric air, containing - The presence of water will lead to the formation of rust and scale
impurities (hydrocarbon or chemical vapours) and water moisture in the air piping system. This solid contamination may cause
is drawn into compressor. Compressors mostly require oil for damage to the equipment.
lubrication, sealing and cooling. At the end of compression, hot
compressed air flows into an aftercooler to remove the heat of - Your air dryers and inline filtration products will not perform
compression. During cooling, processed water and hydrocarbon if they become overloaded with liquid contamination. Slugs
vapours will condense. The air is further cooled in the piping and air of water due to drain failure can cause major problems in a
dryers, where additional condensation takes place. desiccant dryer.

Condensate draining equipment is possibly the most ignored - Also, water can back up into the compressor and wreck the
component of a compressed air system but nevertheless, the most machinery.
important part. No matter how much money you wasted on high-
quality equipment for compressed air (compressors, dryers, filters), - When a drain fails to eject all of the condensate collected, oil
compressed air quality becomes worthless, if the condensate is not and/or water will accumulate, affecting filter efficiency, causing
discharged from the system. carry over into the system and allowing freeze-up in the winter.

Condensate in a compressed air system can cause large problems: - Drains stuck in the open position due to condensate debris can be
a major source of wasted energy in some plants.
- An inconsistent supply of dry air will cause production problems.
For example, the moisture will wash away the lubrication - The condensate transferred to the end user, can lead to
from air tools, and cause erratic performance, downtime and irreparable consequences to the final product or process.
maintenance.

18
 CLEAN DRY AIR
Condensate is an unavoidable result of air compression. It is a
chemically aggressive fluid that mainly consists of water, but also
contains oil and dirt particles. Oil carryover is unavoidable if you
have compressors that use oil in the compression chamber. The
lubricant will mix with the condensation and create an oily water
WOS CD
that must be properly handled to avoid violating environmental
air regulations.

Just one litre of used oil can contaminate up to one million litres
P XM XS of fresh water. Thatswhy environmental regulations strictly

WOS CD
CLEAN WATER OUTLET prohibit the discharge of oily wastes and chemicals, including the
residual oil content <10ppm
condensate drained from a compressed air system. Compressed
PV

air condensate must therefore be treated in accordance with water

RDP

resource legislation to achieve prescribed safety levels before it can

WOS

WOS
be disposed of in the waste water system.

Compressor condensate must therefore be either collected and

treated by special processes or treated prior to disposal to the
environment. An oil/ water separator can be used here to remove
the oil from the condensate. Since the condensate is approximately
95% water and 5% oil, water/oil separators have been developed
Drain valves are installed on moisture separators, coalescing filters, Water moisture is not the only undesirable substance. There are to reduce or eliminate the amount of oil in the condensate.
air receivers, air dryers and drip legs to remove this condensate also other pollutants in compressed air: lubricating oil carry over
from the compressed air system. The condensate should be piped from oil lubricated air compressors, atmospheric corrosive gases
AIR OUTLET
from automatic drain valves to oil/water separators to remove the drawn in by the air compressor, aerosols and vapours, solid particles INLET
» condensate (oil, water) DEPRESSURIZATION
oil from the condensate before it is discharged into a drain. Make and rust from the piping system and pressure vessels and solid » air CHAMBER WITH AIR
FILTER
sure, that the drains operate properly. This is the only way to ensure particles drawn in by the air compressor. 2nd stage 1st stage
that the filters and separators are successful in completing their CLEAN WATER chamber chamber

task. The first stage is to remove the major part of condensate, which OUTLET
contains a large amount of upper mentioned pollutants. This can be residual oil
content <10ppm
Always slope or pitch the pipe in the main air header and in the done by aftercoolers and condensate separators. » condensate
branch air lines downward in the direction of the air flow. This will (oil, water)

allow the condensation to collect at the low points, where it can The second stage is the removal by coalescing filters, and the last
be trapped and drained from the compressed air systems. Always stage is air drying by refrigeration or adsorption dryers. OIL FILTER
CARTRIDGE
install the valves to the end of pipes. If possible, use materials ACTIVATED CARBON (polypropilene
fibres)
FILTER CARTRIDGE
resistant to corrosion and oxidation. Condensate should be then removed from the compressed air - final oil elimination
system by automatic or manual condensate drains.
Since water moisture is a part of atmospheric air, condensate in
compressed air systems can’t be avoided. During the compression
process, the air is heated. It cools down as it passes through hoses,
valves and piping. As it approaches the ambient temperature,
vapour condenses to liquid and can be removed by mechanical
separation. As the air cools further, more condensate is present.
OMEGA AIR
more than air
19
 Water-oil separators
Condensate WOSm
management
Water-oil separators

Condensate drains
Water-oil separators

WATER/OIL SEPARATORS
WOSm Water - oil separators WOS
WOS Water - oil separators Water-oil separators

WOS CD Condensate distributor

CONDENSATE DRAINS Pressure

EMD Electronic condensate drains 16 bar
IED Electronic condensate drain 16 bar
TD M Timer controlled condensate drain 16, 25, 50, 150 bar
AOK 16B Automatic mechanical condensate drain 16 bar
AOK 16F Automatic mechanical condensate drain 16 bar
AOK 13PA Automatic mechanical condensate drain 13 bar
AOK 20B Automatic mechanical condensate drain 20 bar
WOS CD
AOK 20SS Automatic mechanical stainless steel condensate drain 20 bar
Condendate distributor
MCD-B Manual condensate drain 16 bar
MCD Manual condensate drain 20 bar
MCDI Manual condensate drain 20 bar
MCDIs Manual condensate drain 20 bar
TD 420M High pressure timer controlled condensate drains 0-420 bar
EMD HP High pressure electronic condensate drains 50 bar
AOK 50B/SS Automatic mechanical high pressure condensate drain 50 bar
BALL VALVE Valve 16 bar
DRAIN VALVE Valve 64, 420 bar

20
Condensate drains
EMD IED TD M AOK 16B AOK 16F AOK 13PA
Electronic condensate drains Electronic condensate drains Timer controlled condensate drains Automatic mechanical condensate drains Automatic mechanical condensate drains Automatic mechanical plastic cond. drains

Oper. pressure 16 bar Oper. pressure 16 bar Oper. pressure 16, 25, 50, 150 bar Oper. pressure 1,5 - 16 bar Oper. pressure 1,5 - 16 bar Oper. pressure 13 bar
Capacity 12 - 150 l/h Capacity 8 l/h Capacity 0,7 - 3,4 l/h Capacity see product data sheet Capacity 7 - 9,1 l/h Capacity 167 - 226 l/h

AOK 20B AOK 20SS MCD-B MCD MCDI MCDIs

Automatic mechanical condensate drains Autom. mech. stainless steel cond. drains Manual condensate drain Manual condensate drain Manual stainless steel condensate drain Manual stainless steel condensate drain

silicone
free

Oper. pressure 20 bar Oper. pressure 20 bar Oper. pressure 16 bar Oper. pressure 20 bar Oper. pressure 20 bar Oper. pressure 20 bar
Capacity 167 l/h Capacity 167 l/h Capacity see product data sheet Capacity see product data sheet Capacity see product data sheet Capacity see product data sheet

TD 420M EMD HP AOK 50B AOK 50SS BALL VALVE BALL VALVE NV 420
Timer controlled high press. cond. drains High pressure electronic cond. drains Autom. mech. high pressure cond. drain Autom. stainless steel high press. c. drain Valve High pressure valve

Oper. pressure 0 - 420 bar Oper. pressure 50 bar Oper. pressure 8 - 50 bar Oper. pressure 8 - 50 bar Oper. pressure 16 bar Oper. pressure 0 - 420 bar
Capacity see product data sheet Capacity see product data sheet Capacity 145 l/h Capacity 145 l/h Capacity see product data sheet Capacity see product data sheet
OMEGA AIR
more than air
21
 Drying compressed air - basics
Drying Atmospheric air is the mixture of gasses surrounding the earth. on which it condensates. Water vapour only condensates on state when the air contains more than the maximum theoretical
Its density at sea level and 15°C is 1,225 kg/m3 (according to surfaces with temperatures lower than dew point or when air is limit of water vapour. The excessive amount of water vapour
ISA). It is comprised of different gasses like nitrogen, oxygen, theoretically over saturated. condensates to liquid water, while the air becomes saturated.
Basics argon, carbon dioxide, and inevitably water vapour. Water
vapour comes from boiling or evaporating liquid water or from Saturated air is a condition, when air contains a maximum When water vapour condensates on a solid surface it is called
sublimation of ice. amount of water vapour at a certain temperature and cannot dew. This happens when relative humidity reaches 100%. At a
possibly accumulate any more humidity. In this case, relative constant temperature, a volume of air can accumulate a finite
Humidity is the amount of water vapour in the air. Maximum humidity is 100%. Relative humidity indicates the degree amount of water vapour. When air becomes saturated it reaches
humidity is determined solely by air temperature and is of saturation of air at a certain temperature. It ranges from the dew point and water vapour starts to condensate on solid
independent from all other parameters. Warmer air can 0-100%. Non-saturated air is a condition, where air could surfaces, dust, soot and other impurities in air. Since hot air can
accumulate more water vapour than cold air (see table below). accumulate more water vapour by any means (boiling or accumulate more water vapour than cold air, hot air is dryer than
When water evaporates, it cools the surface from which it evaporating from liquid water or sublimation from ice). Relative cold air with the same dew point.
evaporates. When water vapour condensates it heats the surface humidity is below 100%. Theoretically over-saturated air is the

Dew point
Compressed air contains contaminants such as water, oil and particulates
which must be removed or reduced to the acceptable level based on specific
application requirements.

The standard ISO 8573-1 specifies air purity/quality classes for these
contaminants. Humidity (water vapor content) is expressed in terms of
Pressure Dew Point (PDP) where Dew point is the temperature at which air is
100% saturated with moisture. The dew point temperature is the temperature
at which the air can no longer “hold” all of the water vapour which is mixed with
it, and some of the water vapour must condense into liquid water. When the
temperature of the air is reduced to or below the dew point, condensation will
occur. As pressure increases, dew point temperature rises and air becomes more
moist (RH increases), as pressure decreases, dew point temperature goes lower
and air becomes drier (RH decreases).

Reduction of water content down to the pressure dew point +3°C is usually
achieved with refrigerant dryers while for lower pressure dew points adsorption
(also called desiccant) dryers are typically used.

The Mollier diagram is a graphic representation of the relationship between

air temperature, moisture content and enthalpy - and is a basic design tool for
construction engineers and designers.

