Compressed Gas Drying System With After-Cooler Regeneration
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Solution Overview
Problem
Heat-of-compression dryers face inefficiencies when the final stage compressed gas lacks sufficient heat to regenerate desiccant, leading to increased costs and complexity in compressor design, particularly with the removal of after-coolers and impact on compressor controls.
Innovation Solution
A system where the final stage compressed gas is directed to the dryer for desiccant regeneration, with the after-cooler remaining in the compressor to cool the entire gas flow before drying, avoiding additional heat exchanger costs and maintaining compressor control integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the after-cooler is removed from the compressor to reduce system complexity and cost, then the compressor design becomes simpler and less expensive, but the compressor control functionality is disrupted and the system reliability deteriorates
Solution Approach 1:
The patent introduces an intermediary cooling system that operates independently of the compressor's after-cooler. This intermediary system includes a separate heat exchanger and cooling mechanism that can cool the compressed gas without requiring the after-cooler to remain in place, thus maintaining compressor control functionality while allowing compressor design simplification
2Use of energy by moving object
If the final stage compressed gas is used to regenerate desiccant, then the drying efficiency is improved and energy consumption is reduced, but the heat from final stage compression is insufficient for effective desiccant regeneration
Solution Approach 1:
The patent merges the cooling function with the desiccant regeneration process by directing the cooled compressed gas (after intermediary cooling) to contact with the desiccant. This combination allows the system to both cool the gas and provide sufficient thermal energy for desiccant regeneration, overcoming the temperature insufficiency of final stage compression alone
Solution Approach 2:
The patent applies preliminary cooling to the compressed gas before it enters the desiccant regeneration zone. This preliminary action of cooling the gas first, then using it for regeneration, ensures that the gas is at the optimal temperature for effective desiccant regeneration, solving the problem of insufficient heat from final stage compression
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 allows for efficient desiccant regeneration using final stage compressed gas, reduces system costs, and maintains compressor control functionality, providing a cost-effective and efficient compressed gas drying solution.
Implementation Method 1
At the discharge of the final stage of compression a heat exchanger, often termed an 'after-cooler ', is provided in order to lower the temperature of the compressed gas to a suitable level
Implementation Method 2
The dryer 20 is connected to the compressor 22 immediately downstream of the first stage of compression, providing inter stage compressed gas to the dryer in order to regenerate desiccant in the dryer 20
Data Source
AI summary
A system for compressing and drying a gas generally includes a compressor having multiple stages of compression and a dryer. The compressor includes a first heat exchanger and an after-cooler each of which utilizes a fan. A sensor is provided downstream of the after-cooler. The fan and sensor are in communication with the controller. A final stage compressed gas outlet of the compressor provides hot compressed gas to the regenerative portion of the dryer. Utilization of the final stage compressed gas for regeneration while also utilizing the compressor's after-cooler provides gas which is sufficiently hot to regenerate desiccant in the dryer and allows the communication between the sensor, the controller and compressors to remain intact.