Integrated Air Dryer Vessel for Full-Pressure Moisture Separation
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Solution Overview
Problem
Compressor systems face challenges in delivering substantially dry compressed air, as moisture can cause damage or corrosion in machinery and tools, and existing air dryers are not effective in fully removing entrained liquids at full operating pressure.
Innovation Solution
A dryer system within a single pressure vessel that includes a precooler/reheater, evaporator, and separator to cool and separate the compressed gas and entrained liquid, with a drain valve to manage liquid collection and a dual layer evaporator using chilled refrigerant and heat sink fluid to enhance moisture removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing air dryers are used to remove moisture from compressed air, then some moisture removal is achieved, but they are not effective in fully removing entrained liquids at full operating pressure
Solution Approach 1:
The dryer system is segmented into multiple functional components: a precooler section with first and second heat exchangers, a refrigeration system, and a separator. This segmentation allows each component to perform its specific function optimally - the precooler removes heat and condenses moisture, the refrigeration system provides cooling, and the separator removes liquid water - while working together to achieve complete moisture removal at full operating pressure.
Solution Approach 2:
The patent implements a nested structure where the precooler and refrigeration system are integrated within a single pressure vessel. The precooler section contains heat exchangers that are thermally coupled to the refrigeration system, creating a compact nested arrangement. This nesting allows the smaller precooler components to be housed within the larger pressure vessel structure, achieving space efficiency while maintaining full moisture removal capability at operating pressure.
2Productivity
If a precooler/reheater is used to cool compressed gas before drying, then moisture removal efficiency is improved, but energy consumption increases due to the refrigeration system
Solution Approach 1:
The precooler performs preliminary cooling action on the compressed air before it enters the separator. By removing heat and condensing moisture in advance through the heat exchangers thermally coupled to the refrigeration system, the subsequent separation process becomes more efficient. This preliminary action prepares the compressed air for effective moisture removal, reducing the energy required in the final drying stage.
Solution Approach 2:
The reheater section recovers energy by heating the cooled and dried air using heat from the incoming compressed air through the heat exchangers. This heat recovery process reduces the overall energy consumption of the refrigeration system by utilizing the thermal energy that would otherwise be wasted, thereby improving the energy efficiency of the moisture removal process.
3Volume of moving object
If a single pressure vessel is used to contain all dryer components, then device compactness is improved, but maintenance accessibility worsens
Solution Approach 1:
The pressure vessel is segmented into distinct functional sections - a precooler section containing the heat exchangers and a refrigeration section containing the refrigeration system components. This segmentation allows for organized arrangement of components within the compact vessel while providing access points for maintenance. The drain valve is positioned at the bottom of the pressure vessel for easy liquid water removal, and the float valve is accessible for monitoring and adjustment.
Solution Approach 2:
The drain valve is designed to be movable between open and closed positions, allowing dynamic control of liquid water discharge. The float valve mechanism provides automatic response to liquid level changes, enabling easy maintenance operation without requiring disassembly of the pressure vessel. These dynamic features maintain compactness while ensuring ease of repair and maintenance accessibility.
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 separates moisture from compressed air, ensuring the delivery of substantially dry gas while reducing corrosion risks and optimizing the refrigeration system's efficiency by precooling the gas before drying, thus protecting machinery and tools.
Implementation Method 1
A precooler/reheater is positioned within the pressure vessel to receive and cool the flow of gas and the entrained liquid from the inlet
Implementation Method 2
an evaporator is positioned within the pressure vessel to receive and cool the flow of gas and the entrained liquid from the precooler/reheater
Implementation Method 3
The separator is operable to separate the flow of gas and the entrained liquid into a flow of substantially dry gas and a liquid
Data Source
AI summary
A dryer operable to separate a portion of an entrained liquid from a flow of gas includes a pressure vessel to contain the flow of gas and entrained liquid within the pressure vessel. A precooler/reheater is positioned within the pressure vessel to cool the flow of gas and the entrained liquid and an evaporator is positioned within the pressure vessel to cool the flow of gas and the entrained liquid from the precooler/reheater. A separator receives the flow of gas and the entrained liquid from the evaporator and is operable to separate the flow of gas and the entrained liquid into a flow of substantially dry gas and a liquid. The liquid collects in the bottom of the pressure vessel. A drain valve is movable between an open position and a closed position in response to the quantity of liquid within the bottom of the pressure vessel.