Compressed Gas Dryer Flow Split to Prevent Dew Point Peaks
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Solution Overview
Problem
Existing compressed gas dryers face inefficiencies in energy consumption and dryer performance, particularly during startup, leading to potential dew point peaks due to insufficient pressure buildup and leaks between the regeneration and drying zones.
Innovation Solution
A dryer design with a vessel containing a drying zone, regeneration zone, and intermediate zone, utilizing a rotatable drum with a regenerable drying agent, and a control system with sensors and blowers to manage pressure differences and prevent leaks, ensuring deep drying and efficient gas flow through intermediate zones for optimized energy use and reduced dew point peaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the entire compressed gas flow is guided through the regeneration zone and then through the drying zone (full-flow operation), then the drying agent is effectively regenerated using heat of compression, but during startup insufficient pressure buildup occurs leading to leaks between zones and dew point peaks
Solution Approach 1:
The gas flow is segmented into two paths: a first portion (e.g., 10-40%) is directed through the regeneration zone to build pressure, while a second portion (e.g., 60-90%) is directed through the drying zone for drying. This segmentation allows the system to overcome the contradiction by separating the pressure-building function from the drying function during startup conditions
Solution Approach 2:
The system dynamically adjusts the flow distribution between the regeneration zone and drying zone based on operating conditions. During startup when pressure is insufficient, more flow is directed to the regeneration zone to build pressure. Once pressure is sufficient, the flow distribution shifts to optimize drying performance. This dynamic adjustment resolves the contradiction between energy efficiency and reliable operation
2Reliability
If pressure increase means are provided in the tap-off pipe to prevent leaks from regeneration zone to drying zone, then dew point peaks are prevented, but device complexity increases
Solution Approach 1:
The system uses the compressed gas itself to build the necessary pressure in the regeneration zone, eliminating the need for external compressors or complex pressure control devices. The gas flow through the regeneration zone naturally builds pressure to prevent leaks, making the system self-sufficient and reducing complexity
Solution Approach 2:
The pressure-building function is merged with the existing gas flow through the regeneration zone. Instead of adding separate pressure increase means, the system utilizes the natural pressure buildup from compressing the first portion of gas through the regeneration zone, combining multiple functions into a single flow path
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 solution achieves high dryer efficiency, reduces energy consumption, and prevents dew point peaks by ensuring the entire gas flow is processed efficiently, maintaining low relative humidity and reliable operation across various conditions.
Implementation Method 1
The hot compressed gas is first guided through the regeneration zone where it acts as a regeneration gas and absorbs moisture from the drying agent for the regeneration of this drying agent
Implementation Method 2
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 and condensation of the moisture present in this gas occurs. The droplets hereby formed are then removed by means of the condensate separator
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
the drying agent extracts moisture from this compressed gas by means of sorption (adsorption and/or absorption)
Implementation Method 5
drive means for rotating the aforementioned drum such that the drying agent is successively moved through the drying zone and regeneration zone
Data Source
Figure 1
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Figure 3
AI summary
Dryer for a Compressed gas provided with a vessel (2) with a drying agent and a drying zone (7) and a regeneration zone (8); at least one intermediate zone (9) that, viewed in the direction of rotation (R) of the drum (3), is situated between the regeneration zone (7) and the drying zone (5) and which is provided with a separate inlet (24) and an outlet that is shared with or connected to the outlet (15) of the regeneration zone (8); a tap-off pipe (22) that branches off from the outlet (19) of the drying zone (8) and connects to the aforementioned separate inlet (24) of the intermediate zone (9); means for effectuating an intermediate flow from the drying zone (7), through the tap- off pipe (22), to the intermediate zone (9), whereby 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 (8) before flowing through the drying zone (7), characterised in that the aforementioned means are only formed by one or more blowers (25) in the aforementioned tap-off pipe (22).