Air Treatment Solutions

Dryers, Filters, Drains, and Condensate Separators

kaeser.com
Air Treatment

Air quality impacts productivity

Dirt, water vapor, and other impurities enter the compressor with the atmospheric air. Oil (liquid and vapor)
may also be introduced by the compressor. If not removed, these contaminants may cause costly produc-
tion problems such as accelerated tool wear, equipment contamination and downtime, and product rejects.
KAESER offers a complete line of air treatment products to prepare compressed air for any need—from gen-
eral shop tools to CNC machining to the most sensitive applications in food, beverage, and pharmaceutical
processes.

Selecting equipment Global standards

ISO 8573.1:2010 was developed by ISO (International
Your application and the environment should guide you
Organization for Standardization) as a reference to help facility
regarding what level of air quality you need. Higher quality air
engineers specify compressed air quality for solid particulates,
may improve productivity, but it does increase costs—including
humidity, and oil.
higher equipment costs, more frequent maintenance, and higher
energy consumption due to pressure drops and purge air. For A typical pharmaceutical plant, for example, might have a
applications requiring higher air quality levels, you may reduce
compressed air specification of ISO Quality Class 1.2.1 as shown
operating costs with point-of-use air treatment rather than drying/ outlined in the specifications below.
filtering the entire system to the highest level.

SOLID PARTICLES / DUST HUMIDITY AND LIQUID WATER TOTAL OIL*

If particles greater than 5µm have been Class Pressure Dew Point Liquid, aerosol, and vapor
measured, class 0-5 cannot be applied
As specified and more stringent than Class mg/m³ ppm w/w
Maximum particle count per cubic meter 0
Class 1
Class of a particle size with d* (µm) As specified and more stringent than
1 ≤ -70°C ≤ -94°F 0
Class 1
0.1 - 0.5 µm 0.5 - 1 µm 1 - 5 µm 2 ≤ -40°C ≤ -40°F
1 ≤ 0.01 ≤ 0.008
0 As specified and more stringent than Class 1 3 ≤ -20°C ≤ -4°F
2 ≤ 0.1 ≤ 0.08
1 ≤ 20,000 ≤ 400 ≤ 10 4 ≤ 3°C ≤ 37°F
3 ≤ 1.0 ≤ 0.8
2 ≤ 400,000 ≤ 6000 ≤ 100 5 ≤ 7°C ≤ 45°F
4 ≤ 5.0 ≤4
3 --- ≤ 90,000 ≤ 1000 6 ≤ 10°C ≤ 50°F
5
4 --- --- ≤ 10,000
Class Concentration of liquid water* 6
5 --- --- ≤ 100,000
7 ≤ 0.5 g/m³ 7
6 0 - ≤ 5 mg/m³
8 0.5 - ≤ 5 g/m³ 8
7 5 - ≤ 10 mg/m³
9 5 - ≤ 10 g/m³ 9
8
X > 10 g/m³ X > 5.0 >4
9
X > 10 mg/m³

*Reference conditions: 68°F (20°C), 14.5 psia (1 bar), 0% relative humidity

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Example Air Treatment Configurations
with ISO 8573.1:2010 quality classes shown

1
KC

Condensation possible without air drying

2
Quality Class: –.8.–
Low Grade Shop Air

3
KB
2 Quality Class: 4.4-5.3
DHS
General Shop Air
Air Tools
TB19

Sand Blasting

KB KE
2
Quality Class: 1.4-5.2
Paint Spraying DHS
Powder Coating TB19

Packaging

KB KE KA
2
Quality Class: 1.4-5.1
Food and Beverage DHS
Laboratories TB19

2 KB
Quality Class: 4.2-3.3 HTA

Industrial applications DHS

unaffected by high
temperature

Heated Desiccant Dryer

KB KE KD KA
2
Quality Class: 2.2.1 or
2.1.1 DHS
Food and Beverage
High-tech Clean Rooms
Pharmaceuticals
Chemical Industries
Laboratories
Heatless Desiccant Dryer

1
For compressors without an integrated moisture separator.
2
Filters are tested to ISO 12500 and dryers tested to ISO 7183 Option A2.
3
KB not needed if non-corrosive tank and piping are used before dryer

The configurations above do not depict every possible dryer-filter combination. Your KAESER representative will
help select the appropriate air treatment products for your application.
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Filters
Proper filtration plays a vital role in providing clean
compressed air. Using advanced filter media, we
offer a wide range of filters and liquid separators
designed for higher efficiencies and lower pressure
drop. Kaeser filters are designed for long life and
easy service. Features include condensate drains,
modular mounting kits and easy-to-read differential
pressure gauges to indicate when filter elements may
need replacement.