22
Compressed air dryer installation layout
Compressed air dryers
Two most common dryer installation layouts are used for efficient
integration into compressed air installation.
operating range
8

1) Dryer is installed downstream from pressure vessel when only

Refrigeration dryers
4 4 are suitable for all volume flow ranges with pressure dew point down
partial flow rate of compressor is treated or when compressor operates 9
4 to 3°C.
at reduced intermittence and the total consumption equals the
compressor flow rate.
6 6
Adsorption dryers are suitable for all volume flow ranges with
pressure dew point down to -70°C.
1 Compressor 1 2 3 4
2 Aftercooler Membrane dryers are suitable for small volume flow ranges with
3 Condensate separator
5 pressure dew point down to -40°C.
4 Filter
5 Pressure vessel
6 Condensate drain
6 6
7 Compressed Air Dryer
8 Compressed air outlet 7
9 DRY compressed air outlet

6
PDP [°C]

+10
+3 Refrigeration
2) Dryer is installed upstream from pressure vessel when total flow 0
rate of the compressor is treated or when consumption of compressed 4 20.000 [m3/h]

Membrane
4
air varies a lot or when short peaks of high consumption (higher than
dryer/compressor capacity) are expected.
8 -25
6
Adsorption
-40
1 2 3 4 4

1 Compressor
2 Aftercooler 5
3 Condensate separator -70
4 Filter 6 6 6

5 Pressure vessel 7
6 Condensate separator
7 Compressed Air Dryer
8 DRY compressed air outlet
6

OMEGA AIR
more than air
23
 4
P<
01 1

Drying TS
01

6
a
P>
Refrigeration dryers 01
PV
01
Basics b

5
2

T 3
01

c
7 8 9

1
10

1 Heat exchanger module

a
Heat exchanger air/air - pre-cooler
b
Evaporator air/refrigerant
c
Demister
9
2 Compressed air input - wet
8
3 Compressed air output - dry
4 4 Compressor
5 5 Condenser
6 Hot gas by-pass valve
7 Gas filter
8 Expansion valve or capillary tube
9 Electronic condensate drain
10 Controller

24
Operation principle
The operating principle of a refrigeration compressed air dryer is by temperature or pressure sensor. Liquid refrigerant then flows
based on the thermodynamic principle of cooling. The dryer uses through capillary tube or thermostatic expansion valve (8) which
a refrigerant to lower the temperature of compressed air, which acts as a metering device to reduce the pressure of the refrigerant.
in turn lowers the dew point of the air. The compressed air passes Reduction of the pressure is a design function to achieve target
through a heat exchanger where it is cooled by the refrigerant. The temperature inside the evaporator (lower pressure = lower
moisture in the compressed air condenses into liquid form, which temperature). Filter (7) which is installed upstream the metering
is then removed by a drain trap or automatic condensate drain. device intercepts impurities and assures reliable operation of the
system. Low pressure refrigerant in gas form then re-enters the
Operation of refrigeration compressed air dryer can be divided into compressor.
two independent circuits:
RDP dryers operate based on “non-cycling” operating principle
COMPRESSED AIR CIRCUIT which means that when the dryer is without load (e.g. no or low
Warm and humid compressed air enters into three-stage heat inlet flow of compressed air) “hot gas by-pass valve” (6) will
exchanger. In the first stage “air-air” (a) incoming air is precooled release part of the hot refrigerant gas (from discharge side of the
by cold outlet air. This stage is important from energy saving compressor) back to the suction side of the compressor. As a result
point of view as well as for stable operation of entire system. In evaporation pressure/temperature will be constant at the factory
the second stage “air-refrigerant” (b) the air is cooled by the cold pre-set value.
refrigerant. In this stage water vapour condenses into liquid water.
In the third stage “demister” (c) separates all the liquid water In case of high discharge temperature the controller stops the
from the air stream. Cold dry air then enters “First stage” (a) again compressor before permanent damage occurs. Depending on size
where it is re-heated by the hot inlet air. Besides energy saving of the dryer additional safety/protection devices (e.g. low pressure
feature this stage also makes sure that dry air leaving the dryer switch, high pressure switch) are installed in on the refrigerant gas
is warm enough to prevent condensation on the external side circuit.
of downstream piping. Condensed water is discharged from the
system via electronic condensate drain. All of our dryers are equipped with good control mechanisms. This
allows for a very stable dew point. From the smallest dryer sizes
REFRIGERANT CIRCUIT on we offer excellent communication possibilities. Larger dryers
Circulation of the refrigerant gas in the circuit is provided by highly are equipped with more powerful controllers offering advanced
efficient hermetically sealed compressor (4). Compressor rises the control and monitoring features.
pressure of the gas which is then cooled down and condensed in
the condenser (5). Electric fan on the condenser can be controlled
OMEGA AIR
more than air
25
 Drying Applications

Refrigeration dryers Refrigeration compressed air dryers are commonly used in a variety of
industrial and commercial applications, including:

Types Food and beverage industry - to dry compressed air used in

processing, packaging, and storage of food and beverages.

Pharmaceutical industry - to dry compressed air used in the

production of drugs and medical equipment.

Electronics industry - to dry compressed air used in the manufacture

of semiconductors and other electronic components.

Automotive industry - to dry compressed air used in painting,

welding, and other manufacturing processes.

Printing industry - to dry compressed air used in printing presses.

Types of Refrigeration Compressed Air Dryers

There are two main types of refrigeration compressed air dryers: cycling and
non-cycling. The cycling dryer operates by turning the compressor on and off
based on the demand for compressed air. The non-cycling dryer, on the other
hand, operates continuously regardless of the demand for compressed air.

REFRIGERATION DRYERS
RDP Refrigiration compressed air dryers 16/14 bar
RDT Refrigeration compressed air dryers with timer drain 16 bar
RDL Refrigiration compressed air dryers 13 bar
RDHP High pressure refrigiration compressed air dryers 45 bar

26
 RDP RDT RDL RDHP
Refrigiration compressed air dryers Refrigiration dryers with timer drain Refrigiration compressed air dryers High pressure refrigiration dryers

Oper. pressure 16/14 bar Oper. pressure 16 bar Oper. pressure 13 bar Oper. pressure 45 bar
OMEGA AIR
more than air
27
 Drying
Adsorption compressed air dryers are a type of compressed air dryer
that uses an adsorbent material to remove moisture from compressed
Adsorption dryers air. Unlike refrigeration compressed air dryers that use cooling to
remove moisture, adsorption dryers use a desiccant material to adsorb
Basics moisture from the compressed air.

DRYERS, COOLERS, OIL REMOVERS

A-DRY Heatless regeneration adsorption compressed air dryers 4 to 16 bar 6 - 200 Nm3/h -40 °C (-25 °C/-70 °C)
A-DRY TAC Adsorption compressed air dryers with activated carbon tower 4 to 16 bar 6 - 117 Nm3/h -40 °C (-25 °C/-70 °C)
A-DRY BM Heatless regeneration adsorption compressed air dryers 4 to 16 bar 6 - 200 Nm /h
3
-40 °C (-25 °C/-70 °C)
X-DRY Heatless regeneration modular ads. compressed air dryers 4 to 16 bar 300 - 1.050 Nm3/h -40 °C (-25 °C/-70 °C)
B-DRY Heatless regeneration adsorption compressed air dryers 4 to 16 bar 110 - 1.000 Nm3/h -40 °C (-25 °C/-70 °C)
B-DRY TAC Heatless regener. ads. comp. air dryers with act. carbon tower 4 to 16 bar 1200 - 6.500 Nm3/h -40 °C (-25 °C/-70 °C)
B-DRY BM Heatless regeneration adsorption compressed air dryers 4 to 16 bar 110 - 1.000 Nm3/h -40 °C (-25 °C/-70 °C)
F-DRY Heatless regeneration adsorption compressed air dryers 4 to 16 bar 1200 - 6.500 Nm /h 3
-40 °C (-25 °C/-70 °C)
COM-DRY Refrigerant + adsorption compressed air dryers 4 to 11 bar 1200 - 6.500 Nm3/h -40 °C (-25 °C/-70 °C)
R-DRY BVA Heat reg. ads. dryers - cooling with ambient air 4 to 11 bar 390-20.200 Nm /h3
-40°C
R-DRY BP Heat reg. ads. dryers - cooling with purge air 4 to 11 bar 390-20.200 Nm3/h -40°C
R-DRY BVL Heat reg. ads. dryers - cooling with closed loop 4 to 11 bar 390-20.200 Nm /h3
-40°C
R-DRY HOC F/P Heat reg. ads. dryers - heated with full/partial stream 4 to 11 bar 390-20.200 Nm3/h -20°C
R-DRY HP BVA High pressure heat reg. ads. dryers - cooling with ambient air 50 bar 2.485 - 23.400 Nm /h 3
-40°C
R-DRY HP BP High pressure heat reg. ads. dryers - cooling with purge air 50 bar 2.485 - 23.400 Nm3/h -40°C
R-DRY HP BVL High pressure heat reg. ads. dryers - cooling with closed loop 50 bar 2.485 - 23.400 Nm /h 3
-40°C
HP-DRY High pressure heatless regeneration adsorption dryers 50, 100, 150, 420 bar 50 - 1.600 Nm3/h -40°C
MAA-DRY Membrane compressed air dryers 12 bar 3 - 180 Nm /h
3
+15, +3, -20, -40 °C
ACA Air cooled aftercoolers 15 bar 66 - 4.500 Nm3/h
ACW Water cooled aftercoolers 10 bar 132 - 45.570 Nm3/h
TAC Activated carbon towers 16 bar 6 - 2.800 Nm3/h
TAC HP High pressure activated carbon towers 50, 100, 150, 420 bar 50 - 1.600 Nm3/h
SORBEO Adsorbents

28
Operating principle
The working principle of an adsorption compressed air dryer is
based on the process of adsorption. The dryer contains a desiccant
material, that has a high affinity for water molecules. The
compressed air passes through a bed of the desiccant material,
where the moisture in the air is adsorbed onto the surface of the
material.

When the desiccant material becomes saturated with moisture, the

adsorption process stops, and the dryer needs to regenerate the
desiccant material to remove the moisture. The regeneration process
involves heating the desiccant material, usually by using a heating
element, to release the moisture from the material. The moisture is
then vented out of the dryer, and the desiccant material is ready for
use again.

Types of Adsorption Compressed Air Dryers

There are two main types of adsorption compressed air dryers:
heatless and heated. Heatless dryers use the compressed air itself to
regenerate the desiccant material. A portion of the compressed air
is diverted to the dryer's regeneration section to dry the saturated
desiccant material. The dry air is then used to purge the desiccant
material, removing the moisture and preparing it for use again.

Heated dryers use an external heat source, such as an electric heater

or natural gas burner, to regenerate the desiccant material. The
heated air is then used to purge the desiccant material, removing
the moisture and preparing it for use again.

Applications
Adsorption compressed air dryers are commonly used in applications
that require very low dew points, or where compressed air is exposed
to harsh environments, such as oil and gas, chemical processing,
and pharmaceuticals. They are also used in situations where the
compressed air cannot be exposed to oil or other contaminants,
which can damage the desiccant material.
OMEGA AIR
more than air
29
 HEATLESS REGENERATION HEAT REGENERATION COMPRESSED AIR DRYERS
COMPRESSED AIR DRYERS
Drying R-DRY BP (cooling with purge)
Heatless regeneration is done with already dried compressed air which is taken BP dryers are using top to bottom air flow to regenerate the column. First, ambient

Adsorption dryers from the dryer’s outlet, decompressed to the atmospheric pressure and fed to
the regeneration vessel. Extremely under-saturated air extracts moisture from
air is sucked and directed through the heater and then into the column to heat it.
Instead of ambient air, purge is used for cooling. Because dry and cool purge air is
the desiccant and discharges it to the environment via silencer. The full cycle is 10 used, this kind of dryer can operate in environments where BVA cannot, for example,
Ranges minutes long, 5 minutes for adsorption and 5 for regeneration. with higher temperature and humidity. Its disadvantage is that it is that is sensitive
to variation of operating pressure or the variation of purge air flow.

