Compressed air is a vital utility in industrial and petrochemical processes. It is used to operate critical machinery such as jackhammers, pneumatic drills, and wrenches as well as process equipment like air cylinders and pumps.
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An industrial air dryer is a piece of equipment or machinery used to dehumidify compressed (process) air to significantly lessen or eliminate moisture present in the air stream. Industrial air dryers can be used to reduce the dew point of compressed air to below the lowest temperature obtained on the site (typically up to 18°F lower than the coolest point). Compressed air testing can determine if your equipment is at risk.
Atmospheric air typically contains a percentage of water vapor which can create several problems in pneumatic equipment and adversely affect the quality of the final products.
Now that you understand the importance of utilizing an air dryer for your industrial equipment, learn about the common types of air dryers for air compressors to help you select the best option for your needs.
Refrigerated air dryers are a popular option for eliminating water vapors, aerosols, and mist present in compressed air systems. They can achieve dew points suitable for most applications and are relatively simple to design, install, and maintain.
The working principle of a refrigerated air dryer is the same as a domestic refrigerator or air conditioning unit. Compressed air entering the unit is first cooled in an air-to-air heat exchanger.
The outgoing cooled air pre-cools the hot incoming air, condensing the moisture present into liquid water which is drained out of the system. The pre-cooled air then enters an air-to-refrigerant heat exchanger which cools it using a liquid refrigerant. The moisture condenses into liquid form and is drained out of the system.
There are two types of refrigerated air dryers, cycling and non-cycling:
Cycling type dryers use a refrigerant (such as R314A or R407C) to cool a liquid or solid mass surrounding the air inlet of the heat exchanger. The mass may be glycol or metal block which acts as a heat sink which cools the compressed air. A thermostat is used to regulate the temperature by shutting off the compressor during times of partial or zero loads, thus providing energy savings.
In the non-cycling type air dryer, the refrigerant circulates continuously through the system and there is no intermittent shut off. The flow of the refrigerant is regulated using a bypass or unloader valve to match the volume of compressed air entering the system and maintain a stable operating temperature.
The main advantage of using a cycling type air dryer is that it achieves energy savings at partial and no air flow. On the downside, it has a higher initial capital cost than the non-cycling type, takes up more space (due to the heat sink mass) and is prone to dew point swings.
The key benefits of non-cycling air dryers are continuous compressor operation and a consistent dew point. However, there are no energy savings at partial and no air flow.
This type of air dryer utilizes two towers ' one containing a desiccant that removes moisture from the air stream coming from the compressor, while the other regenerates the used desiccant after the pressure has dropped to atmospheric conditions. Similarly, regenerative desiccant dryers are either heatless, externally heated or heat of compression type.
Heatless desiccant air dryers use a desiccant in twin towers ' one for drying, and the other for regeneration. Wet compressed air enters the drying tower and passes over the desiccant which adsorbs it and exits as dry air (dew point between '40 and '100° F). The regenerating tower recovers the desiccant in its pure form. Heatless air dryers do not require internal or external heaters.
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The heatless dryer operation uses internal/external heaters to generate heat and uses a twin-tower arrangement. Like in the heatless type, humid air flows into the drying tower and is dried by the desiccant. The second tower regenerates the desiccant.
Some of the dry air exiting the tower passes through the heater and desiccant which removes the adsorbed moisture. Moist air is drained out of the system through a muffler. Heated type air dryers can achieve dew points of '40 to '100° F.
Membrane dryer systems utilize semi-permeable membrane fibers to separate moisture from compressed air. Membrane systems are low-cost and eco-friendly alternatives to other air dryer types with additional space saving and reduced maintenance benefits.
A membrane air dryer consists of a bundle of hollow fiber membranes of a specific porosity housed in a hollow cylindrical vessel. Wet compressed air introduced via an inlet flows through the cylinder and a pressure differential inside the tube allows water molecules to pass through the membrane pores while dry air flows through the outlet. The efficiency of membrane air dryers depends on the selectivity of the membrane which is dependent on the pore size.
NiGen offers instrument air dryer packages to suit a broad range of industrial operations. Available services include on-site nitrogen generation units, rotary-screw air compressors, desiccant air dryers, and more on a rental basis.
For more information about our industrial solutions or to request a quote, call us at 713-956- or contact us online today!
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Compressed air dryers are essential in a host of industrial facilities that require a regular supply of dry, compressed air. These dryers are critical in industrial operations because the presence of moisture in industrial air can damage pneumatic systems, cause freezing in pipelines, promote corrosion in metallic parts, etc.
A wide range of instrument air dryer types are available on the market today. Understanding the different types of air dryers and their principles of operation will let you choose the ideal compressed air dryer for your unique application.
A compressed air dryer is a piece of equipment designed to separate water vapor or moisture (de-humidify) from industrial process air. In the typical system, a compressor draws in humid air and compresses it, which raises the air temperature and then cooling the air condensing water vapor out of the unit.
However, there are other ways to achieve separation. The main types of air dryers include the refrigerated, desiccant-type, and membrane type air dryer.
Refrigerated air dryers are one of the most common types used in industrial applications due to their ease of maintenance and relative cost-effectiveness. They are suitable for air-drying applications without special requirements such as a minimum dew point.
The refrigerated air dryer working principle is based on de-humidifying air by rapidly cooling it, condensing it, and draining off the moisture. The operation is like that of a domestic refrigerator or home air-conditioning system.
Refrigerated air dryers de-humidify air through the following phases:
Moreover, refrigerated air dryers are available in two variants ' cycling and non-cycling.
Both variants are useful in different applications, although cycling types tend to ramp up maintenance costs.
A desiccant air dryer system consists of two towers, one for drying the air and the other for regenerating the desiccant. The drying tower contains a porous desiccant material that inhibits water molecules as compressed air from the inlet passes over it.
A less common variant, the single tower desiccant air dryer, comprises a single tower containing a desiccant material that dries air coming in from the environment. Single-tower dryers also contain no mechanical parts and do not require electricity to operate. They are suitable for use in hazardous and corrosive environments.
These instrument air dryers use a desiccant material, hygroscopic substances that exhibit a high affinity for water as the de-humidification agent. These types of compressed air dryers achieve a low dew point, making them suitable for use in colder climates and industries that require super dry air.
There are three main types of desiccant dryer systems ' heated, heatless, and heat of compression desiccant air dryers. Let's take a closer look at these below.
Heated desiccant air dryers utilize a source of heating within the drying tower to heat the desiccant material sufficiently to minimize the need for purge air. Typical dew points in heated dryers range from -40°C to -73.3 °C ('40 to '100 °F).
Heatless desiccant dryers do not contain a heated system in the regenerating tower; instead, they utilize 'purge air' to expel moisture from the tower. Typical dew points in heatless dryers range from -40°C to -73.3 °C ('40 to '100 °F).
A heat of compression air dryer uses both towers simultaneously to maintain a uniform temperature. This design allows for lower operating costs but with a less consistent dew point.
Membrane dryers use permeable membranes similar to nitrogen separation membranes or CO2 separation membranes to extract water vapor from process air. These systems are convenient to use, more cost-effective, and require less maintenance since they have no moving parts. They are suitable for low volume air separation.
GENERON is a world-class manufacturer of compressed air systems. We have over 50 years of experience providing a full range of air-drying solutions to the commercial, industrial, and environmental facilities worldwide.
Contact us online today for more information on our compressed air dryer solutions or to request a quote.
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