Compressed Gas Dryer With Intermediate Zone to Prevent Dew Point Peaks
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Solution Overview
Problem
Existing dryers for compressed gas face inefficiencies in energy consumption and dew point control, particularly during startup, due to incomplete utilization of heat of compression and potential leaks leading to dew point peaks.
Innovation Solution
A dryer design with a vessel having a drying zone, regeneration zone, and an intermediate zone, where the entire gas flow is first directed through the regeneration zone and then the drying zone, utilizing a blower in a tap-off pipe to create a pressure increase for the intermediate zone, which acts as a buffer to prevent leaks and enhance drying efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the entire compressed gas flow is guided through the regeneration zone and then through the drying zone, then the heat of compression is fully utilized for regeneration and the drying efficiency is improved, but the risk of moist gas leaking to the dryer output increases, causing dew point peaks
Solution Approach 1:
The dryer is divided into three distinct zones: regeneration zone, intermediate zone, and drying zone. The intermediate zone acts as a buffer between the regeneration and drying zones, preventing direct communication that could allow moist gas to leak to the output. This segmentation maintains the full-flow configuration for energy efficiency while eliminating the reliability issue of dew point peaks.
Solution Approach 2:
The intermediate zone serves as an intermediary buffer between the regeneration zone and drying zone. It receives gas from the regeneration zone, allows cooling and condensation, and then feeds to the drying zone. This intermediary prevents direct leakage pathways while maintaining the beneficial full-flow configuration.
2Reliability
If a blower is installed in the connecting pipe between the regeneration zone outlet and drying zone inlet to increase gas pressure and prevent leaks, then dew point control is improved, but the device complexity and energy consumption increase
Solution Approach 1:
The blower is extracted from the main connecting pipe and relocated to the tap-off pipe leading to the intermediate zone. This reduces the complexity of the main gas flow path while still providing the necessary pressure increase to prevent leaks through the intermediate zone buffer.
Solution Approach 2:
Instead of pressurizing the entire main gas flow through a large blower in the connecting pipe, a smaller blower copies the essential function by pressurizing only the intermediate zone feed through the tap-off pipe. This achieves the same leak prevention effect with reduced device complexity and lower energy consumption.
3Productivity
If a cooling zone is added between the regeneration zone and drying zone to cool the gas and condense moisture, then the drying efficiency is improved, but the device complexity and space requirements increase
Solution Approach 1:
The cooling and condensation functions are merged into the intermediate zone, which combines the cooling zone and condensate separator into a single integrated chamber. This eliminates the need for separate cooling equipment and reduces device complexity while maintaining improved drying efficiency through effective moisture condensation.
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 configuration optimizes energy consumption, ensures deep drying of the gas, and prevents dew point peaks by utilizing the heat of compression effectively and maintaining high dryer efficiency across various conditions, including startup scenarios.
Implementation Method 1
The hot compressed gas is first guided through the regeneration zone where it acts as a regeneration gas... After passing through the regeneration zone the hot regeneration gas presents a higher relative humidity. The moist gas that leaves the regeneration zone is then guided through a cooler in the connecting pipe such that the temperature of this gas falls below the pressure dew point
Implementation Method 2
The droplets hereby formed are then removed by means of the condensate separator such that the now cooled, compressed gas is 100% saturated
Implementation Method 3
whereby the aforementioned outlet of the regeneration zone and any cooling zone is connected to the aforementioned inlet of the drying zone by means of a connecting pipe with a cooler and condensate separator therein, and whereby these dryers are configured such that, during the operation of the dryer, the gas flow rate that leaves the regeneration zone via the outlet of the regeneration zone is equal or practically equal to the gas flow rate that is then guided into the drying zone via the inlet in order to be dried
Implementation Method 4
whereby the aforementioned outlet of the regeneration zone and any cooling zone is connected to the aforementioned inlet of the drying zone by means of a connecting pipe with a cooler and condensate separator therein, and whereby these dryers are configured such that, during the operation of the dryer, the gas flow rate that leaves the regeneration zone via the outlet of the regeneration zone is equal or practically equal to the gas flow rate that is then guided into the drying zone via the inlet in order to be dried
Data Source
AI summary
A dryer for a compressed gas provided with a vessel with a drying agent and a drying zone-and a regeneration zone; at least one intermediate zone that, viewed in the direction of rotation of the drum, is situated between the regeneration zone and the drying zone and which is provided with a separate inlet and an outlet that is shared with or connected to the outlet of the regeneration zone; a tap-off pipe that branches off from the outlet of the drying zone and connects to the aforementioned separate inlet of the intermediate zone; one or more blowers in the tap-off pipe for effectuating an intermediate flow from the drying zone, where the dryer is configured such that the entire flow of gas to be dried supplied to the dryer is first guided through the regeneration zone.