Vacuum Transformer Oil Purifier

ZL series vacuum lubricating oil purifier is widely adopted by application fields of mechanical engineering, metallurgy, mining, petroleum, and chemical engineering to cleanse lubricating oil such as hydraulic oil, machine oil, coolant oil, refrigeration oil, gear oil, gasoline engine oil, diesel engine oil, heat treatment oil to remove the noxious substances like water content, impurities, and volatile matters (e.g. ammonia gas) effectively to improve and recover oil quality and performance, thus to guarantee the normal operation of hydraulic system, power system, and lubrication system

Key Features:

(1) Perfect capability of removing impurities, mass and deep precision purification material enabling removal of tiny and fine particles from oil liquid while equipped permanent magnet filter to remove ferruginous impurities. 

(2) Unique water and gas removal system, which adopts stereo-evaporation technology, multistage oil and water separation technology, enabling fast removal of water and gas from the oil. 

(3) Its heating system adopts most optimized pipeline design to guarantee even and stable oil heating temperature. 

(4) With automatic constant temperature control system, automatic tank level control system, automatic anti-foaming control system, automatic pressure protection system and other devices of best quality to guarantee its efficient operation. 

(5) With gradual, precise and large capacity filtering system of multistage purification stage by stage to effectively remove mechanical impurities from the oil And it has the function of automatic self-detection for its filter elements. 

(6) User-friendly design, low working noise, easy to operate, long interval of maintenance time, low energy consumption, and cost saving. 

(7) Online oil purification, unattended operation, and operation status showed by pilot lumps. 

(8) With filter replacement indicators and filter saturation stop devices. 

(9) With electric leakage and overload stop device to protect its motor. 

(10) With functions of phase sequence and open-phase protection, and sudden shut-down safety controller.

Working Principle: 

Oil to be purified passes through the first filter and the secondary filter into the heater to proceed heating. The hot oil shall be changed into coarse granule mist by a distributor and transferred into the vacuum separator, then its water content shall be evaporated. The oil mist drops on the surface of the reactor, then a three-dimensional and multi-layered evaporating structure shall be formed in the reaction tank, which can be purified by a short cycle. After dehydration and degassing, the oil is filtered through the secondary filter to complete a work cycle. The water vapor which is separated by the vacuum separator shall be vacuum pumped into the condenser, then most of it condenses into liquid water which shall be stored in the water collector and then drained out, while part of it and other gas content shall be discharged by the vacuum pump. The purifier is a single unit without any auxiliary machinery. It adopts saturation temperature curve of water and vacuum drying principle to carry out the technology of rapid and efficient oil and water separation. Multi-stage large flow capacity and deep precision filtration can reliably remove water content, impurities, gas and other harmful substances from the inferior oil thus to recover its using performance fast and efficiently and make the purified oil to meet its s using standard.

Specifications:

Model LS-ZL-100 

Flow Rate 6000 L/H 

Working Vacuum Degree -0.06~-0.098MPa 

Working Pressure ≤ 0.5MPa 

Constant Temperature Control Range 20~80℃ 

Power Supply 380V/50HZ, Three-Phase Four-Lines 

Working Noise ≤78dB 

Heating Power (KW) 70KW 

Total Power (KW) 76 KW, in line with running requirements of oil purifier and national standard. 

Inlet/Out Diameter Φ 50 mm 

Net Weight 800Kg 

Overall Dimension 1250×1450×1850 mm 

Continuous Running Period ≥ 200h 

Mean Time Between Failure ≥ 8000h

 Remark: Above-mentioned size and weight of this equipment are for reference only, the specific data shall be subject to its physical object.

Technical Features And Advantages:

(1) Heating System: 

I. Sufficient heating power, rapid electric heating to rise temperature as required. 

II. It is equipped with an automatic temperature controller, oil temperature can be adjusted between 20～80℃ automatically. The heaters can stop to operate automatically after the temperature reaches to setting point. Two operation modes can be choose, auto heating and manual heating. 

III. It is equipped with a Heating Protection System. The heating system, vacuum system and oil pump system are interlocked to avoid dry heating when there is no oil in heaters. It can ensure the heating operation safety and reliable by adopting our own patent (Patent No. ZL200620111197.7) 

IV. The heaters can be operated in group and can start automatically at low temperature while stop at high temperature. V. The heater adopts German technology, internal/external dual-bar heating system. It can warm up the air in the heaters firstly and the warmed air heat oil evenly. The heating load at surface is less than 1.1W/cm2 with rapid and evenly heating, stable temperature, no blockage oil which can ensure no hydrogen and no ethyne induced from the heating process. 

