Compressed Air Aftercooler With Integral Moisture Separation
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Solution Overview
Problem
Conventional heat exchangers used to cool compressed air often result in condensation, leading to undesirable moisture delivery, necessitating active moisture removal systems which are not always passive or integral.
Innovation Solution
A compressed air aftercooler system with an integral passive moisture separation mechanism, featuring a recessed bottom lined with high porosity material for condensate collection and a shield to prevent direct condensate entry into the outlet, ensuring cooled air is free of entrained moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressed air is cooled in a conventional heat exchanger, then the air temperature is reduced, but condensation of water occurs and contaminates the cooled air
Solution Approach 1:
The patent combines the heat exchanger and moisture separator into a single integrated unit. The heat exchanger cools the compressed air while the moisture separator, positioned at the bottom of the housing, collects and removes condensate. This merging eliminates the need for separate cooling and drying equipment, resolving the contradiction by ensuring that cooling occurs without contaminating the air with condensation.
Solution Approach 2:
The moisture separator acts as an intermediary between the heat exchanger and the outlet. It intercepts condensate formed in the heat exchanger before it can contaminate the cooled air. The separator includes a baffle or wall that prevents condensate spewed from the heat exchanger plates from directly entering the outlet, thus mediating between the cooling process and the air delivery.
2Object-affected harmful factors
If sumps or active demoisturizing means are added to remove condensate, then moisture removal capability is improved, but device complexity increases
Solution Approach 1:
The moisture separator is designed to operate passively without requiring external power or active control systems. Condensate naturally drains to the bottom of the housing due to gravity and is collected in the moisture separator. The system serves itself by using the natural condensation process and gravity-driven drainage, eliminating the need for complex active demoisturizing means while maintaining effective moisture removal.
3Object-affected harmful factors
If a shield is added to prevent condensate spew, then air quality is improved, but manufacturing complexity increases
Solution Approach 1:
The shield is positioned locally at the outlet area where condensate spew is most likely to occur. Rather than requiring a complex overall design change, the shield is a localized component that addresses the specific problem area. This local quality approach allows the rest of the device to remain simple and easy to manufacture while providing the necessary protection against condensate contamination at the critical outlet point.
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
Effectively removes condensate from cooled compressed air without active systems, providing a passive and integral solution for delivering moisture-free air, enhancing operational efficiency.
Implementation Method 1
cooling is typically accomplished by passing the compressed air through one side of a conventional heat exchanger while passing air at ambient pressure and temperature through the other side
Implementation Method 2
At least a portion of a bottom of the output plenum is recessed and lined with a moisture separating material
Implementation Method 3
lined with a moisture separating material
Implementation Method 4
cooling of compressed air immediately produces condensation of water in the heat exchanger
Implementation Method 5
the recessed portion has a drain for passing condensate formed in the heat exchanger
Data Source
AI summary
A system for providing cooled compressed air free of entrained moisture. A housing surrounds a heat exchanger and has an inlet for passage of hot compressed air into an input plenum of the housing and an outlet plenum having an outlet for the cooled and dried compressed air. The bottom of the output plenum extends below the bottom of the heat exchanger to form a trough which collects condensate that collects on the plates of the heat exchanger, flows to the bottom of the heat exchanger, and is pushed by the flow of the compressed air to the output plenum. A shield is placed between the outlet and the heat exchanger to prevent condensate spewed from the plates of the heat exchanger from passing directly across the outlet opening or directly into the outlet opening.