Aquila RE160 UNI User guide

ORIGINAL
Instruction manual for
Recovery unit RE160 UNI
By Aquila Triventek
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. [phone] · [e-mail] · www.aquila-triventek.com
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Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Table of contents
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 (CO
2
) 4
2.2 Safety data for Recovery unit RE160 UNI 6
3 EQUIPMENT FOR OPERATION 7
3.1 Delivery 7
3.2 Delivered equipment 7
3.2.1 Identification of main components in Recovery unit RE160 UNI 8
3.3 Connection of the equipment 13
3.3.1 Power supply 13
3.3.2 Connecting the hoses 13
4 OPERATING LIMITATIONS 14
5 OPERATING THE EQUIPMENT 14
5.1 Operation panel 15
5.2 Pressure gauge panel 16
5.2.1 Normal gauge readings during operations 16
5.2.2 Liquid CO
2
detector and reservoir 16
5.2.3 Automation 17
5.2.4 Power supply and control protection system 17
5.2.5 Pressure protection system 17
5.2.6 Main menu structure 18
5.3 Starting up the RE160 19
5.3.1 Stopping the RE160 20
6 ALARM MESSAGES 21
- Emergency stop 21
- Phase sequence protection 21
- CO
2
compressor protection 21
- CO
2
fan protection 22
- Too much oil in filter 22
- Low oil level 22
- High temperature 1st stage 23
- High temperature 2nd stage 23
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Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Table of contents
6 ALARM MESSAGES
- Cooling 23
- Cooling compressor protection 23
- Cooling internal protection 24
- Cooling fan protection 24
- Cooling low pressure 24
- Cooling high pressure 25
- Cooling compressor oil diff. switch 25
7 MAINTENANCE 26
7.1 Maintenance intervals 26
7.2 Oil filter 26
7.3 Inspection and refill of CO
2
compresor oil 27
7.4 CO
2
pressure and venting 30
7.5 Maintenance and inspection of refrigeration system 31
7.5.1 Insufficient refrigiration 31
7.5.2 Refrigerant condensation high pressure 31
7.5.3 Refrigerant evaporation low pressure 32
7.5.4 Insufficient heat transmission in the CO
2
condenser 32
8 CLEANING THE EQUIPMENT 33
9 STORAGE 33
10 RECOMMENDED SPARE PARTS LIST 34
11 TROUBLESHOOTING 37
12 TECHNICAL DATA 40
12.1 Proporties of carbon dioxide 41
12.2 Electrical charge 42
13 EC DECLARATION OF CONFORMITY 57
14 GUARANTEE 58
15 DELIVERY REPORT 59
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Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Introduction
We are pleased that you have chosen the Recovery Unit RE160 UNI by Aquila Triventek A/S for your company. The re-
covery RE160 UNI is especially designed to be connected to multiple types/brands of pelletizers, and not only the Aquila
Triventek PE80 Pelletizer.
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
operators 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 CO
2
. It can exist in three states: as gas, as liquid or as a solid.
Dry ice is frozen carbon dioxide (CO
2
). 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
is stable at (minus) -79 ºC, at atmospheric pressure. It expands up to 800 times by volume when it
sublimes, and this property is exploited in the blast cleaning application.
1.2 Recovery Unit
Normal dry ice production uses liquid CO
2
which 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 RE160 UNI 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 will, as a result, reduce production costs by up
to 50%.
Safety
2.1 Safety data for carbon dioxide (CO2)
Hazards identification
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 CO
2
hose is blocked by dry ice. The pressure behind the dry ice blockage will rise due to evapo-
ration of liquid CO
2
. 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.
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Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Solid
Contact with product may cause cold burns or frostbite due to the low temperature at (minus) -
79 ºC. (-110 F).
Solid dry ice sublimates into gas. This can cause pressure to build up in e.g. a container which is not suitably vented.
First aid measures
If contact with eyes: immediately flush eyes thoroughly with water for at least 15
minutes. In case of frostbite, spray with tepid water for at least 15 minutes. Apply a sterile
dressing. Obtain medical assistance.
Inhalation of sublimated CO
2
(gas)
CO
2
is 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.
CO
2
is odourless therefore use always a CO
2
detector in working areas.
Low concentrations of CO
2
cause 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. Injured may not be aware of asphyxiation.
First aid measures
Remove Injured 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 Injured warm and rested. Call a
doctor. Apply artificial respiration if breathing has stopped.
Exposure controls / personal protection
Exposure limit: 5000ppm
The normal concentration of CO
2
in 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.
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