Air compressors are helpful machines that power tools and appliances around the business and home. When regularly using an air compressor, an air dryer can help remove the water constantly being created by the compressed air. Utilizing a thorough drying system like an air dryer can prolong the life of the air compressor and minimize future costs. Learn more about air dryers and why they're necessary for every air compressor.
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The best air dryer option depends on the use of the air compressor. When looking for a compressed air dryer, make sure to take note of the maximum amount of pressure and capacity or liters per second of air. Cost is also important in yearly energy needs and hidden costs that you may not realize at the time of purchase.
It's important not to compromise when determining the best tool for the job. Have an understanding of how the air dryer regenerates and the increased costs associated with that process. An air dryer will keep an air compressor safely functioning without rust or damage. Any costs cut by purchasing a cheaper air dryer can double or triple when replacing the whole compressor.
The three most common air dryers are refrigerated, desiccant, and deliquescent.
A refrigerated air dryer can be used in compressors that do not require special requirements like a lower dew point. Refrigerated air dryers are the standard option for most air compressors. They are easy to install without much worry for consistent maintenance. This type of dryer will take in warm, wet air and use refrigerant and an evaporator to cool it down to three degrees Celsius. This average dew point works for most compressors. The water condenses, then is removed from the compressor before the air is reheated back to room temperature and can be used for tools.
Refrigerated compressed air dryers can be either cycling or non-cycling.
A desiccant compressed air dryer uses a unique material to collect water. This water is dried out in the regeneration process so the compressor can reuse the material. This dryer uses desiccant, often inactivated alumina or silica gel, to collect water from the air. Two desiccant towers are used, while one constantly collects moisture, and the other dries out.
The regenerative process allows the desiccant to dry out the tower, not being utilized through dried compressed air or hot air. The hot air method will use a heater to pull air from the room and blow it over the desiccant. Suppose the dryer uses dried compressed air to dry the desiccant. In that case, less air is used by the compressor and, by extension, any tools or devices. Special dryers also use rotating drums to better utilize the air compressor's heat for drying the desiccant.
The desiccant compressed air dryer can have several hidden costs in the regeneration process. First, the pressure drop and the actual desiccant will need replacement after it wears down.
A deliquescent compressed air dryer is the perfect option for significant drying needs. This dryer uses salt tablets inside a pressurized vessel that absorb water from the air. A brine solution forms as the moisture separates from the compressed air. Deliquescent air dryers don't use electricity or moving parts and have low maintenance needs. They're best in colder climates to remove water from pipes that may freeze. However, this type of dryer is not as efficient at suppressing or maintaining the dew point as the other two options.
These air dryers can help remove moisture from an air compressor and keep it running safely.
Every air compressor needs an air dryer to keep the machine running smoothly and without issues. All compressors create water that can be drained but remain an aerosol inside the machine. If this water is not separated, it can damage and corrode parts of the air compressor. To avoid further damage to tools and costly machinery, utilize an air dryer to remove the water you can't easily spot.
Accumulated moisture can manifest in many ways in an air compressor. Pipes may begin to rust, water will come out of hoses, and air tools can begin to display water spots. Many compressor manufacturers specify that the machine needs frequent dry air to remove water and keep it running smoothly. It's essential to purchase and install an air dryer before moisture accumulation negatively affects the compressor.
Businesses and homeowners have many options when removing from their air compressors. You can drain the tank to remove created liquid from the machine. A compressor can also use a piping system for air drying. The storage tank cooling method and absorption drying are also excellent choices. There are many physical ways to remove liquid and vapor from an air compressor before it starts to cause damages.
An air dryer for an air compressor is one of the best options. Many require little maintenance and ensure water is removed constantly from the air. However, it's essential to address the liquids accumulating in the machine and the aerosol or vapor that is not easily seen. Take the time to research the best air dryer options for specific environments and compressors. There are many options to ensure a compressor isn't being corroded or damaged by excessive water in the machine. Visit our Air Power Equipment OKC website and help extend the life of your air compressor.
Some air compressors come with an integrated aftercooler. This built-in component is essential for removing up to 70% of moisture. While protecting your investment, this drying element is suitable for most applications.
However, if you work in an environment that's exceptionally humid or an application requiring the driest possible air, you'll want to add a dryer. Deciding on the right equipment depends on your space and needs.