1 11 10 8 9 8 10 16 12 2 Adsorption Regeneration Adsorption Regeneration

MT F2 Heating MT F2 Cooling
01 01
TT GO TT GO
04 04
CV1 CV2 CV1 CV2

X1 V7 V9 V10 V8 X2 X1 V7 V9 V10 V8 X2

14 V3 V6 V3 V6
13 PT PT PT PT
01 02 01 02
TT TT
03 03
14
PI PI
H1 02 H1 02

3 A1 A2 A1 A2
15 M1 M1
5

3
F3 F3
4
4
RI RI
14

RO RO
TT TT
02 02

V1 V5 V1 V5

V1 V4 V1 V4

GI TT GI TT
01 01
14 6 6 7 7 6 6
F1 F1

1 Comp. air inlet (wet air) 9 Nozzle A1-2 pressure vessel M1 blower
2 Comp. air outlet (dry air) 10 Pressure manometer F1 inlet filter (super fine coalescing) H1 heater
3 Column filled with dessicant 11 Inlet air filter F2 outlet filter (dust) F3 regeneration air filter
4 Two layer desiccant bed 12 Outlet air filter V1-6 ball valve with pneumatic actuator GI air inlet
5 Controller 13 Automatic cond. drain V7-10 angle seated valve with pneum. actuator GO air outlet
6 Solenoid valve 14 Flow distribution insert CV1-2 check valve RI regeneration air inlet
7 Expansion silencer 15 Cable for solenoid valve TT1-4 temperature transducer RO regeneraton air outlet
8 Non-return valve (optional) PI1-2 pressure indicator ES1-2 expansion silencer
16 Dew point sensor PT1-2 pressure transducer
(optional) DT1 dewpoint transducer

30
R-DRY BVA (vacuum regeneration with ambient air) R-DRY BVL (vacuum regeneration with closed loop) RC-DRY (regen. by heat of compression - full flow)
BVA is using ambient air to heat up and cool down the column which is being BVL is using ambient air for heating and for cooling the air that is in the vessel. RC dryers are those with zero compressed air loss. RC dryer uses air directly from
regenerated. The ambient air is sucked from the upper side of the column, first Ambient air is sucked in, heated and directed through the vessel from the top compressor. This means that no source of heat is needed because the air coming
through the heater, then through the adsorbent and then it is discharged into the side and then discharged into the environment. To cool the vessel, some valves from the compressor is already heated. Heated air enters the regeneration column
environment. change their state and the trapped air is used for cooling. Air goes through the heat where it heats, then it flows through the heat exchanger and cools down to a certain
Because it uses ambient air, it cannot be used in environments with high ambient exchanger where it is cooled and then used to cool the vessel. Air coming from the point. Finally, the air is dried in an adsorption column.
temperature and humidity. Air in these environments is already quite saturated and vessel is directed to the heat exchanger. Due to closed loop during cooling, no water Because it uses the heat of compression, it is characterized by a high level of energy
the regeneration wouldn’t be so efficient. Its advantage is that it can be used in areas is entering the system. This means higher adsorbent capacity, which is suitable for efficiency. This kind of dryer has to be dimensioned and modified to closely match
with changeable operating flow and pressure. hotter and more humid environments. Because the heat exchanger uses an external the compressor and operating conditions. Compressors used with RC dryers must be
source of cooling, water is required. oil free compressors.

Regeneration Regeneration Regeneration Regeneration Adsorption Regeneration Adsorption Regeneration

Adsorption Heating Adsorption Cooling Adsorption Heating Adsorption Cooling Heating Cooling
MT F2 MT F2 MT F2 MT F2 MT F2 MT F2
01 01 01 01 01 01
TT GO TT GO TT GO TT GO TT GO TT GO
04 04 04 04 04 04

CV1 CV2 CV1 CV2 CV1 CV2 CV1 CV2 F1 V4 V8 F1 V4 V8

GI GI
X1 V7 V9 V10 V8 X2 X1 V7 V9 V10 V8 X2 X1 V7 V9 V10 V8 X2 X1 V7 V9 V10 V8 X2
V3 V7 V3 V7
V3 V6 V3 V6 V3 V6 V3 V6
PT PT PT PT PT PT PT PT PT V10 V11 PT PT V10 V11 PT
01 02 01 02 01 TT 02 01 TT 02 01 02 01 02
03 03
TT TT
03 03 H1 H1
PI PI PI PI PI PI PI PI
02 02 02 02
01 02 02 02
M1 M1 C1 C2 C1 C2
A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2

RO RO C1 C1
V9 V12 V9 V12

RI RI
M1 M1
F3 F3
F3 F3
H1 H1
RI RI TT TT
RO RO 02 02
TT TT
02 02 TT TT
TT TT 03 03
V1 02 V5 V1 02 V5 V2 V6 V2 V6
V1 V5 V1 V5

V1 V4 V1 V4 V1 V5 V1 V5
V1 V4 V1 V4

GI GI GI TT GI TT
TT TT
01 01
01 01

F1 F1 F1 F1

A1-2 pressure vessel DT1 dewpoint transducer A1-2 pressure vessel M1 blower A1-2 pressure vessel DT1 dewpoint transducer
F1 inlet filter (super fine coalescing) M1 blower F1 inlet filter (super fine coalescing) H1 heater F1 inlet filter (super fine coalescing) GI air inlet
F2 outlet filter (dust) H1 heater F2 outlet filter (dust) F3 regeneration air filter F2 outlet filter (dust) GO air outlet
V1-6 ball valve with pneumatic actuator F3 regeneration air filter V1-6 ball valve with pneumatic actuator GI air inlet V1-6 ball valve with pneumatic actuator RO regeneraton air outlet
V7-10 angle seated valve with pneumatic actuator GI air inlet V7-10 angle seated valve with pneumatic actuator GO air outlet V7-10 angle seated valve with pneumatic actuator C1-2 water cooled heat exchanger
CV1-2 check valve GO air outlet CV1-2 check valve RI regeneration air inlet CV1-2 check valve
TT1-4 temperature transducer RI regeneration air inlet TT1-4 temperature transducer RO regeneraton air outlet TT1-4 temperature transducer
PI1-2 pressure indicator RO regeneraton air outlet PI1-2 pressure indicator ES1-2 expansion silencer PI1-2 pressure indicator
PT1-2 pressure transducer ES1-2 expansion silencer PT1-2 pressure transducer C1 water cooled heat exchanger PT1-2 pressure transducer
DT1 dewpoint transducer

OMEGA AIR
more than air
31
 Drying
- Adsorption dryers
- Membrane dryers A-DRY A-DRY TAC A-DRY BM X-DRY COM-DRY
- Hybrid dryers Heatless regeneration adsorption
compressed air dryers
Adsorption compressed air dryers with
activated carbon tower
Heatless regeneration adsorption
compressed air dryers
Heatless regeneration modular adsorption
compressed air dryers
Refrigerant + adsorption compressed
air dryers

- Adsorbers

Types

Oper. pressure 4 to 16 bar Oper. pressure 4 to 16 bar Oper. pressure 4 to 16 bar Oper. pressure 4 to 16 bar Oper. pressure 4 to 11 bar
Capacity 6 - 200 Nm3/h Capacity 6 - 117 Nm3/h Capacity 6 - 200 Nm3/h Capacity 300 - 1.050 Nm3/h Capacity 1200 - 6.500 Nm3/h
Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C)

B-DRY B-DRY TAC B-DRY BM F-DRY R-DRY HP BP

Heatless regeneration adsorption Heatless regeneration adsorption comp. Heatless regeneration adsorption Heatless regeneration adsorption High pressure heat regen. ads. dryers -
compressed air dryers air dryers with activated carbon tower compressed air dryers compressed air dryers cooling with purge air

Oper. pressure 4 to 16 bar Oper. pressure 4 to 16 bar Oper. pressure 4 to 16 bar Oper. pressure 4 to 16 bar Oper. pressure 50 bar
Capacity 110 - 1.000 Nm3/h Capacity 1200 - 6.500 Nm3/h Capacity 110 - 1.000 Nm3/h Capacity 1200 - 6.500 Nm3/h Capacity 2.485 - 23.400 Nm3/h
Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C (-25 °C/-70 °C) Dew point -40 °C

32
 R-DRY BP R-DRY BVA R-DRY BVL R-DRY HOC F/P R-DRY HP BVA R-DRY HP BVL
Heat regeneration adsorption dryers - Heat regeneration adsorption dryers - Heat regeneration adsorption dryers - Heat regeneration adsorption dryers - High pressure heat regen. ads. dryers - High pressure heat regen. ads. dryers -
cooling with purge air cooling with ambient air cooling with closed loop heated with full/partial stream cooling with ambient air cooling with closed loop

Oper. pressure 4 to 11 bar Oper. pressure 4 to 11 bar Oper. pressure 4 to 11 bar Oper. pressure 4 to 11 bar Oper. pressure 50 bar Oper. pressure 50 bar
Capacity 390-20.200 Nm3/h Capacity 390 - 20.200 Nm3/h Capacity 390-20.200 Nm3/h Capacity 390-20.200 Nm3/h Capacity 2.485 - 23.400 Nm3/h Capacity 2.485 - 23.400 Nm3/h
Dew point -40 °C Dew point -40 °C Dew point -40 °C Dew point -40 °C Dew point -40 °C Dew point -40 °C

HP-DRY MAA-DRY COM-DRY TACm TAC TAC HP

High pressure heatless regeneration
Membrane dryers Hybrid dryers Activated carbon towers Activated carbon towers High pressure activated carbon towers
adsorption dryers

Oper. pressure 50, 100, 150, 420 bar Oper. pressure 12 bar Oper. pressure 4 - 11 bar Oper. pressure 16 bar Oper. pressure 16 bar Oper. pressure 50, 100, 250, 420 bar
Capacity 50 - 1.600 Nm3/h Capacity 3 - 180 Nm3/h Capacity 6 - 6.500 Nm3/h Capacity 6 - 200 Nm3/h Capacity 110 - 1.000 Nm3/h Capacity 50 - 1.600 Nm3/h
Dew point -40 °C Dew point +15, +3, -20, -40 °C Dew point down to -40 °C
OMEGA AIR
more than air
33
 Drying
Adsorbents
Adsorbents are widely used in the compressed air and gas industry to
remove impurities, such as moisture, oil, and particulate matter, from
compressed air and gas streams. The most commonly used adsorbents in
this industry include:

Activated Carbon: Activated carbon is commonly used in the compressed

air and gas industry to remove oil vapor and other organic compounds
from compressed air and gas streams. It is often used in conjunction with
other adsorbents, such as molecular sieves or silica gel, to achieve high
levels of purification.

Molecular Sieves: Molecular sieves are synthetic zeolites that are

highly selective in their adsorption of water vapor, as well as other
impurities, such as CO2, H2S, and mercaptans. They are commonly
used in regenerative adsorption systems, such as PSA (pressure swing
adsorption) or TSA (temperature swing adsorption) systems.

