Aquila RE80 User guide
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
ORIGINAL
Instruction manual for
By Aquila Triventek
Recovery unit RE80
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
2
1 INTRODUCTION 4
1.1 What is dry Ice? 4
1.2 Recovery unit 4
2 SAFETY 4
2.1 Safety data for Carbon Dioxide (CO2) 4
2.2 Safety data for Recovery unit RE80 6
3 EQUIPMENT FOR OPERATION 7
3.1 Delivery 7
3.2 Delivered equipment 7
3.2.1 IdenticationofmaincomponentsinRecoveryunitRE80 8
3.3 Connection of the equipment 12
3.3.1 Power supply 12
3.3.2 Connecting the hoses 12
4 OPERATING LIMITATIONS 13
5 OPERATING THE EQUIPMENT 13
5.1 Operation panel 14
5.2 Pressure gauge panel 15
5.2.1 Normal gauge readings during operations 15
5.2.2 Liquid CO2 detector and reservoir 15
5.2.3 Automation 16
5.2.4 Power supply and control protection system 16
5.2.5 Pressure protection system 16
5.2.6 Main menu structure 17
5.3 Starting up the RE80 18
5.3.1 Stopping the RE80 19
6 ALARM MESSAGES 20
6.1 Emergency stop 20
Phase sequence protection 20
CO2 compressor protection 20
CO2 fan protection 21
Toomuchoilinlter 21
Low oil level 21
High temperature 1st stage 22
High temperature 2nd stage 22
Table of contents
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
3
6 ALARM MESSAGES 20
6.2 Cooling 22
Cooling compressor protection 22
Cooling internal protection 23
Cooling fan protection 23
Cooling low pressure 23
Cooling high pressure 24
Cooling compressor oil diff. switch 24
7 MAINTENANCE 25
7.1 Main intervals 25
7.2 Oillter 25
7.3 InspectionandrellofCO2 compresor oil 26
7.3.1 HowtorellCO2compressor oil ??
7.3.2 How to drain CO2compressor oil ??
7.4 CO2 pressure and venting 29
7.5 Maintenance and inspection of refrigeration system 30
7.5.1 Insufcientrefrigiration 30
7.5.2 Refrigerant condensation high pressure 30
7.5.3 Refrigerant evaporation low pressure 31
7.5.4 InsufcientheattransmissionintheCO2 condenser 31
7.5.5 Solution for improving heat transmission in the CO2 condenser 32
8 CLEANING THE EQUIPMENT 32
9 STORAGE 32
10 RECOMMENDED SPARE PARTS LIST 33
11 TROUBLESHOOTING 36
12 TECHNICAL DATA 39
12.1 Proporties of carbon dioxide 40
12.2 Electrical charge 41
12.3 Safetypartsidentication ??
13 EC DECLARATION OF CONFORMITY 56
14 GUARANTEE 57
15 DELIVERY REPORT 58
Table of contents
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
4
1 Introduction
We are pleased that you have chosen the Recovery Unit RE80 by Aquila Triventek A/S for your company. The recovery
RE80 is especially designed to be connected to the Aquila Triventek Dry Ice Pelletizer type PE80, and cannot be used for
other purpose.
This technology is the subject of a Patent application No. 0408224.4.
To obtain long and trouble-free operation of the equipment we recommend reading this manual carefully. All new opera-
tors of the equipment should also familiarize themselves with the content of this document.
1.1 What is Dry Ice?
Carbon dioxide is a chemical compound formed by combining one atom of carbon with two atoms of oxygen and is
expressed by the chemical symbol CO2. It can exist in three states: as gas, as liquid or as a solid.
Dry ice is frozen carbon dioxide (CO2). The unique property of carbon dioxide is that at normal, atmospheric pressure
and temperature, it changes state directly from solid to gas without going through a liquid phase.
This process, called sublimation, makes the ice ‘dry’ and is exploited both for blast cleaning and for cooling. Dry ice
isstableat(minus)-79C,atatmosphericpressure.Itexpandsupto800timesbyvolumewhenitsublimes,andthis
property is exploited in the blast cleaning application.
1.2 Recovery Unit
Normal dry ice production uses liquid CO2which when brought to normal atmospheric pressure, in e.g. a pelletizer
converts to one half snow and one half gas, called ‘revert’ gas. The snow is then compressed into dry-ice pellets.
But, by using the RE80 Recovery Unit, the revert gas, which is usually lost into atmosphere, is collected and recycled to
make more pellets. This becomes a continuous process and, as a result, will reduce production costs by up to 50%.
2 Safety
2.1 Safety data for carbon dioxide (CO2)
Hazardsidentication
Liquid carbon dioxide is stored in pressure vessels and must be handled according to the vessel manufacturers´ and the
carbon dioxide suppliers´ instructions.
1. Precautions must also be taken when mounting and dismounting the hose for liquid carbon dioxide. The liquid
may be under pressure and could spray into the surrounding area, forming dry ice and causing frostbite and eye
damage.
2. Be careful if a liquid CO2hose is blocked by dry ice. The pressure behind the dry ice blockage will rise due to evapo-
ration of liquid CO2. A powerful blast will occur when the blockage breaks. DO NOT dismount a hose if it is blocked,
or if it is suspected to be blocked by dry ice. Loosen the connection slightly so that gas can escape. Leave the hose
until the blockage is evaporated.
