Blower Purge Dryer Cooling Apparatus for Heat Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dryer systems for compressor flow streams face inefficiencies in moisture removal and regeneration, particularly in managing the desiccant towers' capacity and heat recovery, which affects the overall performance and operational costs.
Innovation Solution
A multi-tower regenerative dryer system with a controller-actuated valve network and heat exchanger system that alternates the flow between desiccant towers for continuous drying and regeneration, utilizing heat recovery and cooling cycles to optimize desiccant performance and reduce moisture load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heat recovery is implemented in regenerative dryer systems, then energy consumption is reduced, but system complexity increases due to additional heat exchanger components and control mechanisms
Solution Approach 1:
The patent combines the cooling apparatus with the existing heat exchanger system in the regenerative dryer. The cooling apparatus integrates thermal exchange functions with the heat recovery system, allowing simultaneous heat recovery and cooling operations through merged components and unified control mechanisms, thereby reducing overall system complexity while maintaining energy efficiency benefits
Solution Approach 2:
The heat exchanger system is designed to perform multiple functions: heat recovery during regeneration cycles and cooling during drying cycles. This multi-functional approach eliminates the need for separate dedicated components, reducing system complexity while achieving both energy conservation and thermal management objectives
2Productivity
If desiccant tower capacity is extended through continuous operation, then productivity increases, but moisture removal efficiency decreases due to tower saturation
Solution Approach 1:
The drying system is divided into multiple desiccant towers that operate in alternating cycles. While one tower is performing drying operations, another undergoes regeneration. This segmentation allows continuous productivity without saturation of individual towers, as each tower can be regenerated offline while others maintain drying efficiency
Solution Approach 2:
The system implements periodic switching between drying and regeneration modes for each desiccant tower. Towers alternate between active drying service and regeneration cycles in a rhythmic pattern, ensuring that each tower is refreshed before saturation while maintaining continuous overall drying capability across the system
3Reliability
If regeneration frequency is increased to maintain desiccant performance, then drying reliability is improved, but energy consumption increases due to more frequent heating cycles
Solution Approach 1:
The system captures and utilizes the heat that would otherwise be wasted during purge operations and from the environment during cooling phases. By redirecting this thermal energy through the heat exchanger system to pre-condition air entering the desiccant towers, the system reduces the heating energy required for regeneration while maintaining drying reliability
Solution Approach 2:
The system dynamically adjusts operating parameters including regeneration timing, heat exchanger flow rates, and tower switching intervals based on actual moisture load conditions. This optimization allows extended regeneration intervals when moisture content is low, reducing energy consumption while maintaining adequate drying performance through adaptive parameter modification
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
The system achieves enhanced drying performance, reduced energy consumption, and extended desiccant capacity by effectively managing the regeneration and drying processes, with improved thermal effectiveness and reduced moisture load on the towers.
Implementation Method 1
a blower purge dryer with integrated cooler including a heat exchanger
Implementation Method 2
desiccant towers for continuous drying and regeneration
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A multi-tower blower purge dryer system for use with a compressed air stream provided from a compressor is disclosed. In one form the system includes two dryers that can be alternated to dry the compressed air stream. The tower used to dry the compressed air stream can be referred to as the drying tower, and the tower being regenerated can be referred to as the regenerated tower. A number of valves and passages are used to connect the towers to one another and/or to an intake passage from the compressor. A blower purge heater is provided to regenerate the dryers. After a regeneration step in which a tower may be relatively warm, the valves can be actuated to place the warm regenerated tower in fluid communication with the intake passage from the compressor, which can then provide air to the drying tower. In this manner the regenerated tower is cooled.