Single-Header Glycol Distribution for Consistent Dryer Dew Points

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Solution Overview

Problem

Compressed air systems face inefficiencies due to variable dew points and inconsistent drying when multiple dryer modules operate with differing cooling medium temperatures, especially during maintenance or failure of one or more modules, leading to performance inconsistencies and energy inefficiencies.

Innovation Solution

A system with a single cooling medium header distributes cooling medium to multiple dryer modules, ensuring uniform temperature through a common storage tank and circulation pumps, maintaining consistent dew points and continuous operation even when modules are inactive.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple dryer modules operate with individual cooling medium circulation, then each module can be independently controlled, but variable dew points and inconsistent drying performance occur due to differing cooling medium temperatures

Engineering Contradiction:

Improveindependent module operationVSAvoiddrying performance consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the cooling medium circulation systems of multiple dryer modules into a single shared circulation system. A common cooling medium header and circulation pump serve all dryer modules, ensuring uniform cooling medium temperature distribution. This consolidation eliminates temperature variations between modules while maintaining independent operational control through individual module valves and controls.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of repair

If one or more dryer modules are inactive or de-energized for maintenance, then maintenance activities can be performed, but cooling medium temperature varies and dew point becomes inconsistent across active modules

Engineering Contradiction:

Improvemodule maintenance capabilityVSAvoiddew point consistency

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

By consolidating cooling medium circulation into a shared system with a common header and circulation pump, the patent ensures that all active dryer modules receive cooling medium at the same temperature regardless of which modules are active. This unified approach maintains consistent dew points across all operating modules even when some modules are taken offline for maintenance.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If individual cooling medium circulation is used for each dryer module, then module independence is maintained, but energy inefficiencies occur due to temperature variations and redundant circulation

Engineering Contradiction:

Improvemodule independenceVSAvoidcooling medium energy efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent merges individual cooling medium circulation systems into a single shared circulation system. A common cooling medium header and circulation pump replace multiple individual circulation pumps, reducing redundant energy consumption. The shared system distributes cooling medium uniformly to all active modules, eliminating energy waste associated with temperature variations and multiple independent circulation systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common cooling medium circulation system serves multiple dryer modules simultaneously, providing universal functionality. The single circulation pump and cooling medium header can supply cooling medium to any combination of active modules, replacing the need for dedicated circulation systems in each module and improving overall energy efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Ensures consistent drying performance and energy efficiency by maintaining uniform cooling medium temperature across all dryer modules, reducing downtime and energy consumption.

Implementation Method 1

heat exchange systems to remove moisture through condensation of moisture and separation of the condensation from the flow of compressed air. The heat exchange systems can circulate a cooling medium, such as water, glycol, synthetic refrigerant, or the like, to cool a flow of compressed air and heat the cooling medium.

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The heated cooling medium can then be discarded or chilled to provide cooling for future applications.

Methodology Applied

Scientific EffectHeat transfer: Convection

Data Source

PatentUS12440803B2Systems and methods for single header glycol distribution for multiplexed heat exchangers

Publication Date: 2025.10.14 INGERSOLL RAND IND US INC

AI summary

Cooling medium circulation systems for supplying a cooling medium through a single header to multiplexed heat exchangers are described. In an aspect, a system includes, but is not limited to, a storage tank configured to hold a cooling medium in a fluid state; first and second circulation pumps fluidically coupled to the storage tank; a single cooling medium header fluidically coupled with each of the circulation pumps; a first dryer module configured to direct a first portion of cooling medium from the single cooling medium header past a first stream of compressed air and to direct the first portion of cooling medium back to the storage tank; and a second dryer module fluidically configured to direct a second portion of cooling medium from the single cooling medium header past a second stream of compressed air.