Read more on the importance of dryers in compressed air. Selecting the proper dryer to treat wet air is largely dependent on the specific requirements and moisture tolerance levels of your set-up.
A refrigerated air dryer is suitable for most industrial and manufacturing facilities. If you work in a laboratory, with spray paint, or with printing and pneumatic tools, a desiccant dryer is the right choice.
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The following section goes further into the different types of refrigerated dryers. This information is meant to help you gain a better understanding of which option is most suitable for your operation.
A refrigerated non-cycling dryer is an excellent cost-effective choice for anyone looking to improve their compressed air quality. The term "non-cycling" means this type of dryer constantly operates refrigeration. It also utilizes a hot bypass valve to redirect the coolant, even at a less than full load condition.
In a refrigerated air compressor dryer, the air temperature is lowered to 3° Celsius (37° Fahrenheit). This drop allows for water to move from a vapor state to dry air. Non-cycling dryers are simple and reliable machines, meaning they're easy to maintain.
This type of refrigerated dryer is affordable, and comes with a relatively low cost of investment. In addition, non-cycling dryers are quick and straightforward to install and operate. This accessibility makes them a market standard in performance and quality, while exceeding expectations.
A non-cycling air compressor dryer works well with any rotary screw compressor. If you use a piston air compressor, a high temperature version is recommended.
Since these machines run nonstop, energy consumption at full or low load is nearly the same. Therefore, these units are less energy efficient than other options on the market. If electricity costs are a priority, you may want to check out a cycling dryer.
Unlike non-cycling dryers, this equipment uses additional components, including thermal mass and frequency controllers. These integrations allow a cycling dryer to turn on and off, based on compressed air demand.
Since these machines adapt to use and application, they're more energy efficient than a non-cycling dryer. They also come with a customer-oriented design, offering high performance and reliability.
While the initial cost of a cycling dryer is slightly higher than a non-cycling dryer, it's a worthwhile investment. They're very reliable, offer easy installation, produce minimal noise, and run efficiently. Cycling dryers are ideal if you're concerned about energy costs.
Due to their advantages, a cycling dryer is highly beneficial to any compressed air system. This point is especially true when considering the overall life-cycle cost of your set-up. If your applications need fluctuating air demand, this equipment is the right choice.
If efficiency and low cost of ownership are your top priorities, the recently introduced VSD dryers will be your best choice. Variable Speed Drive technology has been available for compressors for many years. Matching the compressor's motor speed to the air demand, VSD reduces energy consumption by double digits. This technology is now also available for refrigerated air dryers. The motor speed of the compressor integrated into the dryer adjusts automatically to the air demand with the same energy and cost-saving results. A VSD dryer also ensures a low, stable low dew point and outstanding quality air at all times.
The biggest deciding factor regarding compressed air dryers is the application and desired dew point. As previously pointed out, refrigerated air dryers provide a dew point of 3° Celsius (37° Fahrenheit). This temperature is sufficient for most applications.
However, if exceptionally cold compressed air is important, a desiccant dryer is recommended. These regenerative dryers achieve up to -70 °C (-100 °F) as standard. This low temperature delivers clean, dry air.
Unlike refrigerated air dryers, desiccant dryers utilize desiccant beads or solid desiccant to absorb water vapors. During this process, vapors adhere to the desiccant without changing the air composition. Once the desiccant becomes saturated with moisture, a process of regeneration occurs.
This involves dry purge air, heat or a combination of both to dry the wet desiccant. This type of dryer typically uses a dual tower construction design. One tower dries the wet air, while the other tower regenerates and purges moisture.
Heated purge air desiccant dryers utilize either internal or external heaters, accounting for part of the drying process. This type of desiccant dryer reduces the amount of purge air for the regeneration process to less than 10%.
Due to its design and ability to cut purge air in the process, this dryer comes with a high initial investment. However, a heated dryer provides significant energy efficiency during its lifecycle.
With heated desiccant air dryers, the external purge air is raised to a high temperature and introduced to the desiccant. This process aids with the drying and regeneration process, and utilizes 0-4% of purge air.
In order to completely eliminate purge air in a heated desiccant dryer, you'll want to add a blower. This equipment circulates heated air throughout the desiccant. Due to efficiency gains, a blower heat desiccant dryer tends to be the most expensive option. However, this set-up provides the best return on investment regarding energy consumption.
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