VI. The appearance of heater is flanged. Heating tube is U shape with advantages of good appearance, easy for repairing and long service life. Its cost isabout10 times of common heaters. The heating bar is installed in cylinder to heat up the oil without oil blockage to increase the oil temperature to 30℃inonecirclequickly. The gap between heater and its chamber is 10cm which will not destroy paint surface during heating operation. 

VII. Temperature Controller: intelligent digital temperature controller from Korea, PID fuzzy control, precision automatic adjustment of temperaturebetween20~80℃, high temperature alarm and pull down protection. Temperature is interval control without frequent flip of solenoid to extend its life span.

(2) Oil Pumping System: I. Adopts high quality oil pump. The oil pump can bear high pressure of high viscosity oil to adapt to high vacuum environment with excellent self sucking ability, stable flow, no peak, low noise and long life span. 

II. The high precision machining process in manufacturing guarantees no leakage in oil pump. It can pump oil normally at ultimate vacuum condition. It solves the problems of abnormal oil outlet or no oil outlet at high vacuum status unless we release the vacuum which will affect purification efficiency alot (Under same temperature, the vacuum degree determines purification effects). 

III. Oil Back-flow Prevention Device: It adopts LUSHUN’ s own technology (Patent No.: ZL200820100418.X), by this technique, oil will not flow back at machine’s halt, to guarantee oil in normal level. 

IV. Automatic Oil Level Controller: It adopts LUSHUN’ s own technology (Patent No.: ZL200820100420.7), automatically adjust inlet / outlet oil, without intervention of operators

(3) Vacuum Separation System: 

I. The vacuum separation chamber adopts vertical tank dual evaporation structure with double vacuum tank (Patent No.: ZL200820100419.4), which is composed of atomizer, evaporator, separation chamber, oil collection tank, buffer tank and observation window. 

II. The atomizer atomizes the oil and sprays it into the evaporator. 

III. Evaporator: adopts dual evaporator stereo evaporation structure (US HY-PRO vacuum) with entire stainless steel degassing and dehydration separation tower with large separation area, which makes oil in the best thin-film and realizes the best effect of evaporation. The technique can greatly increase the exposure time of oil in a vacuum chamber to ensure the best effect in just one circle of treatment. 

IV. The separation chamber: located between the evaporator and the oil collection tank. In the chamber, water and gas will be separated again from oil. 

V. The oil collection tank: for gather the oil after the separation of water and gas. Then the oil will be pumped out by oil outlet pump. 

VI. Buffer tank: an individual tank for separated gas and vapor to avoid these materials dissolve with oil again. 

VII. The observation window: adopts glass to replace organic glass to avoid deformation defects in high temperature and high vacuum condition. 

VIII. Defoaming And Anti-injection Device (Patent No.: ZL200620111199.6), adopts advanced automatic level control technology to control the volume of inlet oil by setting normal oil level range. Meanwhile, manual defoamer is adopted to control the oil foam level and timely eliminate it to avoid oil blow out phenomenon. 

IX. Vacuum tank adopts flange connection which is convenient for daily maintenance of vacuum tank (we need to clean the inner surface of vacuum tank as it will be rusted after operating for some time) so as to extend life span of the oil purifier machine and avoid secondary pollution to the oil during the process.

(4) Condensation System: 

I. Adopts heat exchange condensation Technology (Patent No.: ZL200620111198.1) 

II. Based on the optimized design of the condenser to increase the heat dissipation area in maximum and efficiently condense the water from vacuum separation system into water tank and then discharge the water. This operation can prevent large quantity of steam directly into the vacuum pump and make vacuum pump oil emulsified so as to reduce the replacement frequency of vacuum pump oil, thereby prolong the service life of vacuum pump. 

III. Through the condensation system, we can judge qualitatively whether the water has been removed from oil completely.

(5) Filtration System:

I. Equipped with overpressure protection device (Patent No.: ZL200620111200.5). Through the automatic alarm and overflow overpressure protection device, the machine can automatically shut down on the condition that the pressure of the fine filters reaches to 0.5Mpa or more. It can effectively protect the machine and filter automatically and achieve unattended operation. 

II. The machine can alarm and stop working automatically once filters over-pressured and filter element over-loaded with pollutants happens and accordingly indicate to replace filters. 