Silica Gel: Silica gel is a highly porous material that is capable of

adsorbing water vapor and other impurities from compressed air and
gas streams. It is commonly used in small-scale applications or as a
desiccant in disposable cartridges.

Activated Alumina: Activated alumina is a highly porous material that is

capable of adsorbing water vapor and other impurities from compressed
air and gas streams. It is often used in pressure swing adsorption (PSA)
dryers.

Calcium Chloride: Calcium chloride is a highly hygroscopic salt that is

capable of absorbing water vapor from the air. It is commonly used in
industrial refrigeration systems or as a desiccant in disposable cartridges.

The choice of adsorbent will depend on the specific application and the
desired level of purity. Factors such as the flow rate of the compressed
air or gas, the operating pressure, and the required level of purification
will also need to be taken into consideration when selecting an
adsorbent.

34
 SORBEO MS 3A SORBEO MS 4A SORBEO MS 10A SORBEO MS 10 O2 SORBEO AA SORBEO SGWS
Molecular sieve Molecular sieve Molecular sieve Molecular sieve Activated Alumina Water resistance silica gel

Shape granule 2,5 - 5,0 mm Shape granule 2,5 - 5,0 mm Shape granule 2,5 - 5,0 mm Shape granule 1,6 - 2,6 mm Shape granule 2,0 - 5,0 mm Shape granule 2,0 - 5,0 mm
Bulk density 0,7 kg/l Bulk density 0,7 kg/l Bulk density 0,64 kg/l Bulk density 0,68 kg/l Bulk density 0,77 kg/l Bulk density 0,7 kg/l

SORBEO SGR SORBEO AC SORBEO HC SORBEO CMS SORBEO SGC SORBEO SL

Silica gel Activated carbon Catalyst Carbon molecular sieve Silica gel Soda lime

Shape granule 2,0 - 5,0 mm Shape pellet 3,0 mm Shape pellets 3,0 mm Shape pellets 1,18 ± 0,2 mm Shape granulate 2 - 5 mm Shape Menispherical pellets
Bulk density 0,7 kg/l Bulk density 0,5 kg/l Bulk density 0,9 kg/l Bulk density 0,68 - 0,71 kg/l Bulk density 0,8 kg/l Bulk density 0,93 kg/l
OMEGA AIR
more than air
35
 Gas generators
10 2
14

Nitrogen generators 10
13

10
11

3
3

12 1 Cleaned compressed air inlet

2 Gas outlet
3 Column filled with molecular sieve
4 Siemens Interface KTP 400
10 5 Electrical cabinet
6 Pneumatic cabinet
7 Microfilter
8 Pressure regulator
9 Compressed air flow regulator
1
10 Angle seated valve with pneumatic actuator
11 Purge nozzle
12 Exhaust silencer
7 8 9 10 10 10 10
13 Prefilter
14 Gas flow regulator

GENERATORS Pressure Capacity Purity Dew point

N-GEN PSA nitrogen generators 6-10 bar 0,83 - 766,8 Nm3/h up to 99,999 % <-45°C
NM-GEN Membrane nitrogen generators 5-24 bar 0,8 - 780 Nm /h
3
up to 99,5 % <-50°C

36
 Compressed
NITROGEN
Nitrogen line
air line
Nitrogen is an inert gas that is suitable for a wide range of applications, covering
various aspects of chemical manufacturing, processing, handling, and shipping.
Nitrogen has low reactivity and it is excellent for blanketing and is often used
as purging gas. It can be used to remove contaminants from process streams
through methods such as stripping and sparging. Due to its properties it can be
MAX PRESS: 16 BAR

MAX TEMP: 65°C BAR

PROD. YEAR: 2013

MAX PRESS: 16 BAR

MAX TEMP: 65°C BAR

PROD. YEAR: 2013

N-GEN
p_8,7 bar
t_64°C
used for protection of valuable products against harmful contaminants. It also
R M
M enables safe storage, usage of flammable compounds and can help prevent
combustible dust explosions.
MAX PRESS: 16 BAR

MAX TEMP: 65 °C BAR

PROD. YEAR: 2013

Generating nitrogen gas

Compressor Regrigeration Activated Pressure Nitrogen generator N2 receiver N2 high pressure N2 high pressure
dryer carbon tower vessel compressor receiver Industrial nitrogen gas can be produced by either separation of gaseous air
using adsorption (PSA) or fractional distillation of liquefied air using cryogenic
methods.

Pressure swing adsorption

The first step in the PSA process is compressed air passing through a
combination of filters and an activated carbon tower with the purpose of
N-GEN NM-GEN removing dust, entrained oil and water. The purified air is then directed to one
of two adsorption vessels that are packed with carbon molecular sieves (CMS).
PSA Nitrogen generators Membrane Nitrogen generators The remaining impurities such as carbon dioxide and residual moisture are
adsorbed by the CMS at the entrance of the adsorbent bed.

When the CMS is at high pressure, it selectively adsorbs oxygen, allowing

nitrogen to pass through it at the desired purity level. While one vessel is
at high pressure to produce nitrogen, the second vessel is depressurized to
remove the adsorbed oxygen, which is then vented to the atmosphere. The
automatic switching between adsorption and desorption between the two beds
enables the continuous production of nitrogen. By adjusting the size of the air
compressor and adsorption vessels containing the CMS, a large range of flow
and purity combinations can be met. PSAs can economically produce nitrogen
gas at flowrates from less than one cubic meter per hour to greater than a few
Oper. pressure 6 - 10 bar Oper. pressure 5 - 24 bar thousand cubic meter per hour at purities ranging from 96% to 99.999%.
Capacity 0,83 - 766,8 Nm3/h Capacity 0,8 - 780 Nm3/h
Dew point <-45 °C Dew point <-50 °C
Nitrogen purity up to 99,999 % Nitrogen purity up to 99,5 %
OMEGA AIR
more than air
37
 Gas generators
13

Oxygen generators 10
2

10 12

10

8
8
3

3
1 Cleaned compressed air inlet
11 2 Oxygen outlet
3 Column filled with molecular sieve
4 Siemens Interface KTP 400
5 Electrical cabinet
10 6 Pneumatic cabinet
7 Microfilter
8
8 Nozzle
10
9 Pressure regulator
1 10 Angle seated valve with pneumatic actuator
11 Exhaust silencer
7 12 Dust filter
13 Oxygen flow regulator
9 8 8 10 10 10

GENERATORS Pressure Capacity Purity Dew point

O-GEN PSA oxygen generators 5-6 bar 1,02 - 94,9 Nm /h
3
up to 95 % <-60°C

38
 Compressed
Oxygen line
air line

OXYGEN
MAX PRESS: 16 BAR
Oxygen, is present in the air with concentration around 21%. Oxygen is at atmospheric
conditions always present in gas phase with no odour, colour or taste. It is a highly
MAX TEMP: 65°C BAR

PROD. YEAR: 2013

MAX PRESS: 16 BAR

MAX TEMP: 65°C BAR

PROD. YEAR: 2013

O-GEN
p_8,7 bar
t_64°C

reactive substance, reacting with almost all elements, except inert gases. This is why
R M
MAX PRESS:

MAX TEMP:

PROD. YEAR:
16 BAR

65 °C BAR

2013
M it is used in a variety of applications: aquaculture, feed gas for ozone generators,
glass blowing, leaching, NOx reduction for fuel burners, oxygen lancing, welding and
health care.

Compressor Regrigeration Activated Pressure Oxygen generator O2 receiver O2 high pressure O2 high pressure
Generating Oxygen gas
dryer carbon tower vessel compressor receiver
Oxygen gas can be produced by either separation of gaseous air using adsorption
(PSA) or fractional distillation of liquefied air using cryogenic methods.

Pressure swing adsorption

The first step in the PSA process is compressed air passing through a combination
of dryers, filters and an activated carbon tower with the purpose of removing dust,
entrained oil and water. The purified air is then directed to one of two adsorption
O-GEN vessels that are packed with 5% of activated alumina (AA) and 95% of molecular
PSA Oxygen generators sieves (MS). The remaining impurities such as carbon dioxide and residual moisture
are adsorbed by the activated alumina (AA) at the entrance of the adsorbent bed.
When the MS is at high pressure, it selectively adsorbs nitrogen, allowing oxygen
to pass through it at the desired purity level. While one vessel is at high pressure
to produce oxygen, the second vessel is depressurized to remove the adsorbed
nitrogen, which is then vented to the atmosphere.

The automatic switching between adsorption and desorption between the two
beds enables the continuous production of oxygen. By adjusting the size of the air
compressor and adsorption vessels containing the MS, a large range of flow and
purity combinations can be met. PSAs can economically produce oxygen gas at flow
rates from less than one cubic meter per hour to greater than a few hundred cubic
Oper. pressure 5 - 6 bar meter per hour at purities ranging from 90% to 95%.
Capacity 1,02 - 94,9 Nm3/h
Dew point <-60 °C
Oyxgen purity up to 95 %
OMEGA AIR
more than air
39
 Gas dryers
CO2 dryers Under normal conditions, carbon dioxide (CO2) is a
colourless and odourless gas, with a slightly sour taste,
denser than air and non-flammable. It is present in the
atmosphere in a concentration of about 400 ppm.
CO2 is not toxic in small quantity but higher concentration
are dangerous for health due to the reduction of oxygen
rate.
Thanks to its relative neutrality and abundance, this gas
is used in numerous applications such as Food & Beverage
(breweries), Welding, Cooling, Packaging and many
others.
But because it usually needs to be compressed and
liquefied to be stored, we have to treat it first, and
specially dry it.

Heat Regenerated Dryers

Carbon Dioxide is a gas which can be highly corrosive,
- Compact units – perfect for
depending on its level of humidity.
container-sized applications CO2-DRY
Compressed Carbon Dioxide Dryers (CO2 Dryers) are
- Food Grade available on request Carbon dioxide dryers
therefore normally custom made, to meet specific project
- Adapted for 100 % water saturated gas
requirements.
- Covers all pressures, for all applications
Several versions are available, based on operating pressure,
- Higher flows on request
temperature, requested pressure dew point and level
- Design adaptable to each application/
of humidity. Depending on this last criteria, the dryer’s
project
materials will need to be modified.

The type of regeneration is, by default, conducted with

heat provided by an external heater (heating phase), and
blown ambient air cooled by water (cooling phase).
But depending on the existence and the type of the
available fluids to conduct the heating/cooling, we can
adapt the regeneration and the components of the CO2 Oper. pressure 4 - 40 bar
Dryer, to ensure that a strict minimum of gas will be lost Capacity 100 to 12. 550 Nm3/h
during the whole process. Dew point -25 °C to -70 °C

40
The example of CCU from beverage fermentation
Once the fermentation is complete, the CO2 produced is usually recover and add value to this gas by reusing it or selling
released into the atmosphere, which represents a risk for it locally. Last but not least, Carbon Capture systems can
human health (many accidents to be deplored each year) and also be transposed to other applications, whether you
for the environment (CO2 being a greenhouse gas). Instead, could still apply the Direct Capture or you would need to
Omega Air proposes to purify and liquefy this CO2, as the below install a separation unit before the purification process.
simulation shows, in order for the owner of the installation to

GAS HOLDER PROCESS COOLING SYSTEM

FERMENTATION TANK (Chiller)
(Beverage)

DRYER CHILLER
CO2 COMPRESSOR

STORAGE
VESSELS

CAPTURE PURIFICATION LIQUEFACTION STORAGE

Alcoholic fermentation is a biological process Used to create the best conditions (pressure, cleanliness Liquid CO2 is safer and CO2 can be used on-site or sent
in which sugars are converted into energy in and dew point) to enable later Liquefaction. easier to handle as elsewhere for further usage.
the form of adenosine triphosphate (ATP), compressed under high
producing ethanol and carbon dioxide (CO2) pressure.
as metabolic waste products. The CO2 is
gathered in a soft CO2 buffer.

