Integral Sweep Controller for Membrane Dryer
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Solution Overview
Problem
Conventional membrane dryers continuously sweep compressed air, leading to resource wastage and membrane fiber stress due to pressure cycling, which increases operational costs and reduces membrane lifespan.
Innovation Solution
An integral sweep controller is integrated into the membrane dryer, featuring a solenoid valve and sweep manifold to control the sweep flow selectively, eliminating continuous purging and pressure cycling, and allowing the membrane to be swept only when product is drawn, thus reducing energy consumption and extending membrane life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous sweep is used to increase pressure differential and improve dryness, then productivity and product quality are improved, but energy consumption increases and substance is lost
Solution Approach 1:
The patent implements periodic sweep action by cycling the sweep valve between open and closed positions. The controller periodically opens the sweep valve to allow sweep flow through the membrane, then closes it to build pressure differential. This periodic operation maintains membrane productivity while reducing continuous energy consumption and substance loss associated with constant sweeping.
Solution Approach 2:
The system dynamically adjusts sweep flow by controlling the sweep valve based on operating conditions. The controller monitors system state and modulates the sweep valve opening/closing timing and duration, creating dynamic operation that optimizes both productivity and energy efficiency rather than maintaining fixed continuous sweep.
2Loss of energy
If pressure cycling is used to control sweep flow, then energy consumption is reduced, but the membrane fibers are stressed and reliability decreases
Solution Approach 1:
The patent extracts the pressure cycling function from the membrane system itself and relocates it to the sweep valve control mechanism. By cycling the sweep valve rather than cycling pressure directly across the membrane, the system achieves energy savings without subjecting membrane fibers to damaging stress cycles, thereby maintaining reliability.
Solution Approach 2:
The sweep valve acts as an intermediary between the control system and the membrane. Instead of directly applying pressure cycles to the membrane to control sweep flow, the valve mediates the process by modulating sweep gas flow, indirectly achieving energy efficiency while protecting the membrane from direct stress.
3Productivity
If continuous purging is used to maintain membrane performance, then productivity is improved, but substance loss increases
Solution Approach 1:
The system uses periodic sweep valve operation to maintain membrane performance without continuous purging. By cycling the sweep valve to open only when needed to remove accumulated condensate or maintain performance, the system achieves necessary membrane functionality while dramatically reducing continuous compressed air loss compared to constant purging operations.
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 reduces energy consumption by sweeping the membrane only when necessary, minimizing resource wastage and preventing premature membrane fiber failure, thereby lowering operational costs and extending the membrane's lifespan.
Implementation Method 1
Compressed air may be moved through a bundle of hollow fibers, which may be composed of a membrane specifically designed to attract water vapor. Thus, as compressed air passes through the membrane, the water vapor is absorbed on the inside of the fibers and passes quickly to the outer layers of the membrane.
Implementation Method 2
An integral sweep controller is integrated into the membrane dryer, featuring a solenoid valve and sweep manifold to control the sweep flow selectively
Data Source
AI summary
A method and apparatus are provided for controlling the amount of purging that occurs within a membrane separation device. The membrane separation device includes a membrane separation component and sweep controlling component. Within the membrane separation component, a major portion of the non-permeate gas is sent out of the membrane separation device to work, while a minor portion is diverted for use as a sweep gas. The sweep gas is controlled by a valve that cycles with a device, such as a compressor. Thus, the membrane separation device is on when the compressor is on and is off when the compressor is off. As such, the membrane separation device is not required to sweep at all times.