Introducing: Digital Auto Controls for the Hess Machine Ozone Generators
Due to the acquisition of Hess Machine by Ozone Solutions in 2010 we have the opportunity to offer updated technology in your current Hess Machine Ozone Generator.
Using the Q-45H dissolved ozone monitor, or another dissolved ozone monitor this control package will offer completely automated control of your ozone generator.
In the previous post about how ozone is made we covered the basics of a corona discharge ozone generator. In that post we pointed out that there are three main parts to a corona discharge ozone generator:
Power Supply – this edition
Dielectric
Corona Cell
Ozone Generator Power Supplies
In this article we will cover the differences in power supplies used for corona discharge ozone generators. Also, the different parts that are involved in the power supply itself. While some are very simple, other may be very complicated. First, we have to cover the basics of what these power supplies do.
Transformer:
Corona discharge ozone generators operate on the principle of a high voltage spark across a dielectric to form a corona. The main component to any corona discharge power supply is a transformer to increase voltage from the standard 120 or 220 VAC power used to a higher voltage ranging from 500 – 20,000 volts. This high voltage will create the spark (corona) necessary for ozone generation.
Open coil, Line Frequency, 20,000 Volt Transformers. Click on image to see ozone generators this may be used in.
The voltage used by an ozone generator is mainly dependent upon the dielectric and air gap in the corona cell. If there is a larger gap for the spark/corona to jump, a higher voltage is needed. Also, thicker and various types of dielectrics will require varying voltages. We will cover dielectric and corona cell design in future installments of How Ozone is Made.
Another factor is frequency. Higher frequency ozone generators (see below for info in frequency conversions) will typically use lower voltages as this is less stress on the frequency conversion components and smaller gap ozone generators are more conducive to higher frequencies.
Oil Filled, 10,000 Volt, Line Frequency Transformer
Line frequency ozone generators may use a basic rheostat to adjust the voltage into the transformer. This will in turn, adjust the output voltage of the transformer and adjust the rate of ozone production. In these ozone generators only a transformer and rheostat are used, no other electrical devices are necessary for ozone production.
Line Frequency Ozone Generator Rheostat. The dial turns a sweeper on the bottom that will adjust input voltage to the transformer.
Medium frequency ozone generator transformer
Some transformers may use a line choke, or a series of transformers to achieve a the voltage step-up necessary. This is an example of a larger (~450 gram/hour) ozone generator transformer assembly.
Oil filled, Medium frequency ozone generator operates at 1,000 Hz and ~600 volts
Many ozone generators used what is basically a car coil to increase voltage in an ozone generator. When ozone generator design was still new there were very few choices for transformers that could endure the abuse of 1,000 Hz, elevated voltage, and changing variables inside a corona cell. Today, transformer options are greater and the use of a basic car coil is becoming less common.
High Frequency Ozone Transformer
Most high frequency transformers are much smaller, open coil type transformers. This image is very typical for what may be used inside a higher frequency ozone generators. This same style transformer is used in some medium frequency ozone generators.
Frequency Conversion:
The spark inside an ozone generator is generated from high voltages created by the transformer, these voltages are all AC (alternating current). This means the electrical current alternates direction. This reversal of electrical current occurs at a constant speed we call frequency. This is measured with Hz (hertz). Here in the USA typical electrical power is delivered at 120 VAC 60 Hz. This means the voltage is 120 volts of alternating current, that alternates 60 times per second. In other countries power may be delivered at 220 VAC 50 Hz.
This explanation is all to understand that the spark or corona inside the ozone generator with no frequency conversion would occur 50 or 60 times every second. Many of the earlier ozone generators, and some still today operate at line frequency, an unaltered frequency. This is generally referred to as a line frequency ozone generator.
Other ozone generators use a higher frequency to increase ozone output. Higher frequencies would create more spark/corona every second. There are three main types of ozone generators:
Line Frequency – 50-60Hz
Medium Frequency – 100 – 2,000 Hz
High Frequency – 5,000 – 30,000 Hz
Medium frequency ozone generator power supply provides ~1000 Hz output
This circuit board is the driver board for a car coil type transformer as seen in the image above. This is a great example of how simple the circuitry may be in a typical medium frequency ozone generator.
