Containerised Compressed Air Systems

Installed and commissioned for a leading Scottish green energy firm, this bespoke containerised compressed air system is contributing to an impressive Bioenergy project.

The system supports an anaerobic digestion operation that processes large quantities of distillery by-products, turning them into gas.

Designed, constructed, and installed by our expert team of specialist engineers, the system comprises two 7.5kW energy-efficient KAESER SM13 rotary screw compressors, each with a capacity of 1.32 m³/min (46.4 cfm) at 7.5 bar (109 psi).

Connecting the compressors to a galvanised vertical air receiver and a high-quality air treatment package is our versatile and practical EQOfluids pipework system.

To prevent freezing of the external pipework on site in winter, the self-contained system removes moisture to a pressure dewpoint of -40°C. In addition, with up to 96% of the electrical power to the air compressors reusable as heat energy, ducted air from the SM13 compressors can be redirected into the container during periods of cold weather to reduce primary energy consumption.

Designed in accordance with the specific requirements and requests of our customer, the system is internally piped and wired and features a control cabinet with power sub-distribution, an automatic ventilation system, heating, and lighting.

Installed at one of the world’s top universities, this bespoke containerised system generates high-purity on-site nitrogen for a specialist public research process.

Our expert project team was asked to upgrade an existing containerised system that featured ageing, inefficient twin-column steel vessel nitrogen generators.

Removing all the package components, we were able to reduce costs for our customer by utilising the rotary screw compressor from the previous system.

Designed, installed, and maintained by our specialist engineers, the new system features a duplex set of the latest Peak Gas Generation i-Flow N2 Prime 7073 PSA nitrogen generators.

Providing a cost-effective on-site nitrogen solution, each unit generates 400 ltr/min of high-purity nitrogen (10 PPM / 99.999% pure) at 7.5 bar.

The unique design of the Peak N2 Prime range eliminates the requirement for a process tank with its innovative internal control system. Therefore, the discharged nitrogen exits the generator directly to the storage system at the known set-point.

A BEKO Technologies package of downstream equipment provides specialist air treatment to ISO standards for the improved system.

DRYPOINT RA refrigeration dryers and high performance CLEARPOINT filtration remove moisture, dirt, and contaminants from the compressed air supply. A CLEARPOINT V activated carbon adsorber provides the ideal solution to achieve minimum residual oil concentrations (maximum 0.003 mg/m³).

Completing the installation and neatly connecting the air treatment package components to each i-Flow N2 generator’s inlet is our versatile, practical, and corrosion-free EQOfluids aluminium pipework system.

Due to the critical purity of the nitrogen generated, stainless steel pipework connects external KAESER galvanised storage receivers to each i-Flow N2 Prime outlet.

Tailored to the individual needs of one of the leading food manufacturing companies in Europe, this fully-lined 40ft compressed air system container contributes to the sustainable production of high-quality food products.

Designed, constructed, and commissioned by our experienced project team and specialist engineers, the system comprises two 90 kW energy saving KAESER CSDX 175 SFC rotary screw compressors with variable speed drive.

Featuring Ultra Premium Efficiency IE5 electric motors with an IES2 Elite Efficiency Power Drive System (achieving the highest possible efficiency rating in accordance with the European standard IEC 61800-9), each of the innovative CSD(X) Series compressors has a capacity of 3.83 – 17.11 m³/min at 7.5 bar.

Our versatile and practical EQOfluids corrosion-free aluminium pipework system connects the compressors to a fully galvanised 1000 litre vertical air receiver, KAESER DHS65G air main charging valve, and a BEKO Technologies package of specialist air treatment and condensate management products.

Providing high-quality air to ISO standards, an EVERDRY® zero-purge heat regenerative desiccant air dryer and high-performance CLEARPOINT® filtration remove moisture, dirt and contaminants from the air supply. A CLEARPOINT® V activated carbon adsorber with additional filtration provides the ideal solution to achieve minimum residual oil concentrations (max. 0.003 mg/m³).

A KAESER SIGMA Air Manager 4.0 (SAM 4.0) advanced master controller fully controls and monitors the containerised system, allowing continuous remote monitoring by our customer and our service team.

Constructed, delivered and installed in just 8 weeks, this bespoke 40 foot containerised compressed air system was on the front line of Scotland’s response to the COVID-19 pandemic.

The complex project and contract were awarded to us by a key customer expanding their impressive Scottish manufacturing facility and production to support the COVID-19 fight, working to help roll out the Nation’s largest testing programme.

The multiple system components installed in the container include:

• Two energy efficient 55kW KAESER CSD105 SFC variable frequency rotary screw compressor packages
• Two 1000 litre fully galvanised vertical air receivers for air storage
• KAESER DHS 4.0 Series – air main charging system for pressure maintenance
• A BEKO Technologies zero-purge heat regenerative desiccant dryer system with dewpoint dependent switching
• A high temperature activated carbon adsorber
• Full condensate management system
• A KAESER SIGMA Air Manager (SAM) master control system

The bespoke system provides a reliable duty and 100% standby source of 2.32 to 10.01 m³/min of clean, high quality compressed air at 7.5 bar working pressure that is dried to a pressure dewpoint of -40°C and filtered to remove contaminants to achieve the air quality ISO8573.1:2010 Class 1.2.1 as a minimum.

In addition to the containerised air system, our engineers planned and installed over 700m of EQOfluids aluminium tube and stainless-steel pipework. The high-level pipework distribution system efficiently distributes quality compressed air from the container to multiple points of use in the clean rooms, packaging areas and throughout the vast manufacturing facility.

With a compressed air system upgrade required for expanding production and insufficient space in the existing plant room, this containerised package provided an ideal turnkey solution.

A world leader in specialist chemical production, our customers’ unique manufacturing process requires a dependable source of clean compressed air to supply pharmaceutical and food grade chemical products of the highest quality.

Featuring duty and standby KAESER rotary screw compressors, a SIGMA Air Manager (SAM) master controller, BEKO DRYPOINT RA refrigerant dryer with CLEARPOINT compressed air filtration, and a condensate management system, the fully insulated self-contained system was delivered ready-to-run.

Once lifted, and positioned on site, the electrical and compressed air lines were connected and the bespoke system was ready for immediate operation.

Designed to provide excellent accessibility to all maintenance and service-relevant components for our skilled engineers, we can minimise our on-site service time and reduce the maintenance costs for our customer.