Compressors in pneumatic systems pull in ambient air, which always includes some water vapor. Compressing air to roughly 100 psi is ideal for enhancing not just the temperature of the air, but also its water-holding capacity and dew point. Any further cooling will very certainly cause some water vapor to simply condense.
In classic pneumatic systems, liquid water causes corrosion as well as bacteria development. Due to this, slow controls or component malfunctions get very common. To avoid such headaches, air dryers are often required to alleviate common water problems.
In a conventional system, the air is routed from the compressor to an aftercooler. As a result of this, the temperature is reduced and condensation is induced. The bulk water gets removed easily. Coalescing filters are sometimes used to remove excess water. However, if a circuit needs any further treatment, air dryers are regarded as the best option. They eliminate the majority of water in compressed air prior to it reaching key components or critical processes.
Here’s a look at the main kinds of sir dryers and their benefits.
The refrigerated dryer is the most common and widely used form of compressed air dryer. True to its name, a refrigerated air dryer works similarly to a home refrigerator. Both works by following a chilling mechanism to prevent moisture and are composed of quality Jalon molecular sieve for optimum performance.
The fundamental distinction is that the items or components being cooled are entirely different. A refrigerated air dryer maintains the quality of air in big industrial facilities. On the other hand, a household refrigerator cools and preserves perishable goods and drinks you like.
Compressed air is chilled to roughly 35 degrees Fahrenheit in a typical refrigerated dryer. The moisture in the air is taken and drained when it passes through the input valve. At the same time, freshly dry air is warmed by incoming air. The exiting trodden air has a dew point in the 35 to 40 degree Fahrenheit range at the conclusion of each cycle. Overall, the cooled dryer process offers a more hygienic working environment that is also much more suited to production.
Major Advantages of Refrigerant Dryers
Refrigerant dryers are commonly used because they provide a long list of various advantages, including:
- Refrigerant dryers are often quite affordable to install in major industries
- Refrigerated systems provide reduced operating and maintenance expenses to small firms
- Refrigerated systems are impervious to oil particles in the air
Though refrigerant dryers are a fantastic option for many sectors and enterprises, there are a few factors to consider, such as:
- These drying methods are not suggested for temperatures below freezing. This is because the moisture in the air might freeze and harm your massive machine
- Dryers that use refrigerants have a low dew point capacity
Non-Cycling Refrigerant Dryers
The refrigerant circulates indefinitely inside a non-cycling refrigerated dryer. This enables fast reactions to changes in the load, whether low or high moisture concentrations in the incoming air.
As a result, production facilities with steamy engines may be de-moisturized similarly to low-moisture conditions. A bypass or unloader valve controls the flow of the refrigerant the refrigerant is condensed with the help of a heat exchanger in the majority of the systems.
CFC refrigerants (R12 and R220) were employed in vintage refrigerant air dryers. But attitudes about such gases have shifted owing to worries about their environmental effect. As a result, a distinct variety of chlorine-free refrigerants is employed in contemporary refrigerant dryers.
A non-cycling refrigerant drier has two key advantages:
- A stable dew point and the capacity to operate continuously
- Non-cycling dryers do not save energy during times of low airflow due to their continuous operation
Cycling Refrigerant Dryers
Cycling refrigerant dryers employ refrigerant to cool that is responsible for surrounding the air channel. Sink then cools the compressed air. A cycle system, as opposed to a non-cycling refrigerant dryer, attempts to preserve energy during times, on the other hand, varies. Cycling refrigerant dryers have a large overhead cost as well, owing to their size and weight.
Chemical Air Dryers
Chemical dryers work by blowing compressed air over a bed of deliquescent chemicals. This happens until the chemicals become saturated with the excess moisture from the air. The compounds utilized in this special method have a natural ability to attract water. Some of the common examples are sodium, calcium chloride, and lithium.
These chemicals are then disposed of away with the water they have gathered after attracting and collecting moisture. As a result, having a high-quality filtering system in place is critical for the proper functioning of a chemical dryer. Otherwise, you risk these substances accumulating over time and creating compressor performance concerns as well as compressed air quality issues.
Benefits of Chemical Dryer System
- The functioning of these types of dryers is simple and needs minimal continual supervision
- There are no moving components to worry about at all
- Aside from the continuous expense of chemical replenishment, initial setup is often very low-cost
Some dryers dry compressed air using desiccant agents, which is a unique process known as adsorption. These are referred to as desiccant dryers. Adsorption differs from absorption in the following ways:
- Adsorption: Adsorption occurs when moisture binds to a desiccant without being dissolved.
- Absorption: Moisture is absorbed by a drying agent during absorption.
In the context of dryers, the term “desiccant” refers to two specific kinds of dryers which are also known as adsorption dryers and recreating dryers. The hygroscopic drying ingredient included inside desiccant dryers gives them their classic name.
Advantages of Desiccant Dryers
The following are the benefits of using a regenerative desiccant dryer:
- Low dew points are characteristic of regenerative desiccant dryers
- These dryers have a low cost of operation
- Desiccant dryers may be used in isolated and dangerous locations without any worries
Membrane Air Dryers
Membrane dryers are frequently used for dehumidification and gas separation applications. One of the most common examples is food processing. When compressed air makes it way to the membrane air dryer, the passage takes the gas right into the bundles of semi-permeable membrane fibers.
Certain materials, such as oxygen, may flow through the membrane. During the process, it gets separated from the desired gas by these fibers. These dryers are primarily intended for modest projects and single places of application.
Benefits of Membrane Air Dryers
- Membrane dryers do not need power, making them excellent for distance use
- The operation is more silent than that of other dryers
- They are simple and inexpensive to maintain