Process Gas Preparation Device with Relative Humidity Sensor
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Solution Overview
Problem
Existing process gas preparation devices face challenges with high energy consumption and long cooling times, particularly during the drying and cooling phases of process materials.
Innovation Solution
The implementation of a process gas preparation device equipped with a relative humidity sensor and temperature sensor to control device components independently, utilizing a condenser dehumidifier and adsorber dehumidifier for precise dehumidification, and a bypass unit with a cooling unit to reduce energy consumption and cooling times by optimizing the flow through the tempering unit during the cooling phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a process gas preparation device is used to dehumidify and cool process gas, then the process gas is prepared for treating process material, but the energy consumption is high and cooling times are long
Solution Approach 1:
The process gas preparation device is divided into separate functional sections: a dehumidification section with condenser and adsorber dehumidifiers, and a tempering section with heating and cooling units. This segmentation allows each component to operate independently and efficiently, dehumidifying the process gas first before tempering, thereby reducing overall energy consumption compared to mixed-operation systems.
Solution Approach 2:
The device changes the parameters of process gas systematically: first temperature and humidity are adjusted in the dehumidification section (condenser cools to dew point, adsorber removes moisture), then further temperature adjustment occurs in the tempering section. This staged parameter change approach optimizes energy usage by addressing humidity removal before temperature adjustment.
2Manufacturing precision
If a process gas preparation device is used to dehumidify and cool process gas, then the process gas is prepared for treating process material, but the cooling times are long
Solution Approach 1:
The preparation device separates dehumidification and cooling functions into distinct sections. The dehumidification section (condenser + adsorber) prepares the gas by removing moisture first, then the tempering section's cooling unit rapidly cools the pre-dehumidified gas. This segmentation reduces cooling time because the gas is already partially prepared and has lower moisture content before cooling begins.
Solution Approach 2:
The dehumidification section performs preliminary action by removing moisture from the process gas before it enters the cooling section. The condenser cools the gas to its dew point and the adsorber further dehumidifies it, preparing the gas in advance for the rapid cooling phase. This preliminary dehumidification action significantly reduces the time required for subsequent cooling.
3Use of energy by moving object
If device components are controlled independently based on sensor signals, then energy consumption is reduced, but the device complexity increases
Solution Approach 1:
The device incorporates sensors (humidity sensor, temperature sensor) that continuously monitor process gas conditions and feed signals to the control unit. The control unit independently regulates each device component (condenser, adsorber, heating unit, cooling unit) based on real-time sensor feedback, enabling precise control that reduces energy consumption while managing complexity through automated regulation.
Solution Approach 2:
The control unit serves as a universal control element that manages multiple device components through a single integrated system. Rather than requiring separate control mechanisms for each component, the universal control unit receives sensor inputs and coordinates the operation of dehumidification and tempering sections, reducing overall control system complexity while maintaining independent component regulation.
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 solution significantly reduces energy consumption and shortens cooling times for process gases, enhancing the efficiency of the process gas preparation process by enabling precise control and flexible operation of device components based on real-time humidity and temperature measurements.
Implementation Method 1
The condenser dehumidifier designed as a condenser is dimensioned preferably such that the process gas can be cooled to approximately 8° C. when using cooling water. This lowers the relative humidity of the process gas, which causes it to dry.
Implementation Method 2
an adsorber dehumidifier designed as a device component, having an adsorber dehumidifier inlet and an adsorber dehumidifier outlet
Data Source
AI summary
A process gas preparation device for a process gas for treating a process material in a process apparatus and a procedure for preparing process gas to treat a process material in a process apparatus during a drying phase and a cooling phase. The device includes a process gas dehumidifier and a relative humidity sensor to measure the relative humidity of the process gas arranged upstream of the process gas dehumidifier.