Production and quality engineers in industries like food and beverage, pharmaceutical, semiconductor, and the chemical sectors have established internal specifications for oilfree compressed air. The product spoilage and safety issues at risk make oilfree compressed air an absolute necessity in certain processes. Hydrocarbons are better known as oil vapors present in the compressed air system. They are introduced into compressed air systems by two sources. The most common source is the oil lubrication system of the air compressors itself. Under the high temperatures during the compression process, liquid oil is turned into a vapor. The second source is hydrocarbons that are present in the ambient air (like truck exhaust) that are ingested by the air compressor intake. How do carbon absorbers remove hydrocarbons? Unlike oil aerosols, which can be removed by coalescing filters while in their liquid state, hydrocarbons are difficult to detect and to remove from a compressed air system. Traditionally, activated carbon filters and towers (carbon absorbers) have been used to remove hydrocarbons. A simple technology, the carbon bed simply absorbs the hydrocarbons until the bed is saturated. While they do remove hydrocarbons, carbon filters and towers are dependent upon timely and frequent maintenance to maintain the necessary performance levels to continuously remove hydrocarbons. Filters, using elements that are interlaced with charcoal, typically recommend that element replacement is done every 300 hours at 86 F (30 C). A carbon tower is dramatically better with a maintenance interval of 5,000 hours at 86 F (30 C). However, this is not only costly and time consuming, but if these schedules are not adhered to diligently then very little risk is mitigated.
Are there other ways to remove hydrocarbons? The BEKOKAT system literally transforms hydrocarbons, through total oxidation, to produce carbon dioxide and water. The heart of this next generation system is a very specific type of catalytic converter, a pressurevessel filled with a catalytic granulate capable of cracking nearly every form of hydrocarbon chain. The converter is heated to an operating temperature of 302 F. Oilcontaminated compressed air flows into the pores of the catalytic granulate surface. A chemical reaction occurs and the oil molecule chains are split apart. The only remaining byproducts are water and carbon dioxide. The catalytic converter ensures and guarantees the removal of all liquid oils and gaseous hydrocarbons as well as all bacteria and viruses from the compressed air stream. In comparison to carbon absorbers, the BEKOKAT system has a recommended maintenance interval of 25,000 hours. Our criticalprocess customers value the fact that this system virtually eliminates timely maintenance as a factor to be managed in order to ensure oilfree compressed air.
Why measure hydrocarbons? Up until now, end users have not had a way of knowing what the hydrocarbon content was in their compressed air system. They had filters with alarm functions based upon time but little more. They could send samples off to laboratories and wait to see the results while production continues with unknown quality. This was also not very satisfactory, not to mention being rather expensive by comparison. This situation led BEKO Technologies to develop the METPOINT OCV hydrocarbon monitoring system. This innovative and exclusive instrument is designed specifically for compressed air systems wanting realtime measurement and monitoring of hydrocarbons in their compressed air system.
How are hydrocarbons measured? A sample is taken from the compressed air line and supplied to the measuring cell. The measuring cell consists of the reference air generator and the actual measuring cell with a photo ionization detector (PID) sensor. The reference air generator is actually a miniBEKOKAT that produces a 100% pure and oilfree gas sample. The zero reference air and the compressed air sample to be measured are supplied in turns to the measuring cell and are then compared to one another. In the measuring cell, the hydrocarbon vapor portion is measured via the PID. The resulting electrical signal is amplified and then evaluated. For those unfamiliar with PID sensors, the general operating principle works like this. Through the exposure to UV light, the gas molecules are ionized and accumulate on the electrodes. This results in a signal which is evaluated subsequent to amplification.
1. Compressor 6. CLEARPOINT Dust Filter w/ BEKOMAT 2. CLEARPOINT Water Separator 7. DRYPOINT RA Refrigerant Air Dryer 3. Receiver Tank 8. CLEARPOINT Super Fine Coalescing Filter w/ Manual Drain 4. BEKOMAT Zero Air Loss Drain 9. METPOINT OCV Measuring Cell 5. BEKOKAT Hydrocarbon Removal System 10. METPOINT OCV Display Unit