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Compressed Air Dryers

Compressed Air Dryers

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Published by: manpreetsodhi08 on Apr 19, 2012
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01/06/2014

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Why add a dessicant air dryer to the compressed air system?
Browse our selection of 
online. If you have questions or can'tfind what you are looking for online, call our knowledgeable customer service team toll-free: 866-650-1937.Compressed air dryers reduce the quantity of water vapor, liquid water, hydrocarbon, andhydrocarbon vapor in compressed air. Moisture in compressed air is harmful. Water damages a compressed air system several ways
Erosion
--Water mist erodes piping, valves and other system components
Corrosion
--Mist condenses and combines with salts and acids within the systemforming highly corrosive solutions
Microbial Contamination
--Moisture supplies a growth medium for bacteria andmold, which produce acidic waste and can be a health threat
Freezing
--Water can freeze in compressed air lines shutting down the systemThe result is lower productivity, increased maintenance, and higher operating costs. Youcan minimize the damage wet compressed air can inflict on your system by drying it.Compressed air is dried to protect the system's piping and process equipment. Dry air also protects against lost product. Most pneumatic equipment has a recommended operating pressure, dryness level, and a maximum operating temperature. Set your compressed air'ssystems dryness level to exceed the requirements of the equipment it powers.Recommended Dew Points:
ApplicationPressureDew Point(ºF)PressureDew Point(ºC)
Air Motors (highefficiency)-40 to 38-40 to 3.3Air Motors (lowefficiency)-20-28.8Breathing Air (subsequentlyhumidified)-40 to 38-40 to 3.3Chemical Processing-40-40Control Air (industrialservices)-40-40Cryogenic Systems-100-73.3Drying Processes-40 to 4-40 to -15.5General Services(indoors)-40 to 50-40 to 10
 
General Services(outdoors)-100 to 38-73.3 to 3.3Instrumentation(industrial services)-40-40Instrumentation(laboratory services)-60-51.1MicroelectronicService-100 to -40-73.3 to -40Paint Spray Systems-40 to 38-40 to 3.3PharmaceuticalServices-100 to -40-73.3 to -40Figure AD1-1 Audit locations that compressed air is used in your plant and piping runs to determine thedew point requirement.
Types and functions of compressed air dryersRefrigerated Compressed Air Dryers
Refrigerated Air Dryers utilize a mechanical refrigeration system to cool the compressedair and condense water and hydrocarbon vapor. Most refrigerated air dryers cool thecompressed air to a temperature of approximately 35ºF to 50°F (1.6°C to 10°C) whichresults in a pressure dew point range of 33ºF - 39ºF (.5°C to 3.8ºC). This range permits the pressure dew point to fall within limits that are achievable with common refrigerationsystem controls. This pressure dew point range is also the lowest achievable with arefrigerated design since the condensate will begin to freeze at 32ºF (0ºC).Refrigerated air dryers are available in two basic configurations, non-cycling and cycling.
Refrigerated Air Dryers utilize a mechanical refrigeration system to cool the compressedair and condense water and hydrocarbon vapor. Most refrigerated air dryers cool thecompressed air to a temperature of approximately 35ºF to 50°F (1.6°C to 10°C) whichresults in a pressure dew point range of 33ºF - 39ºF (.5°C to 3.8ºC). This range permits the pressure dew point to fall within limits that are achievable with common refrigerationsystem controls. This pressure dew point range is also the lowest achievable with arefrigerated design since the condensate will begin to freeze at 32ºF (0ºC).Refrigerated air dryers are available in two basic configurations,non-cycling and cycling.
 Non-cycling compressed air dryers (fig. AD1-2) cool the compressed
 
air in an air-to-refrigerant heat exchanger (evaporator). The warm compressed air flowsinto one side of the evaporator while low pressure, liquid refrigerant is metered intoanother side of the evaporator. The heat from the compressed air "boils" the refrigerantthereby reducing the temperature of the compressed air. Operation of the refrigerationcompressor is continuous or non-cycling, therefore requiring a combination of controlvalves to regulate refrigerant flow as the heat load from the compressed air changes.
Cycling compressed air dryers (fig. AD1-3) cool the compressed air through an intermediate heat exchanger medium. The intermediate can be sand, metal, or a fluid. Two heat exchangers, a compressed air chiller and refrigerant evaporator are fitted inside a tank which isfilled with a thermal conducting fluid, usually water with propyleneglycol added as a safe guard to prevent freezing and corrosion. Therefrigeration system removes heat from the water/glycol fluid. Thechilled fluid removes heat from the compressed air. Since therefrigeration system is used to only cool the fluid, the refrigerationcompressor is "cycled off" once the fluid temperature is chilled to therequired point. The compressor will "cycle on" only when the fluidtemperature rises to its upper limit. This cycling of the refrigerationcompressor results in significant energy savings on most compressed air systems. Onaverage, cycling compressed air dryers provide energy savings of 50% when compared toequally sized non-cycling designs.Additional cycling compressed air dryers benefits include:
Simplified refrigeration circuit since hot gas bypass valves are not required
A 60% or more reduction in the required quantity of refrigerant charge
Elimination of compressed air dryer freeze-up potential since the refrigerationsystem "cycles off" before freeze-up can occur. Over sizing of the compressed air dryer is therefore not a problem
Additional energy savings since the compressed air dryer dew point can be raised toas high as 60ºF
Microprocessor controls permit automatic dew point suppression below ambienttemperature for maximum energy savings
Montreal Protocol
To protect the ozone layer from further depletion the European Union, Switzerland, UnitedKingdom, United States, and other World powers developed and signed the MontrealProtocol. The protocol freezes HCFC refrigerant production levels at the 1986 level. Under the protocol developed nations will phase HCFC refrigerants out by 2020. Some HCFC production will continue until 2030. HCFC refrigerants contain chlorine, which damagesthe ozone layer.

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