Initial Pressure Aerosol

Remaining Aerosol
Filter Type Differential at Content at Filter Medium Application
Content at Outlet 3
Saturation Inlet 3
KC 1
(Cyclone) 1.5 psi -/- -/- -/- Bulk liquid separation
Moisture Separator
KB 2
Filters solids, liquids, aerosols,
(Basic) 2.0 psi <0.1 mg/m3
Deep pleated with support and particulates
Coalescing and Particulate
10 mg/m3 structure and polyester
KE 2
drainage fiber Same as KB, but for higher
(Extra Fine) <2.9 psi <0.01 mg/m3
compressed air quality
Extra Coalescing and Particulate
KD
<0.5 psi Deep pleated with support Exclusively for filtering
(Dust)
(new, dry) structure particulates
Particulate (Afterfilter)
-/- -/-
KA
0.5 psi Exclusively for removing oil
(Adsorb) High efficiency carbon filter
(new, dry) vapor
Vapor
1
Eco-Drain 31 is standard.
2
Float-type drain is standard. Available with optional zero-loss Eco-Drain 30 or 31 to save energy and prevent compressed air loss.
3
Per ISO 12500-1: 06-2007

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Specialty filters and point-of-use dryers
Oil Mist Eliminators (OME) High Pressure Filters (HP)
Oil Mist Eliminators (OME) are simply large oil removal filters High Pressure filters (HP) are available for applications requiring
with a very low pressure drop. Not only do they pressures up to 1000 psig. They include
remove both oil aerosols and water, but they seam welded stainless steel cores for greater
can handle large slugs of liquid. The cartridge durability and corrosion resistance. The HP
life is normally 8 to 15 years, thus requiring filters are well suited for PET bottling systems
virtually no maintenance. and should be installed downstream of high
pressure compressors or boosters and dryers.
Sizes up to 8000 scfm
They are also available in all filter grades except
HTA.

Activated Carbon Towers (KAT) Single Tower Desiccant Dryer (KDF)

KAESER Activated Carbon Towers (KAT) remove oil vapor, taste, KAESER single tower desiccant air dryers (KDF) provide dew
and odor of oil. They are used where oil vapor points as low as -40°F and are ideal for small
and odor may contaminate end products such volume air applications with intermittent needs.
as food, drugs, and chemicals. The carbon They are excellent for point of use drying where
beds are designed for a long life of up to low dew points are required. No electrical power
30,000 hours. is required and regeneration is achieved by
offline purging or desiccant replacement.
Sizes up to 5500 scfm
Sizes up to 30 scfm

High Temperature Afterfilters (HTA) Membrane Dryers (KMM)

High Temperature Afterfilters (HTA) are particulate filters designed KAESER Membrane Dryers (KMM) provide dew point suppression
for temperatures up to 450°F. They are without requiring any external power or regular
commonly placed after heated desiccant dryers maintenance. These dryers are well suited for
to take out the desiccant fines and handle the point of use applications and are easy to install,
high temperatures induced by the heaters. requiring simple piping connections. They are
lightweight and available with mounting brackets
Sizes up to 11,400 scfm
and prefilters for easy installation. Proper
filtration includes a particulate/oil removal filter
combination to prevent oil from contaminating
the membrane.

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Refrigerated Air Dryers
Refrigerated dryers serve most compressed air applications. KAESER has a very wide range of refrigerated dryers
from 10 to 3,355 scfm for a variety of applications. All KAESER dryers use environmentally friendly refrigerant.

Small Dryers Cycling Dryers

KAESER offers TX and KRYOSEC® dryers for smaller systems KAESER SECOTEC® cycling dryers offer energy savings by
or point of use applications. These non-cycling designs combine using cold storage and the SECOTEC control system. The layout
consistent dew points with simplicity and reliability. is designed for easy maintenance, accessibility, and minimal
floor space. A precooler/reheater provides increased cooling
Sizes from 10 to 159 scfm
efficiency. Their simple design and top quality construction make
them extremely reliable.