High Frequency ozone generator power supply, up to 30,000 Hz output
This is the power supply for a larger (up to 450 gram/hour) high frequency ozone generator. This power supply can supply an output of up to 30,000 Hz, or as low as 1,000 Hz. As you can see this power supply is much more circuitry and components are used to achieve these higher frequencies and flexibility.
Medium frequency ozone generator power supply provides ~1,000 Hz output
This power supply is for a larger (up to 400 gram/hour) medium frequency ozone generator.
Putting it all together
There are many different types of ozone generator power supplies for many different applications. Each serves a unique purpose in the ozone generation world. Each has advantages and disadvantages.
Line Frequency Ozone Generators (50-60 Hz)
Line frequency ozone generators commonly use larger transformers and voltages from 10,000 – 20,000 volts. The only other electrical component for operation is a rheostat as pictures above. These are very simple and reliable setups that perform well for many years. Absolutely nothing beats the reliability of a line frequency ozone generator.
As the components on most line frequency ozone generators are larger to achieve the same ozone output the costs for the transformer and rheostat are higher than the costs for the smaller transformers and simple printed circuit boards used for medium frequency ozone generators. Also, line frequency ozone generators cannot achieve near the performance as the higher frequency ozone generators.
Medium Frequency Ozone Generators (100 – 2,000 Hz)
Medium frequency ozone generator transformer, with driver board.
Medium frequency ozone generators are most common today. These ozone generators may produce 1 gram/hour to thousands of pounds/day of ozone. The image above is a simple printed circuit board to increase line frequency to about 1,000 Hz, this board is attached right to the transformer that increase voltage to about 1000 volts. This is an older design with a oil filled automotive style coil. however this is a good example of the typical size of power supply for a 5 – 20 gram/hour ozone generator. There may be multiple power supplies powering multiple corona cells in one ozone generator to produce more ozone. This is a very compact, cost effective, and efficient method to produce ozone.
While medium frequency ozone generators are fairly simple there are still more components than a line frequency ozone generator. This means there are more things to fail and cause problems. Due to the elevated frequency these generators also produce more heat, both in the electronics and corona cell. Heat is the enemy of ozone.
Medium frequency ozone generators are also louder than others. While this may not be a large concern in every application, at some frequencies there is a high pitched whine that is not acceptable in some occupied spaces.
High Frequency Ozone Generators (5,000 – 30,000 Hz)
High Frequency ozone generator power supply with transformer
High frequency ozone generators offer very compact designs due to smaller transformers and corona cells. As the spark/corona is occurring up to 30,000 times per second the need for a large air gap and high voltage are alleviated. In return the electronic circuit board becomes the largest, and most expensive component of some high frequency ozone generators. This is illustrated very well in the above image. This shows 3 power supply circuit boards with the small transformer mounted right to the circuit board!
High frequency ozone generators may be very energy efficient and compact in size allowing for a very flexible platform to either use multiple cells for redundancy or other configuration changes. Many high frequency ozone generators are very cost effective as the large parts that carry a higher price (transformer and corona cell) are smaller, while the circuit board and electronics are more elaborate.
High frequency ozone generators contain many components that may fail. They also produce a great deal of heat due to the high frequency. However, with the very high frequency there is no audible sound from the ozone generators, they are the most silent of all types. Many manufacturers have just begun implementing more high frequency components in the last 5 years. Expect big changes in the future in this area of ozone generation.
This covers the basics of ozone generator power supplies. I promise the following editions of How Ozone is Made will be shorter and less technical.
The next edition of How Ozone Is Made will cover Corona Cell design in Corona Discharge Ozone Generators.
If you have any questions about ozone generators, or what may be best for you, call our application engineers today! We are glad to answer questions, dispel myths, and be a general information source for your ozone related questions.