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
5
Solid
Contactwithproductmaycausecoldburnsorfrostbiteduetothelowtemperatureat(minus)-79C.
(-110F).
Solid dry ice sublimes into gas. This can cause pressure to build up in e.g. a container which is not suitably vented.
First aid measures
Ifcontactwitheyes:immediatelyusheyesthoroughlywithwaterforatleast15minutes.
In case of frostbite, spray with tepid water for at least 15 minutes. Apply a sterile dressing.
Obtain medical assistance.
Inhalation of sublimated CO2(gas)
CO2is heavier than air and may accumulate to hazardous levels in an unventilated enclosed area such as a small room,
tank, silo or pit. Always ensure adequate natural or mechanical ventilation or breathing apparatus in any hazardous area
such as a tank, silo or pit.
CO2is odourless therefore use always a CO2detector in working areas.
Low concentrations of CO2cause increased respiration and headache.
In high concentrations carbon dioxide gas can cause asphyxiation by displacing the oxygen required for breathing.
Symptoms may include loss of mobility or consciousness. Victim may not be aware of asphyxiation.
First aid measures
Remove victim to uncontaminated area, the rescuer should wear breathing apparatus e.g. an emergency breathing air
bottle and mask to ensure that he/she does not also fall victim to asphyxiation. Keep victim warm and rested. Call a
doctor.Applyarticialrespirationifbreathinghasstopped.
Exposure controls / personal protection
Exposure limit: 5000ppm
The normal concentration of CO2in the atmosphere is 300ppm.
Personal protection: Protect eyes, face and skin from contact with solid product. Protect skin, especially hands,
from cold by wearing insulated gloves.
Training
The hazard of asphyxiation can be overlooked and must be stressed during operator training. Before using dry ice in
any new process or experiment, a thorough material compatibility and safety study should be carried out.
Ensure all national / local regulations are observed. The European Industrial Gas Association (EIGA), see www.eiga.org/,
provides useful background material and guides to good practice.
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
6
2.2 Safety data for Recovery Unit RE80
Always use the following safety precautions:
Breathing apparatus
Wheresufcientventilation,eithernaturallyorbymechanicalmeans,can-
not be provided then a suitable supply of breathing air should be arranged.
It is also recommended that an emergency breathing air bottle and mask be
provided in the vicinity of any carbon dioxide operations. The emergency
apparatus is for use by the rescuer in case of any incapacitation of a person
in an area where carbon dioxide has accumulated and could cause asphyxia-
tion to the rescuer.
System under pressure
Become aware that some part of the system is under pressure during opera-
tion. Do not disconnect hoses when pressurized.
Inhalation of vaporized CO2
Ininsufcientlyventilatedrooms,anincreasedconcentrationofCO2might
leadtobreathingdifcultiesaswellastosuffocation.Alwaysensureasup-
ply of fresh air in enclosed rooms. A CO2detectorshouldbeusedtoconrm
safe conditions. Where necessary, use a breathing mask with suitable fresh
air supply.
As CO2gas is heavier than air, please be aware of CO2build-up in lower working areas.
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
7
3 Equipment for operation
3.1 Delivery
Transport
After the Recovery Unit RE80 has been delivered, it must be checked for damage which may have occurred during
transport. If necessary, the transport company must be informed to register the damage. Check that all parts described
on the delivery note have been delivered.
3.2 Delivered equipment
The Recovery Unit RE80 by Aquila Triventek consists of the following items:
RecoveryUnitRE80withbuildcondensingunit
OnecompleteconnectionhoseRecoveryUnitRE80andPelletizerPE80consistingof:
1x5mof25mminsulatedhoseforCO2gas
1x5mof16mminsulatedhoseforliquidCO2
1x5mof16mminsulatedhoseforpressurecompensation
1x5controlcable.Cat5patchcable
The Recovery Unit RE80 and must be handled carefully to avoid shock damage to mechanical and electrical
components.
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
8
3.2.1Identicationofmaincomponentsinrecoveryunit
2RE80008 RE80004
RE80009
RE80015
RE80012
RE80017 RE80013
1
1: First stage CO2 Compressor / FK 30/32,5K - 22400001
2: Second stage CO2 compressor / FK 20/245N - 22400002
3: Plug housing
4: Female socket
N.B.:ForreferencetotheRE-numberspleaseseePartsIdenticationforRE80
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
9
12
5
4
3
1: St.1 motor 7,5kW 50/60Hz 44010132
2: St.2 motor 4kW 50/60Hz 22103008
3: CO2 Gas cooler 36359484
4: Filterhousing -----------
5: Complete refrigiation unit condenser Bitzer 36329626
N.B.:ForreferencetotheRE-numberspleaseseePartsIdenticationforRE80
DIP - DRY ICE PRODUCTION
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · [email protected] · www.aquila-triventek.com
10
3
1
RE80009 RE80006
RE80015RE80010
1: CO2 Gas cooler 36359484
2: Solenoid valve EVR6 34439301
Solenoid coil 230V AC
3: Check valve NRV16 34739502
N.B.:ForreferencetotheRE-numberspleaseseePartsIdenticationforRE80
2
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