Compressed Air Dryer Cooling Control for Stable Dew Point
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Solution Overview
Problem
Existing cool drying methods for compressed air face issues such as energy inefficiency, excessive heat exchanger heating, and complex construction due to continuous operation or the use of thermal masses, which lead to increased energy consumption and potential corrosion from temperature and dew point peaks.
Innovation Solution
A method that measures ambient temperature and dew point to dynamically switch the cooling circuit on and off, maintaining the gas temperature or dew point within predetermined thresholds using an algorithm, eliminating the need for additional thermal mass and ensuring efficient energy use by only activating the cooling circuit when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cooling circuit stays operational at all times, then the gas temperature is continuously controlled and dew point peaks are avoided, but energy consumption increases considerably
Solution Approach 1:
The cooling circuit operates periodically rather than continuously. The control device switches the cooling circuit on and off based on measured temperature or dew point values, creating a periodic operation pattern that reduces energy consumption while maintaining temperature control reliability through timely activation.
2Use of energy by moving object
If the cooling circuit is switched off when no gas is supplied, then energy is saved, but the heat exchanger heats up and causes temperature and dew point peaks when gas supply resumes
Solution Approach 1:
A control device continuously measures the temperature or dew point in the heat exchanger and uses this feedback to determine when to switch the cooling circuit on or off. This feedback mechanism ensures the cooling circuit is activated before temperature peaks occur, maintaining temperature stability while saving energy during idle periods.
Solution Approach 2:
The cooling circuit is activated in advance based on predicted gas supply conditions. When the control device detects that gas supply is about to resume or when temperature approaches threshold values, it switches on the cooling circuit beforehand to prevent temperature and dew point peaks, rather than waiting for peaks to occur.
3Use of energy by moving object
If an intermediary thermal mass is used to cool the compressed air, then the compressor can be switched off to save energy, but the cooling circuit becomes very heavy and sizeable
Solution Approach 1:
The invention extracts and removes the intermediary thermal mass from the cooling circuit. Instead of using a separate thermal mass medium (such as water-glycol mixtures) to store and transfer cooling capacity, the system directly cools the gas in the heat exchanger, eliminating the weight and volume associated with thermal mass components while maintaining energy-saving capabilities.
4Use of energy by moving object
If an intermediary thermal mass is used, then energy can be saved by switching off the compressor, but additional parts such as reservoir and additional heat exchanger make the construction expensive and complicated
Solution Approach 1:
The invention removes the intermediary thermal mass and its associated components (reservoir, additional heat exchangers) from the cooling circuit. By directly cooling the gas in the existing heat exchanger, the system simplifies the construction, reduces the number of parts, lowers manufacturing costs, and maintains energy-saving functionality through intelligent control.
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 approach saves energy by only operating the cooling circuit when needed, prevents temperature and dew point peaks, and avoids the complexities and costs associated with thermal masses, ensuring effective condensation and preventing corrosion.
Implementation Method 1
by lowering the air or gas temperature in the vaporizer, moisture in the air or gas will condense
Implementation Method 2
the gas to be dried is guided through the secondary part of a heat exchanger whose primary part is the vaporizer of a cooling circuit
Data Source
AI summary
Method for cool drying gas, in particular air, whereby this gas is guided through the secondary part of a heat exchanger (2) whose primary part is the vaporizer (3) of a cooling circuit (4), which consists in measuring the ambient temperature (Tamb), as well as the lowest gas temperature (LAT) or the dew point, and to switch the cooling circuit (4) on and off on the basis of these measurements in order to always maintain the lowest gas temperature (LAT) or the dew point between a pre-determined minimum and maximum threshold value, and whereby pre-determined threshold values are calculated on the basis of an algorithm which is a function of the measured ambient temperature (Tamb).