Sizes up to 3070 scfm

High Inlet Temperature Dryers High Pressure Dryers (HT)

Our HTRD’s are designed for use with piston compressors High pressure applications are also subject to the threat of
with higher operating temperatures. They combine a separate contaminants and harmful moisture. KAESER offers its HT line of
aftercooler, separator, dryer, and filter and are ideal for facilities dryers for PET bottling systems and other applications from 230-
with 5 to 30 hp piston compressors. HTRD’s are lightweight and 725 psig.
have a small footprint for convenient installation.
Sizes up to 2400 scfm
Sizes up to 145 scfm

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7
Desiccant Air Dryers
Desiccant dryers provide extremely dry air for processes that are very moisture sensitive or applications where the
compressed air system is exposed to very low ambient temperatures. Dew points may be as low as -94°F. The
desiccant material adsorbs moisture from the compressed air until it reaches its maximum saturation point and then
must be regenerated. The method of regeneration is what differentiates the lifecycle costs of desiccant dryer types.

Heatless Desiccant Dryers (DC-HF and KAD) KAESER Heated Purge Dryers (KED)
Also called “pressure swing” desiccant dryers, these dryers These dryers use only 7% of air flow for regeneration. Dried air
regenerate without added heat. At rated conditions, up to 15% of passes through a heater and then into the wet desiccant bed to
flow is used to purge moisture and regenerate the saturated tower purge the moisture. An external heater enables better temperature
(purge volume and target dew point can be adjusted with onboard control within the desiccant bed. This extends desiccant life by
controls). Heatless dryers can reach lower pressure dew points preventing hot spots that could accelerate the decay of desiccant
and are initially less expensive than heated dryers, but typically material. KED dryers are typically less costly to operate than
consume more energy due to the purge air used. heatless dryers for larger flows.

Sizes: 7 – 5400 scfm Sizes: 300 – 3200 scfm

KAESER Heated Blower Purge Dryers (KBD) Breathing Air Purifiers

Blower purge dryers further reduce purge loss using heated KAESER Breathing Air Purifiers (KBS) provide air for applications
ambient air, which lowers the relative humidity, increasing its where workers cannot safely breath ambient air. KBS purifiers
ability to hold moisture. The hot, dry ambient air regenerates the include filters to remove contaminants and oil, a desiccant air
desiccant with little or no compressed air. While the initial price is dryer to remove moisture, and catalytic materials to reduce
higher, the KBD design results in lower overall lifecycle costs for carbon monoxide concentrations to a level safe for continuous
larger flows by eliminating the energy associated with producing breathing. The KBS delivers OSHA’s Grade D breathing air.
extra compressed air for purging.
Sizes up to 940 scfm
Sizes: 500 – 4300 scfm
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Condensate Removal
Compressed air condensate is a mixture of water, compressor lubricant, particulates and ambient hydrocarbons
that have been concentrated during the compression process. KAESER’s Eco-Drain and Automatic Magnetic Drain
(AMD) are automatic demand drains that reliably remove condensate from receiver tanks, liquid separators, dryers,
filters, and drip legs. They conserve air by only activating when condensate is present. In most locales, condensate
is classified as hazardous waste and cannot be discharged into municipal wastewater systems unless the oil
and contaminants are removed. The KAESER Condensate Filters offer a low cost, convenient way to safely and
responsibly dispose of condensate.

Eco-Drain Automatic Magnetic Drain (AMD 6550)

The Eco-Drain series is ideal for filters including our liquid The AMD 6550 is a heavy-duty drain designed for very large
separators (KC), particulate filters (KB), and oil removal filters liquid loads and severe conditions. Its float and magnetic actuator
(KE). It employs a capacitance sensor for actuation and a are completely isolated from the condensate for high reliability
patented 3/2 way valve ensures that pilot air is contaminant free. and it requires no electricity.

AQUAMAT Condensate Filters KAESER Condensate Manifold (KCM)

Our AQUAMAT condensate systems effectively separate oil and The KCM is a small vessel that collects condensate from multiple
other contaminants from the water in compressor condensate. sources and safely diffuses residual air pressure to maximize
This promotes more economical and environmentally responsible separation effectiveness in the KAESER Condensate Filter (or any
disposal. oil/water separator).

