Integrated Air Dryer Assembly for Moisture Separation in One Vessel
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Solution Overview
Problem
Compressor systems face challenges in delivering substantially dry compressed air, as moisture can cause damage or corrosion in machinery and tools, and existing air dryers are not effective in fully separating entrained liquids from gas within a single pressure vessel.
Innovation Solution
A dryer system within a single pressure vessel that includes a precooler/reheater and an evaporator to cool and separate the gas and entrained liquid, with a separator to produce substantially dry gas, and a drain valve to manage liquid collection, utilizing a corrugated plate design for enhanced heat transfer and flow separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional air dryer is used, then the structure is simple, but the separation effectiveness of entrained liquid from gas is insufficient
Solution Approach 1:
The air dryer is divided into multiple functional zones: a precooler section, an evaporator section, and a separator section. Each zone performs a specific function in the moisture removal process, with the precooler condensing moisture, the evaporator further cooling and separating moisture, and the separator collecting liquid while allowing dry gas to pass through.
Solution Approach 2:
The precooler and evaporator are nested within the same pressure vessel, with the precooler positioned at the bottom and the evaporator above it. The separator is also integrated into the same vessel structure, creating a compact multi-functional system where components are arranged concentrically or in sequence within the vessel volume.
2Reliability
If moisture is not effectively removed, then the system structure remains simple, but corrosion and damage occur in machinery and tools
Solution Approach 1:
The precooler performs preliminary cooling and condensation of moisture from the compressed air before the gas enters the evaporator section. This preliminary action removes a significant portion of moisture early in the process, preventing corrosion before it can occur in downstream machinery and tools.
Solution Approach 2:
The separator acts as an intermediary component that collects liquid moisture in a separate chamber while allowing the dry gas to pass through to the outlet. This intermediary separation mechanism ensures that moisture is removed from the gas stream without complicating the overall system architecture.
3Volume of moving object
If the pressure vessel contains all components, then the system is compact, but heat transfer efficiency may be reduced
Solution Approach 1:
The precooler and evaporator utilize vertical stacking within the pressure vessel, with the precooler at the bottom and the evaporator above it. This vertical arrangement in the third dimension allows both heat exchange components to be included in a compact footprint while maintaining adequate heat transfer surface area and flow paths.
Solution Approach 2:
The corrugated plates in the evaporator create localized turbulence and extended surface area for heat transfer in specific regions. This local quality enhancement ensures efficient heat exchange within the constrained volume of the integrated system.
4Temperature
If corrugated plates are used in the evaporator, then heat transfer is enhanced, but manufacturing complexity increases
Solution Approach 1:
The evaporator employs corrugated plates with specific geometric parameters (wave patterns, amplitude, wavelength) that are optimized for heat transfer performance. By carefully selecting and standardizing these geometric parameters, the design achieves enhanced heat transfer while remaining compatible with conventional manufacturing processes.
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
Effectively separates moisture from compressed air, ensuring the delivery of dry air while reducing corrosion risks and optimizing the system's efficiency by preheating the dry gas and using a thermal sink for enhanced cooling, thus improving the reliability and longevity of machinery and tools.
Implementation Method 1
A precooler/reheater is positioned within the pressure vessel to receive and cool the flow of gas and the entrained liquid from the inlet
Implementation Method 2
an evaporator is positioned within the pressure vessel to receive and cool the flow of gas and the entrained liquid from the precooler/reheater
Implementation Method 3
A separator is positioned to receive the flow of gas and the entrained liquid from the evaporator. The separator is operable to separate the flow of gas and the entrained liquid into a flow of substantially dry gas and a liquid
Implementation Method 4
The liquid collects in the bottom of the pressure vessel, and the flow of substantially dry gas flows upward through the precooler/reheater to heat the flow of substantially dry gas and out the gas outlet
Data Source
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AI summary
A dryer operable to separate a portion of an entrained liquid from a flow of gas includes a pressure vessel operable to contain the flow of gas and entrained liquid within the pressure vessel at a full operating pressure. The pressure vessel including a gas inlet, a gas outlet, and a drain positioned at a bottom of the pressure vessel. A precooler/reheater is positioned within the pressure vessel to receive and cool the flow of gas and the entrained liquid from the inlet and an evaporator is positioned within the pressure vessel to receive and cool the flow of gas and the entrained liquid from the precooler/reheater. A separator is positioned to receive the flow of gas and the entrained liquid from the evaporator. The separator is operable to separate the flow of gas and the entrained liquid into a flow of substantially dry gas and a liquid. The liquid collects in the bottom of the pressure vessel, and the flow of substantially dry gas flows upward through the precooler/reheater to heat the flow of substantially dry gas and out the gas outlet. A drain valve is movable between an open position and a closed position in response to the quantity of liquid within the bottom of the pressure vessel. The liquid in the bottom of the pressure vessel exits via the drain when the drain valve is in the open position.