OMEGA AIR
more than air
41
 Gas dryers
CNG dryers Process gas drying is a critical operation in many industries, Benefits of Process Gas Drying
including petrochemical, natural gas, and chemical manufacturing.
He dryers The process involves removing moisture from gases used in Corrosion Prevention
Moisture in process gases can cause corrosion in pipelines and
manufacturing, processing, and transportation to prevent
corrosion, maintain product quality, and ensure safe operations. equipment, leading to costly repairs and downtime. Process gas
This article explores the different types of process gas drying drying helps prevent corrosion and maintain equipment integrity.
methods used in industry, their applications, and the benefits they
offer.
Product Quality
Moisture in process gases can also affect product quality. Process
Types of Process Gas Drying Methods gas drying helps maintain product quality by ensuring that
the process gases used in manufacturing are dry and free of
Adsorption contaminants.
Adsorption is a commonly used process gas drying method that
involves passing the gas through a bed of desiccant material. The
desiccant material, which can be silica gel, activated alumina, Safe Operations
or molecular sieves, adsorbs the moisture in the gas, leaving it Moisture in process gases can create safety hazards, such as
dry. The desiccant material can be regenerated by heating it to a explosions and fires. Process gas drying helps ensure safe
high temperature, which releases the moisture it has adsorbed. operations by removing moisture from process gases and reducing
Adsorption is a highly efficient process gas drying method that can the risk of accidents.
achieve very low dew points.

Refrigeration Process gas drying is a critical operation in many industries,

Refrigeration is another common process gas drying method including petrochemical, natural gas, and chemical manufacturing.
that uses a refrigeration unit to cool the gas below its dew point, The process involves removing moisture from gases used in
causing the moisture in the gas to condense and form liquid manufacturing, processing, and transportation to prevent
droplets. The liquid droplets are then removed from the gas using corrosion, maintain product quality, and ensure safe operations.
a separator. Refrigeration is a highly effective process gas drying There are several types of process gas drying methods available,
method that can achieve very low dew points. including adsorption, refrigeration, and membrane separation.
Each method offers its unique benefits and is suitable for different
Membrane Separation applications. By choosing the right process gas drying method,
Membrane separation is a process gas drying method that uses a industries can achieve cost savings, improved product quality, and
semi-permeable membrane to remove moisture from the gas. The safer operations.
membrane allows the water molecules in the gas to pass through
while preventing other gases from passing through. Membrane
separation is a highly efficient process gas drying method that can
achieve very low dew points.

42
 CNG-DRY
Compressed natural gas dryers (CNG dryers) are designed for continuous
Compressed natural gas dryers separation of water vapour from compressed natural gas thus lowering the dew
point.

CNG-DRY dryers are normally custom made to meet specific project requirements.
Several versions are available based on operating pressure and type of
regeneration.
G-DRY type of the dryers are manual controlled and without regeneration.
After the saturation of the dryer it is possible to replace adsorption material or
regenerate it with external regeneration system.
CNG-R-DRY has two columns that operate alternately. Adsorption takes place
under pressure in the first column while the second column is heat regenerated.
CNG-HP-DRY has also two columns that operate alternately. Regeneration is
Oper. pressure 0,1 - 420 bar made by small portion of already dried CNG at the ambient pressure. Purge CNG is
Capacity on request let to the suction side of the compressor.
Dew point -40 °C

He-DRY
Since Helium is an inert gas that has many similarities with air, it can therefore be
Helium dryers used with our standard products to purify and dry it.
Since many industries can benefit from its unique properties to optimize their
performance and productivity, to reduce labor costs and to make their operations
safer, it is very important to determine in advance the technology which will best fit
your Helium application.

He-A-B-F-DRY are different series of Low Pressure Heatless Regenerated

Adsorption He Dryers
He-HP-DRY is a series of High Pressure Heatless Regenerated Adsorption He Dryers
He-R-DRY is a series of Low Pressure Heat Regenerated Adsorption He Dryers
He-HPR-DRY is a series of High Pressure Heat Regenerated Adsorption He Dryers

Oper. pressure 5 - 420 bar

Capacity on request
Dew point -25 °C to -70 °C
OMEGA AIR
more than air
43
 Gas purifiers Characteristics Applications
The dihydrogen H2 molecule, made up of two hydrogen atoms, is The earliest known important chemical property of hydrogen is that it
commonly called “hydrogen” and was discovered in 1766 by the British burns with oxygen to form water (H2O), it was therefore made famous
Hydrogen purifiers physicist Cavendish. Under normal conditions of temperature and
pressure, hydrogen is a colorless and odorless gas but also the lightest
for its usage in the process of nuclear fusion. But it is now even more
famous for its extremely low density, allowing it to be an energy vector
element of the periodic table. It is soluble in water up to 1.6 mg/L at to answer the problematic of electricity storage. Therefore Hydrogen
21 °C. is today widely considered as one of the key features that will play a
major role in the world’s energy transition.
It is the simplest member of the family of chemical elements and
the most abundant one in the universe (main element of the Sun Hydrogen can be used for a variety of Industrial, Residential and
and stars). However, it is rarely found alone on and in the Earth, and Mobility applications:
is very often an integral part of various organic materials and, more - Chemical industry | Production of ammonia and other fertilizers
importantly, water (H20). (50% of global consumption)
- Petrochemical industry | Sulfur removal | Creation of gasoline and
Depending on its temperature and pressure, it can be found in different diesel (hydrocracking) | Methanol production (synthesis of amines
states: gaseous, liquid, solid, metallic and triatomic. Here, we will only and alkanes by hydrogenation)
concentrate on hydrogen in its gaseous state. - Food industry | Production of margarine and butter (fat
hydrogenation)
- Welding | Atomic Hydrogen Welding (also called Plasma)
- Glass production | As antioxidant or shielding gas when coupled
with nitrogen
- Electronics manufacturing | Production of semiconductors, LEDs,
displays, etc
- Aerospace | Rocket’s engines (liquid form)
- Housing | Lighting, Heating
- Hydrogen Refueling Stations (HRS) for ‘’Green Mobility’’ | Fuel Cells
Electric Vehicles, FCEVs

H2 Pure Units – Specifications

H2 Pure Units are designed for continuous separation of water vapour, oxygen and solid particles
from hydrogen gas, making them eligible to all applications possible, including Fuel Cells (ISO
14687:2019). The unit is designed for fully automatic operation.

A proven and robust design enables efficient and reliable operation, fast installation and simple
maintenance. The Purification Unit is suitable for easy integration in electrolyser hydrogen
package. Version “P” consumes up to 2 % of hydrogen for regeneration while version “X” performs
regeneration in closed loop meaning zero hydrogen is wasted during regeneration. Both versions are
available with optional deoxo unit which reduces oxygen content down to <5 ppm.

44
 HYDROGENE SUPPLY
POWER SOURCE
PURIFICATION MODULE IN ELECTROLYSIS PLANT (To fuel cell or other consumer)
(Electricity)
The basis of every electrolysis plant is to have the COOLING SYSTEM HIGH PRESSURE COMPRESSION
insurance to receive constant power source (e.g.
renewable for green hydrogen) and water supply. (Chiller) (Booster compressor & Cylinders)

PEM STACK
It then goes into PEM stack where,
when it reacts with water, hydrogen and
oxygen will be produced.
DEOXO
(Oxygen removal)
DRYER
FILTRATION

H2 Pure
Hydrogen purifiers PURIFICATION UNIT
The mix of gas will enter our PURIFICATION UNIT, composed of filtration, DEOXO and HIGH PRESSURE STORAGE
dryer units. Thanks to this stage, the exiting gas will be free of any excess of solid (Cylinders)
particles, oxygen and humidity.
CENTRAL CONTROLLER
This whole system needs to be closely LOW PRESSURE STORAGE
monitored thanks to a CENTRAL Purification unit main features (Metal hydride)
CONTROLLER and cooled via a COOLING All-in-one unit, built on the most compact SKID.
SYSTEM. - Performances according to ISO 14687:2019 for Fuel Cells
Hydrogen needs to be stored at different
< 5 ppm of O2 residual content
pressures depending on the point of use
< 5 ppm of H2O residual content
application: low pressure storage or high
DC POWER SUPPLY < 1 um solid particles
pressure storage (where a high pressure
The supplied electricity being usually AC, it - ZERO LOSS of HYDROGEN during the regeneration
compressor is needed upstream).
Oper. pressure 5 - 45 bar needs to go first through a DC power supply
before being further processed.
Capacity on request
Dew point -25 °C to -70 °C
OMEGA AIR
more than air
45
 Industrial water
chillers
Cooling types
Basics Cooling in general
- Direct cooling of a product
Industrial as well as commercial sector comprise many applications where
- Injection moulding of plastic
cooling is required. Based on end application we differentiate:
- Metal casting
- Metal machinning
- PROCESS COOLING when accurate and constant temperature within a
process is required.
Applications
- COMFORT COOLING when accurate and constant temperature inside
- Cooling of a process buildings is required.
- Fermentation of beer
- Fermentation of wine Process cooling can further be described as removal of unwanted heat
- Chemical reactions from a process. Quite often cooling liquid (e.g. water) is used for this
- Machine cooling purpose.
- Hydraulic circuit cooling
- Gearbox cooling Industrial water chillers are devices that remove heat from a process or
- Welding equipment using water as the cooling medium. They are commonly used
- Laser cutting in industrial applications, such as cooling machines and equipment, in
- Metal treatment owens- manufacturing plants, and in the production of food and beverages.

The basic operation of an industrial water chiller involves the circulation of

water through a heat exchanger that removes the heat generated by the
process or equipment. The heat is then transferred to a refrigerant, which
is compressed and condensed, releasing the heat to the surrounding
environment.
The refrigerant is then expanded, which causes it to cool, and the process
is repeated.

There are several types of industrial water chillers available, including air-
cooled, water-cooled, and evaporative cooled chillers. The choice of chiller
depends on various factors, such as the cooling capacity required, the
ambient temperature, the availability of water, and the cost of electricity.

Industrial water chillers are an essential component in many industrial

processes, as they help to maintain a consistent temperature and prevent
equipment from overheating, which can result in costly downtime and
repairs.

46
Process water circuit
Hot water from the process enters water tank where it is being
cooled by the refrigerant circuit. Integrated water pump assures
recirculation of the water.

