A drying device for processing a gas, in particular air
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Solution Overview
Problem
Existing gas drying devices using phase change materials (PCMs) for thermal storage are not optimally efficient in heat exchange and are not suitable for industrialization, leading to suboptimal energy efficiency and compactness, especially during partial loads and operational transients.
Innovation Solution
A drying device with a plate and fin heat exchanger configuration in the evaporator, utilizing multiple layers with phase change material, where each layer includes a plate and fins forming channels for refrigerant and gas flow, optimizing thermal storage and heat exchange, and allowing for compact and industrial-scale production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If phase change material is used as thermal mass in the evaporator, then energy efficiency is improved, but heat exchange efficiency deteriorates due to inadequate utilization of thermal storage capacity
Solution Approach 1:
The evaporator is divided into multiple layers with alternating configurations: layers containing phase change material and layers without phase change material. This segmentation allows different zones to perform different functions - some zones store thermal energy while others facilitate direct heat exchange, resolving the contradiction between thermal storage and heat exchange efficiency
Solution Approach 2:
Different regions of the evaporator are assigned different properties: certain layers contain phase change material for thermal storage while other layers are designed for optimal heat exchange. This local differentiation allows each region to excel at its specific function, achieving both energy efficiency and heat exchange efficiency simultaneously
2Stability of the object's composition
If phase change material is used for thermal storage, then stability of discharged air temperature is improved, but device complexity increases due to specialized production requirements
Solution Approach 1:
The evaporator layers are designed to serve multiple functions: they provide structural support, facilitate heat exchange, and contain phase change material. This multi-functionality allows standard manufacturing processes to be used while achieving temperature stability, reducing production complexity
Solution Approach 2:
The system dynamically adapts to operational conditions through the phase change material's ability to absorb and release thermal energy as needed. This dynamic response stabilizes discharged air temperature during operational transients without requiring complex control mechanisms or specialized production
3Use of energy by moving object
If phase change material is used in the evaporator, then energy efficiency with partial loads is improved, but spatial dimensions increase reducing compactness
Solution Approach 1:
The evaporator is organized in a layered, multi-dimensional structure where phase change material layers and heat exchange layers are stacked alternately. This vertical arrangement maximizes thermal storage capacity within a compact footprint, improving energy efficiency with partial loads without significantly increasing overall device volume
Solution Approach 2:
The phase change material is contained within the evaporator structure itself, with layers nested within the overall evaporator assembly. This nesting approach integrates thermal storage functionality into the existing heat exchange structure, achieving compact dimensions while maintaining energy efficiency
4Productivity
If phase change material is used for thermal storage, then productivity is improved through better energy efficiency, but ease of manufacture deteriorates due to specialized production requirements
Solution Approach 1:
The evaporator is segmented into standardized layers that can be manufactured independently and assembled systematically. This modular segmentation enables industrial production using conventional manufacturing processes, improving ease of manufacture while maintaining the productivity benefits of phase change material
Solution Approach 2:
The system is designed to dynamically respond to varying operational loads, with phase change material automatically absorbing or releasing thermal energy as needed. This dynamic behavior improves energy efficiency and productivity across different operating conditions without requiring complex control systems that would complicate manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances energy efficiency, particularly during partial loads, stabilizes air temperature, and simplifies production, enabling better control of humidity and reduced variations during operational transients.
Implementation Method 1
the use of a phase change material (PCM) is suggested as the thermal mass to be used in the evaporator
Implementation Method 2
allowing the use of constructive methodologies which are also common to the construction of drying devices which do not provide for the use of phase change materials
Implementation Method 3
an air flow to be dried is cooled, by means of the refrigerating circuit, to the temperature of the dew point
Implementation Method 4
heat exchange occurs between the refrigerating fluid and the air to be dried
Implementation Method 5
the fins form a plurality of channels for the passage of the refrigerating fluid, and for the passage of the air/gas to be dried
Data Source
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AI summary
A drying device for processing a gas to be dried, in particular air, comprises an air/air exchanger which includes an inlet for the gas to be dried and an outlet for the dried gas, an evaporator which receives the gas to be dried from the air/air exchanger, the evaporator being formed by means of a plurality of adjacent layers. The layers comprise at least a first layer configured for the passage of a refrigerating fluid, at least a second layer configured to receive the gas to be dried from the air/air exchanger and a plurality of third layers configured to receive a phase change material. The layers are arranged in a sequence which comprises in alternation a first layer, a third layer, a second layer and a further third layer.