BEKOKAT The catalytic converter for efficient and reliable oil free air
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- Elwin Murphy
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1 Compressed air in its safest form BEKOKAT The catalytic converter for efficient and reliable oil free air
2 Why reliable oil free compressed air? Pharmaceutical industry Food industry Packaging industry, PET Coating, surface treatment Chemical industry Medical and laboratory
3 Oil free air without treatment? Class 1 residual oil content Oil content after BEKOKAT Often hydrocarbon content of ambient suction air already is above class 1, ISO Oil free compressed air is not possible any more Safety of production and quality can only be assured by treatment of compressed air Data source: Rheinland-pfälzisches Landesamt für Umwelt, Wasserwirtschaft und Gewerbe
4 Certified quality of the BEKOKAT Certified oil free air acc. to class 1 ISO (and better) Residual oil content of down to mg/m³ Oil free air independent from quality of ambient air Certified by independent third party organisation by extensive testing
5 Certified quality of the BEKOKAT Certified germ free air Certified by independent and competent third party organisation Knowingly germ contaminated compressed air was sterilised to become germ free high quality air by the BEKOKAT
6 BEKOKAT: Design and components BEKOKAT CC-060 to CC-120 (incl. housing) 1: Heat exchanger 2: Vessel with catalytic material 3: Control 4: Heating 5: Safety temperature switch 6/7: Inlet / outlet valve 8: Safety valve 9: Pressure gauge
7 BEKOKAT: Design and components BEKOKAT CC-180 to CC-1200 (without housing) 1: Heat exchanger 2: Vessel with catalytic material 3: Control 4: Heating 5: Safety temperature switch 6/7: Inlet / outlet valve 8: Safety valve 9: Pressure gauge
8 Flow chart Safety and efficiency united: Reaction temperature of about 150 C to 160 C in heat exchanger: incoming air is efficiently heated by outgoing air Energy saving process: Only temperature loss of outgoing air has to be added by heater Save monitoring of process by two safety temperature switches
9 Function
10 The catalytic process 1/3 Compressed air with long chains of hydrocarbons and oxygen gets into the converter Reaction temperature of the catalytic material about 150 C Catalytic reaction of oil molecules with oxygen
11 The catalytic process 2/3 The long hydrocarbon chains are cracked in the catalytic process Oil components (carbon and hydrogen) react with oxygen in compressed air Reaction is exothermic and creates heat Reaction heat enables save monitoring against oil break through
12 The catalytic process 3/3 Oil components react to harmless CO 2 and H 2 O Long hydrocarbon chains are cracked until compressed air is oil free Therefore also condensate in following downstream treatment is oil free
13 Reaction in the BEKOKAT + Hydrocarbons C x H y Oxygen O 2
14 Technical data
15 Technical data
16 Energy efficiency of the BEKOKAT Installed power is only necessary during heating phase Average power consumption in full load is only 30% to 50% of installed power and even less when not used in full load Specific energy consumption at only kwh/m³ (CC-1200) Total efficiency of an oil injected screw compressor plus BEKOKAT is better than efficiency of an oil free screw compressor, and it offers certified oil free air BEKOKAT offers efficient oil free compressed air, independent from ambient suction conditions
17 Cost advantages of the BEKOKAT Advantages in energy consumption of a BEKOKAT solution vs. oil free screw compressor Specific energy consumption [kw/m³/min] Oil free screw Saving potential by BEKOKAT Oil lubricated screw + BEKOKAT + pressure loss Comparison of specific energy consumption including energy consumption and pressure loss of BEKOKAT Quality of compressed air from oil free screw can only be as good as intake air quality BEKOKAT offers energy efficient and reliable high quality oil free compressed air down to mg/m³ oil content, independent from intake air conditions
18 Cost advantages of the BEKOKAT Advantages in investment costs of a BEKOKAT solution vs. oil free screw compressor Investment costs [Euro] Compressor Saving potential by BEKOKAT BEKOKAT Compressor Comparison of investment costs for compressor and BEKOKAT BEKOKAT solution also has advantages in maintenance costs BEKOKAT can also be retrofitted into existing compressed air stations Oil free screw Oil lubricated screw + BEKOKAT
19 BEKOKAT advantages The BEKOKAT offers: Energy efficient oil free compressed air supply Cost effective oil free compressed air supply Advantages in energy consumption Advantages in investment costs TUV certified class 1 (and better) oil free compressed air, down to mg/m³ Safety against oil break through Oil free air independent from ambient air pollution Certified germ free air Easy to be retrofitted in existing compressor stations Flexibility in installation (centralized or point of use)
20 BEKOKAT installation examples
21 BEKOKAT installation examples With external air cooler for higher efficiency of downstream adsorption dryer
22 BEKOKAT installation examples with bypass Activated carbon tower for longer lifetime of bypass (including pre filter and after filter) Activated carbon filter for shorter lifetime of bypass (including pre filter)
23 BEKOKAT references Oil free compressed air for laboratory use in a research center (Germany) safe and reliable oil free air for a nitrogen generator (nitrogen is used as sealing air in a mass spectrometer) for removing fluids on a venturi nozzle for pneumatic pumps on a chromatograph
24 BEKOKAT references Oil free compressed air for metal surface treatment (Thailand) safe and reliable oil free compressed air with a pressure dew point of -40 C investment costs were cut in half, compared to conventional systems low operating costs
25 BEKOKAT references Oil free compressed air for the manufacturing of medical aluminum tubes (Germany) safe and reliable oil free compressed air safe and reliable germ free compressed air for medical collapsible tubes for drugs highest compressed air quality for safe manufacturing processes
26 BEKOKAT references Oil free compressed air for a brewery (Germany) safe and reliable oil free compressed air safe and reliable germ free compressed air for the brewing process highest compressed air quality for safe manufacturing processes
27 BEKOKAT
Process Technology Catalytic Converter BEKOKAT
Process Technology Catalytic Converter BEKOKAT Constant oil-free and germ-free compressed air by utilising certified catalytic converter technology: BEKOKAT Highest possible process safety Would you like
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