Based on tank type we differentiate two versions:

- Closed type (pressurised system)
- Open type

OPEN TYPE WATER TANK

PROCESS
CHILLER

Hot water
from process
Hot water
to chiller
Heat
exchanger
Cold water
from chiller
Cold water
to process
CLOSED TYPE WATER TANK

PROCESS
CHILLER

Hot water
from process
Hot water
to chiller
Heat
exchanger
Cold water
from chiller
Cold water
to process

OMEGA AIR
more than air
47
 Industrial water
chillers
Types

Refrigeration circut
Circulation of the refrigerant gas in the circuit is provided by highly
efficient hermetically sealed compressor (6). Compressor rises the
pressure of the gas which is then cooled down and liquified in the
condenser (6). Electric fan on the condenser can be controlled by
temperature or pressure sensor. Liquid refrigerant then flows through
capillary tube or thermostatic expansion valve (9) which acts as a
metering device to reduce the pressure of the refrigerant. Reduction of
the pressure is a design function to achieve target temperature inside
the evaporator (lower pressure = lower temperature). Filter (8) which is
installed upstream the metering device intercepts impurities and assures
reliable operation of the system. Liquid refrigerant is then guided through
water tank where it is being evaporated by hy temperature of the process
water (water gets cooled down). Low pressure refrigerant in gas form then
re-enters the compressor.

PCI chillers operate based on “non-cycling” operating principle which

means that when the chiller is without load “hot gas by-pass valve”
(7) will release part of the hot refrigerant gas (from discharge side of
the compressor) back to the suction side of the compressor. As a result
evaporation pressure/temperature will be constant at the factory pre-set
value. As an alternative the chiller can also be operated in ON/OFF
operating mode.

In case of high discharge temperature controller stops the compressor

before permanent damage occurs. Depending on size of the chiller
additional safety/protection devices (e.g. low pressure switch, high
pressure switch) are installed in on the refrigerant gas circuit.

48
 5

1 Hot process water inlet

TS 2 Chilled process water outlet
01
3 Chilled water buffer
P< 4 Heat exchanger module
01
P>
5 Compressor
01 4 6 Condenser
7
PV 7 Hot gas by-pass valve
01 8 Gas filter
9 Expansion valve or capillary tube
T
01 10 Circulation pump
6

3 1
8 9
2

10

PCI
Industrial process chillers

Cooling power: up to 150 kW

Ambient temp.: up to +45°C
Water outlet: down to 5°C (-5°C glycol)
OMEGA AIR
more than air
49
 Compressed air receiver Air receiver equipment Manufacture
Pressure vessels A compressed air receiver is an essential part of every
compressed air system. Air receivers are tanks used for
Air could be dangerous in compressed stage because of
accumulated energy. Therefore compressed air receivers
There is extreme danger in the use of air receivers of
unsound or questionable construction. In the interest of
compressed air storage and are recommended to be in all must be equipped with a pressure safety valve, this is a safety, it is essential that the air receivers are manufactured
compressed air systems. But they are not just vessels, they device, which releases the compressed air from the receiver strictly in accordance with a reputable engineering standard
Basics serve several important purposes: into the environment in case of excessive pressure. When or code.
the set pressure is exceeded, the pressure safety valve
- Eliminate pulsations from the discharge line. becomes the “path of least resistance” as the valve is All welds should be carried out by welders who have been
- Decrease wear and tear on the compression module, forced open and a portion of the fluid is diverted through tested to the relevant National Code. All the materials
control system and motor by reducing excessive the auxiliary route. The pressure safety valve is designed or used in the manufacture of the receivers must comply
compressor cycling. set to open at a predetermined pressure setting to protect with the requirements of the relevant design code, and be
- Help reduce dew point and temperature spikes that follow pressure vessels and other equipment from being subjected identifiable with mill sheets.
regeneration. to pressures that exceed their design limits. All safety valves
- Separate moisture oil and solid particles provide extra should be tested frequently and at regular intervals to
storage for compensating surges in compressed air usage. determine whether they are in good operating condition. No Design
- Reduce energy costs associated with excessive starting of valve of any type should be placed between the air receiver
the compressor motor. and its safety valve or valves. There are many engineering standards which give
information on the design, construction and fittings of
Air receivers have a drain valve to eliminate accumulated an air receiver. Pressure vessels are loaded with internal
moisture. A drain pipe and valve should be installed at the pressure, for this reason, their operation is potentially
lowest point of every air receiver to provide for the removal hazardous. Their manufacture, testing, installation and
of accumulated oil and water. Adequate automatic traps operation must be carried out in accordance with the
may be installed in addition to drain valves. The drain European Pressure Equipment Directive (PED) or other
valve on the air receiver must be opened and the receiver standards (ASME, DNV...).
completely drained frequently and at such intervals as to
prevent the accumulation of excessive amounts of liquid in The content of the directive is changing, therefore it is
the receiver. necessary to continuously follow to possible variations.
Documentation of the pressure vessel should be carefully
They also have pressure gauges (installed in visible kept. Pressure vessels must always bear a data plate with
locations), handholes or manholes, and a base for vertical the content required by the Pressure Equipment Directive.
air receivers. Standard receivers are designed for horizontal
or vertical mounting.

50
Installation Safety requirements
There is always a question of where to install the air receiver Air in compressed stage could be dangerous because of
in the compressed air system. This decision depends on accumulated energy. Therefore, it is necessary to strictly
what function it is meant to perform. It can serve for several observe the safety criteria for safe operation of the system.
different purposes:
Safety measures include the following equipment and
- Dampening of compressor pulsation precautions:
- Air flow buffering - A pressure vessel must be equipped with a suitable
- Air cooling spring-loaded safety valve, which prevents exceeding it’s
- Collection and draining of oil and water maximum allowable operating pressure.
- Storage of wet air before a dryer - Suitable pressure gauge must be fitted to the pressure
- Storage of dry air after a dryer vessel to indicate current pressure.
- Suitable condensate drain device must be fitted to the
Air receiver must be protected against external damage, lowest bottom connection of the pressure vessel.
for example, against falling objects. It must be installed - It must be provided with suitable manhole, handhole
in such manner, that access to all receiver components is or other means to allow the interior to be thoroughly
easy, undisturbed and safe. The pressure vessel must be inspected and cleaned.
positioned securely and reliably, and should not be moved - It must be clearly marked with the maximum permissible
or tilted. Observe the additional load due to the pressure of working pressure and temperature.
the air inside. Integrated data plate must be easily visible. - Suitable shut-off valves with appropriate pressure
The pressure vessel must be protected against corrosion level should be fitted on upstream and downstream
and harmful atmospheric conditions. connections to isolate the pressure vessel from the other
system.

OMEGA AIR
more than air
51
 Pressure vessels MATERIALS DESIGN LIMITS
Carbon steel Volume 0,1 to 75 m3
Stainless steel Length 10 m
Types Diameter 3m
Mass 12 T (22 T)
Shell thickness 30 mm

DESIGN CODES / CERTIFICATES

STANDARD
• Directive 2014/68/EU PED Pressure Equipment

OPTION
• ASME “U” Designator (The American Society of Mechanical Engineers (section VIII div. 1)
• ASME “UM”
• CRN Canadian Registration Number
• EAC - REGULATIONS Customs Union “On the safety equipment of high pressure” (TR TC 032/2013)
• EAC - REGULATIONS Customs Union “On the safety on machines and equipment” (TR CU 010/2011)
• DGM / DPP Algeria (ex ARH)
• UKR Ukraine
• JBA Japan boiler Association approval
• AS 1210 Australian Standard
• MOM Singapore
• NR13 Brazil
• Serbia AAA
• ABS American Bureauof Shipping
• DNV

PRESSURE VESSELS Pressure

PV PED Pressure vessels according to PED certification 11 bar
HPV PED High pressure vessels according to PED certification 16, 21, 32, 42, 48 bar
CUSTOM MADE PV Pressure vessels according to customer specification on request

52
 Compressed air receiver is an essential part of every compressed air system. It acts as a buffer and a storage
medium between the compressor and the consumption system.

Air receivers are much more than just buffers. Their purpose is also:
- reducing excessive compressor cycling,
- eliminating pulsations from discharge line,
- collecting condensate and water in the air after the compressor,
- reducing energy costs by minimizing excessive starting of the compressor motor,
- help reducing dew point and temperature spikes...

Omega Air d.o.o is also a producer of custom made pressure vessels according to PED, ASME and other
standards. Each of our pressure vessels is calculated, assembled, tested and guaranteed to conform
standards and to withstand the process necessary for your application.

Custom made pressure vessels can include a diverse range of:

- sizes and volumes,
- horizontal or vertical designs,
- modular or packaged systems,
- special alloys and materials,
- high or low pressure ratings,
- heating and cooling options,
- accessory valves and piping,
- ladders and platforms,
- anticorrosion protection...

PV PED HPV PED CUSTOM PV

Pressure vessels High pressure vessels Pressure vessels
according to PED certification according to PED certification according to customer specifications

Oper. pressure 11 bar Oper. pressure 11, 21, 32, 48 bar Oper. pressure on request
OMEGA AIR
more than air
53
 Measuring Measuring compressed air properties and characteristics is important for several
reasons:

equipment Compressed air is one of the most common Efficiency

Measuring compressed air properties such as pressure, flow rate, and temperature
but also one of the most expensive energy
sources in industry. Quality and energy can help ensure that the system is running at peak efficiency. This can help reduce
efficient air compressors are definitely energy costs and increase productivity.
Basics the most important components of every
compressed air system, but without Safety
appropriate air treatment and measuring Compressed air systems can be dangerous if not properly maintained and
equipment it is not possible to provide monitored. Measuring properties such as moisture content and oil content can help
quality and low cost compressed air. identify potential safety hazards and prevent accidents.
Stable product quality, process optimization
and energy savings are just some of Quality control
the reasons why measuring equipment Measuring compressed air properties can help ensure that the air is clean and
is becoming essential part of today’s dry, which is important for applications such as food and beverage production,
compressed air/gas systems. pharmaceutical manufacturing, and electronics manufacturing.

Maintenance
Measuring properties such as air quality and pressure can help identify potential
issues before they become major problems, allowing for timely maintenance and
repair.

Compliance
Certain industries, such as food and beverage and pharmaceuticals, have strict
regulations regarding air quality. Measuring compressed air properties can help
ensure that the air meets these regulatory requirements.

Cost savings
Measuring compressed air properties can help identify leaks and inefficiencies in
the system. By addressing these issues, energy costs can be reduced and overall
system efficiency can be improved.

Equipment protection
Measuring properties such as humidity and dew point can help prevent damage to
equipment from moisture and corrosion.

Process control
Measuring compressed air properties can help ensure that the air is suitable for
specific applications, such as controlling the consistency of paint or coatings.

Overall, measuring compressed air properties and characteristics is important for

a variety of reasons, including efficiency, safety, quality control, maintenance,
compliance, cost savings, equipment protection, and process control.

