KAESER Adsorption dryer, heat regenerating CALOSEC

The KAESER CALOSEC dryers are equipped with a high-quality pressure dew point sensor as standard. The CALOSEC CONTROL control from KAESER continuously monitors the pressure dew point of the dried compressed air. It only ends a drying cycle when the desiccant capacity of a container is exhausted or the configurable switchover value is reached. This needs-based control not only contributes to energy savings, but also ensures gentle operation. The sensor’s measured values can be displayed graphically and can be accessed via the Ethernet interface.

Adsorption dryers naturally have temperature and dew point peaks, especially after switching the containers. However, due to the generous dimensions and the use of high-quality individual fittings, KAESER CALOSEC dryers go through a parallel phase before the complete switchover. In this phase, the compressed air is dried in both containers until the still warm container has cooled down sufficiently. During this process, the peaks in temperature and pressure dew points are reduced to a minimum using the still active container. As a result, the pressure dew point remains stable and a specified maximum pressure dew point can be safely maintained with appropriate dimensioning

The generous dimensions of the KAESER CALOSEC dryers enable a fixed cycle of a full 12 hours. Thanks to the standard pressure dew point control, the cycle time can even be extended further depending on requirements. The extended contact times between compressed air and desiccant ensure high system stability, especially under partial load and demanding operating conditions.

The premium desiccant SILICAGEL ECO is characterized by an energy saving of approximately 15% during regeneration compared to activated aluminum oxide. This saving results from a desorption temperature that is up to 20% lower. The reduced temperature level effectively helps minimize temperature and pressure dew point peaks. In addition, SILICAGEL ECO has a higher adsorption capacity, which has a positive effect on the dimensioning of desiccant quantities, cycle times and material load. Due to these outstanding properties, SILICAGEL ECO is used as standard in the premium series CSA(-V) and CSL(-V).

The high-quality individual fittings of the CALOSEC dryers are characterized by minimal pressure loss and a clear flow path compared to reusable fittings. A bypass if the end position or seal is incomplete is excluded. In addition, the housings are designed in two parts, which enables the seat ring to be replaced cost-effectively during service instead of having to replace the entire valve. Compared to reusable fittings, reliable sealing is much easier to achieve during service.

CALOSEC dryers have a separate pneumatic cabinet next to the electrical control cabinet. This ensures optimal protection for the valve island, the control air unit, the pressure transmitter and the pressure dew point sensor.

All compressed air lines of the CALOSEC dryers are provided with high-temperature galvanizing both inside and outside. This galvanizing ensures excellent corrosion protection in the damp area of the dryer. The coating process requires no oil or grease and enables a reliably adjustable layer thickness. In addition, the coating is characterized by very high abrasion resistance and offers effective protection against mechanical damage.

The inlet temperature of the compressed air is recorded as standard in all CALOSEC dryers and monitored by an adjustable limit value. With CALOSEC CONTROL it is also possible to specify the most efficient regeneration temperature based on the individual process parameters, including the inlet temperature

The CALOSEC CONTROL control with 7″ touch color display ensures a smooth process flow and also offers comprehensive system monitoring. It is equipped with a Modbus TCP (Ethernet) interface for connection to higher-level controls or for integration into the KAESER SIGMA NETWORK.

The inlet flaps K1 and K2 are equipped with end position monitoring at the factory. This proves to be extremely practical for maintenance, as the LED display (green/red) shows the position of the flaps transmitted by CALOSEC CONTROL.

By default, CALOSEC CONTROL is able to estimate the utilization of the dryer. As an optional feature, a high-quality power measuring device can be integrated into the control cabinet, which enables the measurement and display of power consumption and average energy consumption. If a volume flow measurement is connected, a specific consumption measurement is also possible.

CALOSEC Control enables the integration of the 4-20 mA signal from a volume flow sensor into the dryer’s system monitoring. The advantage is that, among other things, a configurable limit value can be set for monitoring and CALOSEC CONTROL records the specific performance data.

In the globally applicable intelligent KAESER CALOSEC CSP series, desorption takes place in countercurrent to the adsorption direction using heated ambient air, while cooling is achieved by a relaxed partial flow from the already dried compressed air flow.

In the premium KAESER CALOSEC CSA(-V) series, desorption occurs in countercurrent to the adsorption direction using heated ambient air. Cooling, on the other hand, takes place using ambient air in direct current. This process results in no loss of compressed air for regeneration, which is referred to as zero purge. The use of the zero purge process depends on the dew point of the environment and can only be used up to a maximum value. In contrast to conventional zero-purge dryers, the KAESER CALOSEC CSA(-V) series can also be used reliably in phases with higher ambient dew points when AMBIENT CONTROL is activated..

In the water-cooled KAESER CALOSEC CSL(-V) series, desorption occurs in countercurrent to the adsorption direction using heated forced air. Cooling is carried out by forced air in direct flow, using a closed cooling circuit (loop). This configuration allows a cooling phase that is independent of the ambient conditions. This enables stable pressure dew points down to -70°C. KAESER CALOSEC CSL(-V) can be used in all climate zones worldwide. No compressed air is required for the cooling phase, which is known as zero purge.