Compressed Gas Dryer Regeneration Using Heated Dried Gas
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Solution Overview
Problem
The existing dryer systems for compressed gas in compressor installations have suboptimal drying efficiency due to high humidity in the regeneration gas, limiting the drying agent's moisture absorption capacity and requiring costly heating of the entire gas flow for regeneration.
Innovation Solution
The system incorporates a heat exchanger to heat only the second regeneration gas flow, which has lower moisture content, allowing for deeper drying of the agent and improving efficiency without heating the entire gas flow, resulting in a more compact and energy-saving design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compressed gas is used for regeneration in the conventional way, then the drying agent can be regenerated, but the drying efficiency is limited due to high humidity in the regeneration gas
Solution Approach 1:
The regeneration zone is divided into two subzones: a first subzone where the drying agent contacts hot compressed gas for initial regeneration, and a second subzone where the drying agent contacts heated dried gas for deep drying. This segmentation allows different gas flows to serve different purposes in the regeneration process, improving overall drying efficiency while managing humidity levels effectively.
2Temperature
If a heating element is installed to raise the temperature of the compressed gas for regeneration, then the drying process improves, but the energy cost increases significantly
Solution Approach 1:
The system uses the compressor's own output gas to provide the heating function. The compressed gas, which is already hot from compression, is directed through the first subzone to regenerate the drying agent. Additionally, dried gas from the outlet is heated and used in the second subzone, eliminating the need for external heating elements and reducing energy costs.
Solution Approach 2:
The system recovers heat from the compressed gas that would otherwise be wasted. The hot compressed gas is utilized for regenerating the drying agent in the first subzone, and the dried gas is heated and used in the second subzone for deep drying. This heat recovery approach eliminates the need for additional heating elements and reduces energy consumption.
3Reliability
If the complete gas flow through the regeneration zone is heated, then the drying agent can remove more moisture, but the installation becomes larger and more energy-consuming
Solution Approach 1:
The regeneration zone is divided into two subzones, each handling different gas flows for specific purposes. The first subzone uses hot compressed gas for initial regeneration, while the second subzone uses heated dried gas for deep drying. This segmentation allows a smaller heat exchanger to heat only the dried gas stream rather than the entire gas flow, reducing installation size and energy consumption while maintaining effective moisture removal capacity.
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 enhances the drying agent's moisture absorption capacity, leading to improved dryer performance and increased efficiency by utilizing a smaller heat exchanger and reducing energy costs.
Implementation Method 1
the drying agent in this drying zone extracts moisture from said gas
Implementation Method 2
said hot gas desorbs the moisture present in the drying agent
Implementation Method 3
the second regeneration gas flow, before being guided through the second subzone, can be heated by means of said heat exchanger
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Compressed gas dryer, provided with a drying zone (3) and a regeneration zone (5), and a drum (9) rotatable in the housing (2) containing a drying agent (8) that is transferred successively through the drying zone (3) and the regeneration zone (5), whereby said regeneration zone (5) comprises a first subzone (6) having a first inlet to supply a first regeneration gas flow, and a second subzone (7) having a second inlet to supply a second regeneration gas flow of which the relative humidity is lower compared to that of the first regeneration gas flow; and that an outlet of said drying zone (3) is connected via a connection conduit (17) to the second inlet of the second subzone (7).