About a week ago we posted about how ozone is made. That original post gave the fundamentals of how ozone is produced in nature and the basics of how ozone is produced within ozone generators, both UV ozone generators and corona discharge ozone generators. It was pointed out then that most (almost every) industrial ozone generator uses corona discharge to produce ozone. This 2nd installment is dedicated to informing you the reader about ozone generation from corona discharge.
The fundamentals are simple. A spark (corona discharge) is used to split the diatomic oxygen molecule into valant oxygen atoms. These oxygen atoms have a negative charge and will bond quickly with another oxygen molecule to produce ozone! For each split oxygen molecule 2 ozone molecules are produced.
Ozone Generation from Corona Discharge
A power supply is used to produce an electrical discharge across a dielectric, and an air gap. The dielectric is used to diffuse the discharge across a large area as opposed to single point like a normal spark. The oxygen molecules passing through the air gap are exposed to the electrical discharge and are split into ozone (at least that is the hope). A great deal of heat is generated from this process and is removed from the electrodes as shown.
Corona Discharge Tube
This image shows a more complete picture of a very typical ozone generation corona cell. The dielectric is a tube allowing the air gap to flow around the outside of the dielectric, with the electrode around the outside. This allows heat to be dissipated to the outside of the electrode efficiently.
This video shows a great example of ozone production from corona discharge.
There are three main factors when generating ozone from corona discharge:
Power supply
Operating voltage
Operating frequency
Dielectric
Glass
Ceramic
Mica
Quartz
Corona Cell
Tube – cylindrical style
Flat plate
When generating ozone from corona discharge there are a few factors that will affect performance that must be evaluated.
Cooling of the corona cell
Water cooled
Air cooled
Feed gas
Oxygen
Dry Air
I will try to cover some of these fundamentals and why one may be better than another for your specific application in future installments of “how ozone is made“
Why buy new, when used will do? Here at Ozone Solutions we maintain a full line of used ozone equipment on our Ozone Classifieds page. Recently we received a few new items that are in great shape and common sellers.
We had a customer with 2 OZV-8S Ozone Generators and 2 V-20 Air Dryers with only a few months of use that decided to upgrade to different equipment. These pieces are in great shape, look almost like new, and are listed well below list price. Together these components will generate 4 g/hr of ozone from dry air. This is a great combination to be used with an existing ozone injection system, or a new project. These components would work great with an ozone injection system like the OSW-10.
New price for the V-20 Air Dryer is $1295. We are selling these used air dryers at a price of $550 each.
For more used ozone equipment, including used ozone generators, used oxygen concentrators, and used ozone monitors, see our entire classified site HERE.
Ozone is produced naturally through sparks and UV-Light, ozone is also produced commercially for many uses. This will outline a few methods ozone is produced.
Ozone is Produced Naturally from Lightening During Thunderstorms.
Ozone is Produced Naturally from UV Light from the Sun
These same methods of ozone generations can be used commercially for industrial ozone applications. Great advancements have been made in the ozone industry to produce ozone more reliably and efficiently.
Ozone Production from Corona Discharge
Oxygen flowing between an electrode and cathode produces ozone from a spark, more commonly referred to as Corona Discharge.
Ozone Production from UV Light
Ozone can be produced from a UV light tuned to the proper wavelength inside an enclosed chamber.
Ozone can also be produced directly in water using an electrolytic cell. This method uses a current within the water to split the oxygen and hydrogen atoms, then converts the oxygen directly into ozone. This is a fairly new commercial ozone generation method that may show great promise in the future. At this time, this application has very limited application.
Commercial Ozone Generation
Corona Discharge (electrical discharge field)
High voltage spark at medium to high frequencies
Creates ozone at medium – high concentrations (up to 22%)
Most commonly used
UV Ozone Generation (photochemical)
Low concentration ( max 2% concentration)
Small ozone outputs
Electrolytic
Currently only small outputs
Ultra pure water is necessary
The most common method of ozone generation is corona discharge. Due to the low operation costs, and improved reliability this will be the main method of ozone generation for many years to come, for more information on ozone generation watch for future installments of “How Ozone is Made“
Ozone Solutions has recently completed the validation of a Semozone 250.3 High Concentration Ozone Generator. This generator is used but in great condition. If your application is looking for a great deal on one of the largest high concentration ozone generators available give us a call today.