III. Prevent filters from damage for over-pressured which may increase operation to keep safety of filtration system. 

IV. Configuration of filtration system: Adopts multi-stage filtration system. Oil can be firstly filtrated by magnetic filters to remove metallic materials then pass through primary filters to remove large particles to protect oil pump from damage by the large particles. The magnetic filters and primary filters are made of stainless steel and can be cleaned and reused for long time. The fine filters adopt imported high precision filtering elements with progressive fine-meshed structure to block the impurities step by step. The filtration area of fine filters is 20 times of oil flow rate with strong pollutant-contain ability and long life span. It can effectively prolong the replacement period and lower the operation cost. The precision of fine filters can be 10µm. 

V. The structure of filtration system adopts quick-change style for convenience of filers dispatch and replacement. The threaded coupling of primary filters is equipped with special O-ring seal to ensure the precision of that. 

VI. In the oil outlet, sampling port is provided, convenient for oil sampling and test. Alarm Controller: adopts stainless steel pressure controller to ensure the control performance. Meanwhile it is equipped with shockproof pressure meter.

(6) Control System: 

I. Control system adopts Schneider Electric products with reliable quality and stable performance to ensure continuous operation of the machine. 

II. Equipped with sequential relay and phase sequence indicator to realize fault shutdown protection with light and sound alarm. 

III. With perfect protection and alarm functions, such as motor overload, over-current, lack-phase and fault-phase protection. While electrical cabinet is equipped with damping device. 

IV. Trinitarian electrical control inter-lock design. Vacuum pump, oil pump and heaters are interlocked in control. Any problems happen from the three components will cause emergency stop to avoid dry heating, oil leak and electric leakage as well as machine damage for incorrect operation. 

V. Vacuum pump is interlocked with heaters. The heaters start to work only when vacuum pump start and oil comes into the heaters. Oil pumpisalsointerlocked with heaters. When the oil pump stop, the heaters will stop working automatically. 

VI. Electrical control system is manufactured based on standard IEC60204-1: 2000/GB5226.1-2002. VII. There are intelligent digital temperature controller, oil pump operation status indicators, vacuum pump operation status indicators, heaters operation status indicators, power supply indicators, sound and light alarm and other components on the control panel

(7) Vacuum Pumping System: 
I. Vacuum Pump adopts high quality air-cooled two-stage rotary vane vacuum pump. 

II. Equipped with external circulation device for vacuum pump (Patent No:ZL200620111201.X) to increase volume of vacuum oil for circulation, reducere placement frequency and lower the operating temperature of vacuum pump oil, change vacuum pump oil automatically and prolong the life span of vacuum pump. 

III. Equipped with vacuum pump oil anti-backflow device to prevent vacuum pump oil flow back into vacuum tank to contaminate the treated oil and lower vacuum pump oil consumption so as to avoid vacuum pump damage because of lack of vacuum pump oil and reduce replacement frequency of vacuum pump oil (Patent No.: 200920294061.8). 

IV. Vacuum gauge adopts shockproof model to ensure stable performance. V. There is no oil injection phenomenon for the vacuum pump and the vacuum pump can be running without clamping stagnation for long time.

(8) Other Description 

I. Reliability of the machine: structure as simple as possible; intuitive and clear in operation; No matter in theory or in practice, the less connection interface and adopted components with the machine, the higher reliability and the less malfunction happening as well as the easier maintenance. BZL absorbs advantages in structure and appearance design of different brand such as HY-PRO, ABB, KATO and Mitsumi etc. 

II. Appearance of the machine: All the components such as vacuum separation tank, electric heaters, condenser and their brackets etc should be intact without connection loose, weld flaw, burr and rust. All the structure parts are treated with sand blast and shot blast treatment while the inner surface paintedwith1032antirust paint. The surface of the whole machine adopts plastic spray process to enhance surface strength and hardness. Meanwhile, the machine is equipped with lifting eyes for easy loading and unloading operation. 

III. The quick change coupler: Inlet and outlet connections adopt quick change couplers for reliable sealing and convenient operation. IV. Sealing: all the connection parts, adopt imported special non leakage sealing materials with strict inspection process to ensure excellent performance and no leakage.

V. Materials: The machine base adopts rectangular steel tube well welded to make it more reliable; Pipe line adopts seamless steel tube; Valves are stainless teel ball valve. Oil hoses adopt acid-proof, pressure-resistant and high temperature resistance PVC stainless steel enhanced flexible hoses. VI. The machine supports on-line operation without supervision. No easily damaged parts, so no additional expenses. VII. Whole structure of the machine: Frame style with four wheels. VIII. Customized designs and optional functions are available according to clients requirements.

Product Info Gallery:

Technological Flow Chart And Working Principle:

Figure List:

Oil Quality Index After Purification Treatment: