project title (50pt) lorem ipsomAn Innovative Solution to Save Energy, Improve Reliability and Reduce Maintenance Cost
Abdulmajeed Alshaye, Saudi Aramco
• Objective
• High air temperature effect on desiccant dryer
• Hybrid dryer configuration
Saudi Aramco: Company General Use
To share with you a new concept of compressed air drying:
• Use the minimum amount of energy to operate
• Ensure a constant, low and reliable outlet dew point
• Safe failure mode
Objective
4
Introduction to IA
After filter
PA
IA
5
Introduction to IA
[CATEGOR Y NAME] [VALUE]
[CATEGOR Y NAME] [VALUE]
10%
1 hp (Final use) 10 hp (Motor) 30 hp (Power plant)
=
Q. How much compressed air cost us?
6
Challenges with IA
• Header pressure fluctuation (15%)
• Frequent dryer valves failures
0
2000
4000
6000
8000
10000
12000
14000
8
0
10
20
30
40
50
60
70
: : : : : : : : : : : : :
De w
p oi
Challenges with IA (dew point)
9
90
95
100
105
110
H ea
de r
pr es
su re
Dryer pre-filter Dryer after filter Dryer after filter Plant instruments
11
12
High air temperature effect (dryer Inlet)
1. High energy consumption
2. Dryer valve malfunctioning
3. Short desiccant life
13
High air temperature effect (dryer Inlet)
90
100
110
120
130
140
14
High air temperature effect (dryer Inlet)
15
47.1
32.2
24.6
19.61
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0

W at
er c
on te
nt g
al /h
Air water content for 5,000 scfm at 132 PSIA
High air temperature effect (Dryer Inlet)
16
Hybrid dryer configuration
1. Precooling the compressed air before the desiccant dryer
2. Utilize a external purge heated type desiccant dryer
Working In
Hybrid dryer configuration
To IA 250°F 70°F 140°F
250° F
[VALUE]° F
50
100
150
200
250
300
Ai r
te m
PDP:5°F
Traditional dryer configuration
• Heatless dryer design
• Purge losses > 20%
• Using single aftercooler
Hybrid dryer configuration
• High capital cost
• High pressure drop
22
Hybrid dryer configuration (aftercooler)
Hybrid dryer configuration (benefits)
1. Reduce the compressed air losses in the utility to less than 2% (now 30-50%).
2. Increase the desiccant dryer switching time from 5 minutes to 48 hours.
3. Significantly improve the quality of the delivered instrument air dew point.
4. Provide dry air for plant air application.
5. Reduce the maintenance cost.
6. Increase instrumentation reliability.
7. Minimize process interruption.
9. Reduce instrument air pressure fluctuation.
10. Condense the majority of harmful gases in the air.
24
Summary
• Compressed air is inherently energy inefficient
• Hybrid dryer design is well suited for hot and humid locations
• Benefits: Energy, Safety, Reliability, Environment, Asset integrity
Availability, Maintenance cost and Compliance
• Flexible operation
• Potential energy saving (kingdom): 150 Mw
25
Thank you
High air temperature effect (dryer Inlet)
High air temperature effect (dryer Inlet)
High air temperature effect (dryer Inlet)
High air temperature effect (Dryer Inlet)
Hybrid dryer configuration
Hybrid dryer configuration
Traditional dryer configuration
Hybrid dryer configuration
Hybrid dryer configuration
Hybrid dryer configuration (aftercooler)
Hybrid dryer configuration (benefits)