54
DISPLAY / DATA LOGGER PRESSURE SENSOR DEW POINT SENSOR FLOW / CONSUMPTION SENSOR RESIDUAL OIL SENSOR LASER PARTICLE COUNTER
Measuring means knowing the actual Operating pressure is one of the In order to provide stable product Flow measurement is essential part Oil presence in compressed air Dust and particle elimination
performance of your system and our most important parameters of any quality, contaminants including water of every compressed air/gas system. has negative effect on most air through increasingly fine levels of
display units/data loggers provide compressed air/gas system. Precise must be removed or reduced to the By knowing the exact air production treatment applications (PSA systems, filtration is common throughout the
a user friendly and cost effective measurement of pressure is vital acceptable level based on specific or consumption rate, we can optimize membranes, …) as well as on end compressor plant. But even then
solution for monitoring of different for most stages of air treatment application requirements. complete system, assure stable quality product/process quality and safety. further contamination throughout
operating parameters (pressure, flow, (e.g. filters, dryers, …) as well as for Humidity (water vapour content) is and also reduce energy losses. Flow Therefore it is essential that oil content the distribution system can occur,
dew point, …). applications at consumption side (e.g. expressed in the terms of Pressure monitoring of existing system also does not exceed permissible value. which makes point of use filtration
Number and type of input signals, as machines, end-users, …). Dew Point (PDP) where dew point is gives us valuable information in case Proper air treatment equipment and measurement essential for
well as analytics capability depend on Indirect pressure sensors can also give the temperature at which air is 100 % we are dimensioning a new system or reduces oil content but only the use maintaining compliance with plant or
the version of display/data logger unit us information about energy losses saturated with moisture. considering an upgrade to the system. of a proper residual oil sensor and international standards.
used. through pressure drop. Dew point sensor gives us reliable sufficient monitoring assures that Monitoring the particle sizes and
information about actual PDP of air quality meets requirements of concentration is a key indicator of the
compressed air and makes it possible specific application. Sensor with PID system’s efficiency that can be used to
to react quick in case PDP is out of (photoionization detector) offers an guide maintenance tasks, as well as
limit. easy to use, affordable and reliable contribute to plant compliance with
solution. the purity classes set in ISO 8573-1.

OMEGA AIR
more than air
55
 Measuring
equipment
Types

MEASURING EQUIPMENT
OS 331 Display and Data logger
OS 401 Thermal mass flow sensor
OS 421 Thermal mass flow sensor
OS 415 Thermal mass flow sensor
OS 430 Pitot tube flow sensor
OS 211, OS 215, OS 220 Dew point sensors
OS 305 Dew point monitor
OS 520 Portable dew point sensor
OS 16, OS 40 Pressure sensors
OS 531 Portable ultrasonic leak detector
OS 120 Residual oil sensor
OS 130, OS 132 Laser particle counter
OS 600 set Portable compressed air purity analyser
OS 601 Portable compressed air purity analyser
OS 551-P4 set Portable data logger, flow, dew point, pressure sensors
OS 551-P6 set Portable data logger, flow, dew point, pressure sensors

56
OS 331 OS 401 OS 421 OS 415 OS 430 OS 211, OS 215, OS 220
Display and Data logger Thermal mass flow sensor Thermal mass flow sensor Thermal mass flow sensor Pitot tube flow sensor Dew point sensors

OS 305 OS 520 OS 16, OS 40 OS 531 OS 120 OS 130, OS 132

Dew point monitor Portable dew point sensor Pressure sensor Portable ultrasonic leak detector Residual oil sensor Laser particle counter

OS 600 set OS 601 OS 551-P4 set OS 551-P6 set

Portable data logger, flow, dew point, Portable data logger, flow, dew point,
Portable compressed air purity analyser Portable compressed air purity analyser
pressure sensors pressure sensors

OMEGA AIR
more than air
57
 Compressed air
additional program
Compressed air is a versatile form of energy that can be Painting Air Filters
used for a wide variety of applications, from powering When compressed air is used for painting or other finishing

Products tools and machinery to providing clean breathing air in

hazardous environments. To maximize the benefits of
applications, it is important to remove any impurities
that could mar the surface finish. Painting air filters
compressed air, additional equipment can be added to the remove moisture, oil, and other contaminants from the
system to enhance performance, efficiency, and safety. compressed air, ensuring a clean and smooth finish.

Heat Regeneration Units Compressors for Petrol Stations

Compressed air systems generate a lot of heat during Compressed air is also used in petrol stations to power
operation, which can be wasteful and expensive. Heat air compressors for filling tires and other automotive
regeneration units can help recover some of that energy components. These compressors need to be robust and
by transferring the heat from the compressed air to water reliable, with the ability to deliver compressed air at high
or other fluids. This can be used to preheat water for pressure quickly and efficiently.
industrial processes or for space heating, which can result
in significant energy savings. In conclusion, compressed air systems can benefit from
a range of additional equipment that can improve
Breathing Air Equipment performance, efficiency, and safety. Heat regeneration
Compressed air is often used to provide clean breathing air units, breathing air equipment, painting air filters,
in hazardous environments, such as in mining, firefighting, compressors for petrol stations, air dryers, air filters,
and industrial settings. Breathing air equipment, such as and air receivers are just some of the options available
air compressors and filters, are used to ensure that the air to optimize compressed air systems. By investing in the
is free of contaminants, such as dust, oil, and moisture. right equipment, users can maximize the benefits of
This is crucial for the safety and health of workers who compressed air and ensure a safe and reliable system for
need to breathe in such environments. years to come.

COMPRESSED AIR EQUIPMENT Pressure Capacity

PP Painting air filtration systems 16 bar 78 - 120 Nm3/h

B-AIR Breathing air filtration systems 16 bar 78 - 780 Nm3/h
B-AIR plus Portable breathing air filtration system 16 bar 120 Nm3/h
AIRWATT Heat recovery units 16 bar
BS 12-3,5 Petrol station equipment 12 bar 350 Nl/h
AWS Petrol station equipment 10 bar 170 Nl/h
PETRO-PACK Petrol station equipment 12 bar 350 Nl/h
BS TOWER Petrol station equipment 12 bar

58
 PP B-AIR B-AIR plus AIRWATT BS 12-3,5
Painting air filtration systems Breathing air filtration systems Portable breathing air filtration systems Heat recovery units Petrol station equipment

Oper. pressure 16 bar Oper. pressure 16 bar Oper. pressure 16 bar Oper. pressure 16 bar Oper. pressure 12 bar

AWS PETRO-PACK BS TOWER ES FA

Petrol station equipment Petrol station equipment Petrol station equipment Exhaust silencers Flange adapter

Oper. pressure 10 bar Oper. pressure 12 bar Oper. pressure 12 bar Oper. pressure 16 bar Oper. pressure 16 bar, 63 bar
OMEGA AIR
more than air
59
 Industrial We have the knowledge and the
engineering solution
We guarantee you reliable problem management
and finding simple but effective solutions for your
We know how and we can produce
From design to system. With our rich knowledge and experience in the
domestic and global markets, we have improved the
We are convinced that it is best if we face the problems
ourselves. Therefore, almost all production processes
the end product energy of a huge number of systems, built energetically
and economically efficient solutions, and helped
for system components are carried out in our factories,
and most of the components are also the result of our
eliminate many technical problems. Proof of this is our knowledge and development and are created in our
loyal and satisfied customers. production. We are experts with globally recognized
quality.

Your needs - our challenge

We like challenges that encourage us to find innovative solutions. Surely
there is an expert among us who knows the answer to even such a difficult
technical question. Over 30 of our development engineers and technicians
from various branches of industry will look for solutions to reduce your
costs and make the system economically efficient.
There are no obstacles! We have helped many, so can you.

60
 Maintenance - our responsibility
In order for your system to be ready for reliable operation, the
system will be commissioned by our engineers, who will also provide
Transportation is taken care of a warranty for the installed components. Our service will ensure
good maintenance and operation of your system for many years
Transporting the delivered system to the place of after installation. To make your work easier, you can also opt for
installation is the concern of our logistics department. contractual maintenance.

Assembly as it should be
The entire supplied system will be installed by
experienced specialists for the implementation of
hardware installations. For works that we cannot
carry out ourselves, we cooperate with verified
quality subcontractors.
Worrying about the quality of installation is
completely unnecessary.

OMEGA AIR
more than air
61
 Filtration
Aftercooler

SKID and
BOX UNITS SKID units
Controller

Skid based compressed air/gas supply system is a compact N2 pressure

All our knowledge unit intended to generate and supply compressed air, nitrogen
or oxygen according to specific project requirements. Robust
vessel

integrated in one product frame is optimised for safe and fast movement. Skids are
available in variety of configurations based on capacity, type
Electrical cabinet

and quality of air/gas.

Refrigeration
dryer

Compressor

N2 SKID units - components

Professional selection
Correct sizing Controller

Profesional installation Modularity Electrical cabinet

Small size CONTAINERS Saving time and money

AND
Compactness Saving space N2 generator
SKIDS Compressor

Flexibility Outdoor installation (BOX)

System tested before dispatching
Plug and play units Compressed air
pressure vessel

62
 CONTAINER units
Container units are used for outdoor installation. Such
systems are completely independent and protected from N2 BOX units - components
the weather conditions, and are characterized by high
mobility, as they can be easily moved to a new location. LED LIGHTING
COMPRESSED AIR RECEIVER
FRONT DOORS
WITH FULL OPENING COMPRESSED AIR FILTERS ACTIVATED CARBON TOWER
INSULATION (optional) PSA NITROGEN GENERATOR
SIDE DOORS NITROGEN RECEIVER
ROOM VENTILATION
MAIN ELECTRIC BOX

TRANSPORT HINGES

CENTRAL CONTROL UNIT

(optional)

WATER/OIL SEPARATOR

FORKLIFT OPENINGS

REFRIGERATION COMPRESSED AIR DRYER

SCREW COMPRESSOR
AUTOMATIC ROOM HEATER (optional)
STEEL BASE CONSTRUCTION CONDENSATE SEPARATOR
METAL FLOOR

OMEGA AIR
more than air
63
 SKID and
BOX UNITS STANDARD UNITS Air station Class
SOLID PARTICLES
Maximum number of particles per cubic meter as a
function of particle size, d(2)
0,1μm < d ≤ 0,5μm 0,5μm < d ≤ 1,0μm 1,0μm < d ≤ 5,0μm
Our industrial engineering division is able to integrate Air+ is the label for our high-quality compressed air units
Types
As specified by the equipment user or supplier and more stringent than
0
standard or custom made products into a skid/ in accordance with ISO 8573-1. These units represent class 1
container based package according to specific project complete air treatment for your system and can be 1 ≤ 20.000 ≤ 400 ≤ 10
requirements. SKID and BOX units can be designed integrated into a compact unit with constant and stable 2 ≤ 400.000 ≤ 6.000 ≤ 100
according to variety of design codes (PED, ASME, DNV, outlet parameters, that ensure reliable production of 3 Not specified ≤ 90.000 ≤ 1.000
ABS, NR13, AS1210 …). compressed air for your process. 4 Not specified Not specified ≤ 10.000
5 Not specified Not specified ≤ 100.000
All we need is the following information from you: Air+ units basically contain the following components: 6
- type of gas - compressor(s)
HUMIDITY AND LIQUID WATER OIL
- flow range - compressed air filtration
Concentration of total oil(2)
- pressure range - moisture separation Class Pressure dew point
(liquid, aerosol and vapour)
- temperature range - compressed air drying
°C °F mg/m3 ppm/w/w
- min. solids content - water/oil separation...
0
- min. moisture content
1 ≤ -70 -94 ≤ 0,01 ≤ 0,008
- min. oil content Compressed air at the outlet of the unit reaches and
maintains the parameters, required by the customer 2 ≤ -40 -40 ≤ 0,1 ≤ 0,08
Based on this, our engineers will determine the when ordering. 3 ≤ -20 -4 ≤1 ≤ 0,8
components of the system and combine them into a The unit is compact and mobile and contains everything 4 ≤ +3 38 ≤5 ≤4
unique unit with reliable supply of constant output gas for the normal operation of your process. 5 ≤ +7 45 Not specified Not specified
parameters for your production process. The system can be integrated into a SKID or BOX unit. 6 ≤ ±10 50
To qualify for a class designation, each size range and particle number within a
(1)

class shall be met. (2) At reference conditions: air temperature of 20° C, absolute
air pressure of 100 kPa (1 bar), 0 relative water vapour pressure.