Features
High Concentration Ozone
Ultra pure, semiconductor-quality ozone
Closed-loop concentration control
Real time status monitoring and tool interface
Safety and performance interlocked
Compact footprint
High reliability, production proven
Agency approvals including CE Mark and S2-93
Environmentally friendly alternative to many process chemicals
The above chart is actual testing data from the Semozone 250.3 Ozone Generator. This is how the ozone generator performed here at Ozone Solutions on 93% pure oxygen feed gas.
Specifications
Feedgas
Oxygen
Rated output
370 g/h
Rated gas flow
2.5 m3/hr (42sim @ 0 degrees C)
Rated (allowed pressure)
44.5 PSI abs
Mains supply
3~ delta 208 V +/- 10% (4 wire), 22 Amax, 50/60Hz
Year of Production
1999
Link to this page on our website:
http://www.ozonesolutions.com/Semozon.html
For more information on this ozone generator, or any of our used equipment contact our office today!
Ozone is produced from oxygen. The oxygen source for ozone generation can be found either in the air we breathe every day, or from concentrated oxygen produced by an oxygen concentrator or other device. While most ozone generators produce ozone from concentrated oxygen, the oxygen found in ambient air can also be used. The oxygen level in ambient air is about 20%. While this is a less efficient method to produce ozone, it may be useful depending upon your application. The following information is helpful when producing ozone from dry air.
Importance of Dry Air for Ozone Generation
The moisture level of feedgas to a corona-discharge-based ozone generator is directly related to the ozone output. More moisture equals lower ozone output. See the chart below:
Critical to all corona discharge ozone systems is proper air preparation. Because the presence of moisture affects ozone production and leads to the formation of nitric acid, the gas feeding the ozone generator must be very dry (minimum -60 degrees F). Nitric acid is very corrosive to critical internal parts of a corona-discharge-based ozone generator, can cause premature failure, and will increase the frequency of required maintenance. Make sure you have reliable air drying equipment.
Ozone Solutions rents many systems for Groundwater Remediation. We now have our Ozone Remediation Trailers available for rent.
Trailer mounted Groundwater Remediation Systems built to your specifications. The trailer is portable, reliable, and a simple to use systems for your remediation project.
All Ozone Remediation Trailers are built with Ozone Generators that operate at oxygen pressures up to 50 PSI. This ensures no re-compression of the ozone gas. The benefits of this trailer system are less moving parts, more ozone delivery, and a lower cost system.
Our ozone remediation trailers are built into custom built trailers. These trailers are built and designed to our specifications for your specific application.
These trailers are built for specific applications and uses, and can be customized for your unique application. For more information on these trailers please visit our website.
Did you know that Ozone Solutions sells used ozone equipment? Well, we do. We have a full classified listing service where we list all the used ozone equipment we get in the door. We also allow any user to post their used equipment for the world to see.
This week we received two large high concentration Ozone Generators commonly used in the semiconductor industry. When we get these cleaned up and tested they will get posted. Check back often, new equipment is posted frequently.
Ozone Solutions has recently added a new Ozone Generator to our rental line. This is an exciting addition, as this Ozone Generator produces 150 g/hr of ozone from oxygen.
The Water Cooled TG-150 is an extremely efficient and versatile Ozone Generator offering ozone effective concentrations up to 10% by weight. At an oxygen flow rate of only 15 SCFH the TG-150 will produce 55 g/hr of ozone. At an oxygen flow rate of 20 SCFH the TG-150 will produce 70 g/hr of ozone. Check out the entire TG-150 performance data here.
For a complete package, Ozone Solutions also rents the oxygen concentrators necessary to produce ozone from this Ozone Generator.
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