Deoiling and dehumidification of compressed air is the core link to ensure the precision of industrial production and the reliability of equipment operation, which needs to be realized by combining source control and post-processing technology. The following from the specification requirements, technical path and industry application of three aspects of the system:
specification Requirements and Technical Path of 1. Oil Removal
1. Oil content control standard
according to the ISO 8573-1 international standard, the total oil content in compressed air (the sum of liquid oil, suspended oil mist and oil vapor) needs to be strictly controlled in stages:
- semiconductor Industry: The oil content is required to be ≤ 0.001 mg/m & sup3;(ISO 8573-1 Class 0) to ensure that there is no oil contamination during the wafer manufacturing process.
- Pharmaceutical industry: It is necessary to meet the "oil-free" standard (oil content ≤ 0.01 mg/m & sup3;) to avoid oil molecules reacting with drug ingredients or breeding bacteria.
- food packaging industry according to the food and beverage processing standards, the oil content should be ≤ 0.01 mg/m & sup3;, to prevent oil pollution from affecting product hygiene.
2. Oil removal technology path
- coalescing filtration: The residual oil content can be reduced to 0.01 mg/m & sup3 by intercepting liquid oil droplets and oil aerosols through multiple layers of filter materials, but oil vapor cannot be processed.
- activated carbon adsorption: The high specific surface area of activated carbon is used to adsorb oil vapor, which is suitable for low flow scenarios, but the filter element needs to be replaced regularly, and the adsorption efficiency is affected by temperature and flow rate.
- catalytic oxidation method: The oil molecules are cracked into carbon dioxide and water through a chemical reaction, which can achieve continuous and stable oil removal, and is suitable for scenarios that require extremely high oil content (such as semiconductor manufacturing).
Specification Requirements and Technical Path of 2. Dehumidification
1. Dew point temperature control standard
according to GB/T 13277.1-2023 standard, the dew point temperature of compressed air needs to be controlled in stages:
- semiconductor Industry dew point ≤-70 ℃ (equivalent to water vapor content ≤ 2.598ppmv) is required to prevent condensation on the inner wall of the pipeline from affecting the accuracy of the equipment.
- Pharmaceutical industry dew point ≤-40 ℃ (water vapor content ≤ 127.34ppmv) is usually required to avoid microbial breeding.
- Food Industry: The dew point shall be controlled at ≤-20 ℃ (water vapor content ≤ 1024.22ppmv) to prevent the product from being affected with moisture and deterioration.
2. Dehumidification technology path
- freeze dryer: The water vapor is condensed by cooling the compressed air, which is suitable for scenarios with high dew point requirements (such as dew point ≥ 3 ℃), and has the characteristics of large flow range and continuous gas supply.
- adsorption dryer: Using activated alumina or molecular sieve to adsorb water vapor, the dew point can be reduced to below -40 ℃, which is suitable for low dew point demand scenarios.
- Combined drying system: Refrigerated and adsorption dryers are used in combination to achieve deep drying (such as dew point ≤-70 ℃) to meet the extreme requirements of semiconductor and other industries.
3. System Design and Maintenance Specification
1. Pipeline and material requirements
- the pipe material is 316L stainless steel or aluminum-magnesium alloy, and electrolytic polishing treatment is done to avoid secondary pollution caused by corrosion.
- Key nodes are equipped with redundant backup, such as dual compressors running in parallel, dual power supply, etc., to ensure continuous gas supply.
2. Monitoring and control requirements
- install online monitoring equipment (such as dew point meter, laser particle counter, oil content detector), real-time feedback of gas quality parameters.
- Quarterly third-party testing to verify compliance with ISO 8573-1 for oil content, dew point, particulate matter concentration, etc.
3. Maintenance and maintenance requirements
- regularly replace filter elements, adsorbents and catalysts to ensure filtration and drying efficiency.
- For catalytic oxidation equipment, it is necessary to regularly check the catalyst activity and reaction temperature control to avoid performance degradation.
Grankering water-lubricated single screw compressor application advantages
1. Oil-free design
using single screw and star wheel precision meshing technology, pure water instead of traditional lubricating oil, from the source to eliminate the risk of oil pollution, the output gas oil content is stable below the detection limit (≤ 0.001 mg/m & sup3;), fully meet the semiconductor, pharmaceutical and other industries of the oil-free requirements.
2. Efficient dehumidification capacity
with the adsorption dryer, the dew point can be reduced to below -70 degrees C, to meet the semiconductor industry's demanding demand for ultra-low dew point. The water lubricating medium has natural heat absorption characteristics, which can reduce the exhaust temperature and reduce the load of the after-treatment equipment.
3. Intelligent control and reliability
integrated online monitoring system, real-time feedback of oil content, dew point, pressure and other parameters, abnormal situation automatic alarm and start the standby equipment. Through frequency conversion control technology, the output pressure of the compressor can match the terminal demand in real time to avoid energy waste.
4. Low maintenance cost
there is no need for a complex oil circuit system, which greatly reduces the frequency of filter element replacement and the cost of consumables. Water lubrication medium with environmental characteristics, in line with the requirements of sustainable development.
In summary, Grantklin water-lubricated single screw compressors provide clean compressed air solutions in line with international standards for various industries through oil-free design and efficient post-processing systems. It is an ideal choice for precision manufacturing, medicine, semiconductors and other fields.