Sizes up to 3300 scfm

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Aftercoolers and Separators
Atmospheric air entering a compressor contains water vapor, and when air leaves the compressor it is saturated
with water vapor and also carries condensed liquid. As the air cools in the piping and tank, more moisture
condenses. It is a best practice to install a liquid separator after the compressor’s aftercooler and before a tank,
dryer or filter.

While all major brands of rotary screw compressors have built-in aftercoolers, there are times when supplemental
cooling is recommended. If the compressors are running hot, additional cooling may be necessary in order for the
air treatment to function to specification. Further, additional cooling can increase the amount of moisture removed
from liquid separators and tanks, and it can enhance the performance of heated desiccant dryers.

KAESER liquid separators (KC) Air-Cooled (KAC) and Water-Cooled (KWC)

KAESER separators remove bulk liquid loads including water Aftercoolers
droplets and aerosols. Water is forced out of the air stream The KAC and KWC are recommended mainly for compressors
and falls to the bottom for collection. They are typically placed with discharge temperatures above 110°F. Aftercoolers provide
immediately after the compressor discharge (or supplemental an economical way to remove as much as 70% of the water
aftercoolers if used), but can be used in any number of vapor in compressed air. KAESER air-cooled models can cool
applications where large amounts of liquid must be removed. compressed air down to 5°F above the ambient temperature. If
KAESER KC liquid separators include the Eco-Drain automatic cost effective cooling water is readily available, our shell-and-tube
condensate drain. water-cooled aftercoolers can cool air within 10°F of the cooling
water temperature.
Sizes up to 11,875 scfm
Sizes: Air-cooled, up to 4800 scfm
Sizes: Water-cooled, up to 3170 scfm

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Pressure Holding Valves
Air quality protection
Compressed air dryers and filters are designed to treat specified
volumes of air at specific conditions. Refrigerated dryers, for
example, are often rated to achieve a specified dew point for a
particular volume (scfm) at 100 psig. When line pressure drops, air
velocity will increase. This negatively impacts moisture removal in
dryers and can damage filters.

If compressors are shut down overnight, weekends or holidays,

the system pressure will drop as air escapes through leaks. When
the compressors are restarted, air will flow at very high velocity
until the whole system reaches target pressure. During that time
dryers and filters may not work to specification and contaminants
may be swept downstream.

The DHS pressure holding valves prevents high velocity air flowing
through air treatment equipment while the air system is being
pressurized. The DHS also prevents possible overflow conditions
caused by leaks, artificial demand, and unregulated uses. The
DHS is also able to isolate the treatment line in the event that an
air treatment component malfunctions. This assures consistent
air quality and safeguards the pipe distribution network and
production equipment from moisture and contaminants.

Velocity Profile

Compressed air Air velocity Without a pressure holding valve, contaminants such as
supply water, oil, and particles can be swept into the system and the
air treatment components will be “overrun” by very high air
velocities during the initial pump-up of the system. Dryers and
filters might be permanently damaged.

Wit
hou
tp r e ss
ur e
hold
ing v
alve
◄ DHS controlled
TB19

velocity With pressure holding valve

Time

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The world is our home
As one of the world’s largest compressed air
systems providers and compressor manufacturers,
KAESER COMPRESSORS is represented throughout
the world by a comprehensive network of branches,
subsidiary companies and factory trained partners.

With innovative products and services, KAESER

COMPRESSORS’ experienced consultants and
engineers help customers to enhance their
competitive edge by working in close partnership
to develop progressive system concepts that
continuously push the boundaries of performance
and compressed air efficiency. Every KAESER
customer benefits from the decades of knowledge
and experience gained from hundreds of thousands
of installations worldwide and over ten thousand
formal compressed air system audits.

These advantages, coupled with KAESER’s

worldwide service organization, ensure that our
compressed air products and systems deliver
superior performance with maximum uptime.

Kaeser Compressors, Inc. Kaeser Compressors Canada Inc. Kaeser Compresores de México Kaeser Compresores de
511 Sigma Drive 3760 La Vérendrye Street S de RL de CV Guatemala y Cia. Ltda.
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Telephone: 540-898-5500 Telephone: (450) 971-1414 Parque Industrial Juríca Colonia Pomplona
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[email protected] [email protected] Telephone: 01 (442) 218 64 48 Telephone: +502 2412-6000
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