64
 Oxygen station Nitrogen station

O2SKID or O2BOX are oxygen production systems. They Field of use Purity of the oxygen N2SKID or N2BOX are nitrogen production systems. They Field of use Purity of the N2
are basically the Air+ compressed air preparation unit are basically the Air+ compressed air preparation unit
Metal production, Food processing: 99,0 % to 99,9 %
with built-in oxygen production components. welding, cutting
95 % with built-in nitrogen production components. - Wine blanketing
- Beer dispense
Glass production 95 % - Oil sparging
O2 unit consists of: N2 unit consists of:
Fish farms 90 % to 95 % - Fruit storage
Air+ components: Air+ components:
Healthcare, veterinary medicine 95 % Fire prevention 95 %
- compressor(s) - compressor(s)
- compressed air filtration
Ozone generators 90 % to 95 % - compressed air filtration Explosion prevention 98% to 95 %

- moisture separation Waste water treatment plants 90 % to 95 % - moisture separation Chemical blanketing 99 % to 95 %
- compressed air drying - compressed air drying Pressure testing 95 %
- water/oil separation... - water/oil separation...
Injection molding 99 % to 99,5 %
+ +
N2 production components: Electronic soldering 99,95 % to 99,995 %
O2 production components:
- activated carbon tower - activated carbon tower Laser cutting 99,95 % to 99,995 %

- oxygen PSA generator - nitrogen PSA generator Pharmaceutical 99,95 to 99,999 %

Oxygen station can produce oxygen at various ranges of Nitrogen station can produce nitrogen at various range
purities. Normally, the purity of oxygen produced by PSA of purities. Normal nitrogen purity for food processing is
is from 90% to 95%. in the range from 99% to 99,5%. Lower purity nitrogen
in the range from 96% to 99% is often used in fire
and explosion prevention. High purity with nitrogen
content from 99,9 % to 99,999 % is typically used for
laser cutting, electronics soldering and pharmaceutical
applications.

OMEGA AIR
more than air
65
 Projects Industrial project engineering is a specialized field that
involves designing, developing, and implementing complex
Industrial project engineering is a critical component
of modern manufacturing and production processes.
Engineering
The engineering phase involves developing detailed
systems and custom-made solutions for various industries. The success of a project depends on the ability of the designs, drawings, and specifications for the system. This
These solutions are tailored to meet the specific needs of engineering team to design, develop, and implement a phase also includes selecting the appropriate materials,
each client and can range from large-scale industrial plants system that meets the client's requirements, while also equipment, and technologies needed to implement the
to smaller, more focused systems. In this article, we will complying with safety and regulatory standards. project.
explore the importance of industrial project engineering
and the key components of a successful project. A well-executed industrial project can result in increased Fabrication and Assembly
efficiency, productivity, and profitability for the client. It The fabrication and assembly phase involves the
can also improve the quality of the end product, reduce construction and assembly of the system. This phase
waste, and minimize environmental impact. A successful includes procuring the necessary materials and equipment,
project can also enhance the reputation of the client, as as well as managing the construction process to ensure
well as the engineering team responsible for the project. that the project is completed on time and within budget.

Testing and Commissioning

Key Components of a Successful Industrial Project
The testing and commissioning phase involves testing the
Design and Planning: The design and planning phase is
system to ensure that it operates as intended. This phase
critical to the success of an industrial project. It involves
includes conducting performance tests, troubleshooting
gathering information about the client's requirements,
any issues, and ensuring that the system meets all safety
analyzing data, and developing a comprehensive plan that
and regulatory requirements.
outlines the scope, timeline, and budget of the project.
This phase also involves identifying potential risks and
Maintenance and Support
developing strategies to mitigate them.
The maintenance and support phase involves providing
ongoing support to the client to ensure that the system
operates at peak performance. This includes providing
training to personnel, conducting regular maintenance, and
troubleshooting any issues that arise.

SPECIAL PROJECTS
Compressed air stations Custom made compressed air stations
Special designed SKID units Custom made SKID units
Special designed BOX units Custom made BOX units
CCS Carbon capture systems

66
COMPRESSED AIR STATIONS SKID UNITS
Custom made compressed air stations Custom made SKID units

BOX UNITS CCS

Custom made BOX units Carbon capture systems

OMEGA AIR
more than air
67
 The AirSys is selection software designed by Omega

AirSys Air.

It is being developed for fast and user friendly

selection of Omega Air products.

Product selection software The AirSys software provides suggestions for

components which enables the user to select the
best suited component based on several deciding
parameters such as operating pressure, operating
temperature, flow capacities...

With AirSys you can easily select proper filters, filter

elements, drains, dryers etc.

68
OMEGA AIR
more than air
69
 Alternative
filter elements ABAC (new)
plastic end caps
BEA ARS
aluminium end caps
ABAC (old) BEA ARV
plastic end caps aluminium end caps
AGRE (new) BEA BST
plastic end caps aluminium end caps
AGRE (old) BEKO
plastic end caps plastic end caps
BOGE HP
AIRFILTER ENGINEERING D plastic end caps
plastic end caps
AIRFILTER ENGINEERING BOGE
plastic end caps
plastic end caps
AIRFILTER ENGINEERING CECCATO (new)
plastic end caps
aluminium end caps
ALMIG CECCATO (old)
plastic end caps
plastic end caps
ALUP (new) CHICHAGO PNEUMATIC (new)
plastic end caps
plastic end caps
ALUP (previous) CHICHAGO PNEUMATIC (old)
plastic end caps
plastic end caps
ALUP (old) COMPAIR
plastic end caps
plastic end caps
ATLAS COPCO + COMPAIR (previous)
plastic end caps
plastic end caps
ATLAS COPCO COMPAIR (previous)
aluminium end caps
plastic end caps
ATLAS COPCO DELTECH 300
plastic end caps
aluminium end caps
ATLAS COPCO (old) DELTECH
aluminium end caps
plastic end caps
ATLAS COPCO (old) DOMNICK HUNTER OIL-X EVOLUTION
plastic end caps
aluminium end caps
IUTA DOMNICK HUNTER OIL-X PLUS
ATS plastic end caps
plastic end caps
Filter elements are designed to meet the
requirements of standard ISO8573-1. Validation BALMA DOMNICK HUNTER OIL-X PLUS
aluminium end caps
and testing is done in an independent instutute plastic end caps
IUTA in Germany.

70
 ALTERNATIVE FILTER ELEMENTS ALTERNATIVE FILTER HOUSINGS
DONALDSON
DOMNICK HUNTER HT FUSHENG (old) MARK (new) SMC DOMNICK HUNTER
aluminium end caps plastic end caps plastic end caps plastic end caps
DOMNICK HUNTER NH3 FUSHENG (old) MARK (old) SMC
aluminium end caps aluminium end caps plastic end caps aluminium end caps ALTERNATIVE FILTER HOUSINGS
DONALDSON DF HANKISON NGF MATTEI OMAT SPX NGF JORC
plastic end caps plastic end caps plastic end caps plastic end caps (Boge)
DONALDSON 90' series HANKISON MAUGUIERE (new) SULLAIR BEKO
plastic end caps plastic end caps plastic end caps plastic end caps (Atlas Copco, Kaeser, Ecoair, Schneider, Quincy)
DONALDSON 90' series HANKISON MAUGUIERE (old) WALKER OWA ALFA WORTMANN
aluminium end caps aluminium end caps plastic end caps plastic end caps (Zander, Kaeser, Hankinson, Schneider, Motivair)
DONALDSON 80' series HIROSS (new) MIKROPOR G WALKER OWA 20HP & 50HP DOMNICK HUNTER
aluminium end caps plastic end caps aluminium end caps aluminium end caps (Airtek, Hiross, Zander, Hiross, Compair, Ingersoll Rand)
Alt. silicone and grease free filt. elem. HIROSS (new) MIKROPOR GO WALKER DONALDSON
aluminium end caps aluminium end caps aluminium end caps (Almig, Gardner Denver, Quincy, Aircel, Kaeser, Finite, Boge, Ultrafilter)
DONALDSON
silicone and grease free plastic end cap HIROSS (old) OMI ALPS WALKER HP KAESER
plastic end caps plastic end caps aluminium end caps
DONALDSON
silicone and grease free aluminium end cap HIROSS (old) OMI (old) WORTHINGTON CREYSSENSAC (new) ATLAS COPCO
aluminium end caps plastic end caps plastic end caps (Alup, Abac)
Alt. sterile/vent filter elements
HITACHI ORION (new) WORTHINGTON CREYSSENSAC (old) OMI
DONALDSON aluminium end caps plastic end caps plastic end caps (Devair)
stainless steel end caps 1.4301 (304)
Alternative process filter elements INGERSOLL RAND ORION (new) ZANDER GL
plastic end caps aluminium end caps plastic end caps
DONALDSON INGERSOLL RAND F PNEUMATECH (new) ZANDER ALTERNATIVE DESSICANT
stainless steel end caps 1.4301 (304) plastic end caps plastic end caps plastic end caps DRYERS CARTRIDGES
EKOMAK INGERSOLL RAND FA PNEUMATECH (old) ZANDER
plastic end caps plastic end caps plastic end caps DONALDSON
aluminium end caps
EKOMAK Ultrapac 2000
KAESER (old) PREVOST MICRO Alternative sterile/vent filter elements
aluminium end caps aluminium end caps plastic end caps
FIAC ZANDER
plastic end caps
KAESER HP PREVOST
aluminium end caps
stainless steel end caps 1.4301 (304) ALTERNATIVE DRYER SERVICE KIT
aluminium end caps
Alternative process filter elements
FINITE J KNOCKS PUSKA (new) HANKISON
aluminium end caps aluminium end caps plastic end caps ZANDER
stainless steel end caps 1.4301 (304)
FINITE (old) KOBELCO PUSKA (old)
aluminium end caps plastic end caps plastic end caps ZONDER
plastic end caps
FUSHENG (new) KSI SCHNEIDER
plastic end caps plastic end caps plastic end caps ...and many more...

OMEGA AIR
more than air
71
 OMEGA AIR
more than air

OMEGA AIR d.o.o. Ljubljana 950502 - 04/2023

Cesta Dolomitskega odreda 10
SI-1000 Ljubljana, Slovenia
00 386 1 200 68 00
[email protected]
www.omega-air.si