Roberto Costa Product Manager - e-compresoare.ro · If the temperature falls below its dew point,...

Roberto CostaProduct Manager

AD 7 up to 3780( Adsorption Dryer )

Modern industries require compressed

air that is increasingly filtered an low

in condensate with low dew points

DEW POINT

DEW POINT

What is the DEW POINT ?

The Dew Point is the value of the temperature than we

have the max. water vapour at one specific pressure.

If the temperature falls below its dew point, further

condensation takes place resulting in separation of

humidity and formation of condensate.

This method is based on the capacity of some “polymers

with cave microfibres” to filter the vapour molecules.

Application field is limited to small air flows :

(from 15-20 up to 800-1.000 l/min.)

MEMBRANE DRYERS

An innovative method

ADSORPTION IS ONLY A VALID ALTERNATIVE

It is very well known that water is solidifying at ZERO °C ,

so we can not cool down the compressed air to a value

equal or lower than ZERO °C.

But if we need to go down in order to remove more

humidity how do we do ?

REFRIGERATION

Method with a limit

This method is based on the principle of molecular attraction

between the “adsorption substance” and the water molecule in the

vapour present in the compressed air.

(NO cooling of the compressed air)

ADSORPTION DRYERS

ADSORPTION

DESSICCANT MATERIAL

PORES

DRY AIRHUMID AIR

ADSORPTION DRYERS

CONCEPT

Water molecules are transported into the pores through diffusion.Molecules are accumulated on the pore surface due to:

- physical binding ( attraction )

- chemical binding

- capillary-condensation

HUMID AIR DRY AIR

ADSORPTION DRYERS

ADSORBING MATERIAL CONTAINING TOWER

The air moving upward transfers

water molecules to the adsorbent

material and causes the saturation at

lower levels

The saturated material is loosing the

water retaining capacity, therefore

the air still humid is passing by the

higher levels still efficient.

A

Dry

erA

irW

etA

ir

ADSORPTION DRYERS

Over time the whole column

becomes saturated and the DP

value starts increasing.

Lower is the DP, lower is the

residual water content in the air

A

Dry

erA

irW

etA

ir

ADSORPTION DRYERS

Wet

Air

Once the set DP is reached, the flow

in the tower “A” is stopped.

but…….

Once the flow stopped we’re stopping

the production process; that is why

we need a second tower

A

Dry

erA

ir

ADSORPTION DRYERS

…we need a second tower

to guarantee a continuous

production cycle.

The primary flow is

switched over from tower

“A” to the second tower

“B”; and the cycle is

repeated without any

interruption of the flow.W

etA

ir

A

Dry

erA

ir

Wet

Air

B

Dry

erA

ir

ADSORPTION DRYERS

There are different types of regenerations:

- cold: only with air consumption for regeneration

- hot: with or without air consumption and with internal or externalresistence.

- under vacuum ect.

Regeneration is the phase in which the humidity accumulated in the adsoprtion material in the tower is taken out.

ADSORPTION DRYERS

REGENERATION

The regeneration of the sature (or humid) bed, is done using onlycompressed and dried air.

These dryers are also named

“HEATLESS Dryers ”

COLD RE-GENERATION

RE-GENERATION

The dry air to re-generate the adsorbing

material is taken out of the plant air inlet.

The dry air passing the bed (always with

molecular forces attraction) is re-

adsorbing the water particles retained in

the adsorbing material.

A

RE-GENERATION

The air needed for the re-generation is

vented in the atmosphere.

The quantity of regenaration air

needed depends on the nominal

capacity and on the type of

installation.

Average 15% of nominal capacity.

A

RE-GENERATION

In a complete cycle we’re identfying FOUR phases:

- two “active”

DRYING and RE-GENERATION

- two of “preparation”

DISCHARGE and PRESSURIZZATION

DRYING PRICESS DISCARGE RIGENERATION A

DISCARGE RIGENERATION DRYING PROCESS B

PRESSURE

PRESSURE

THE CYCLE

THE CYCLE

Keep always in mind:

- The humid tower regeneration occurs consuming compressed dried air.

- Air consumption needed for regeneration is always constant whatever the load condition (even when no compressed air is used).

THE CHOICE

FOUR are the essential data:

- Air flow

- Working pressure min. and max

- Air inlet temperature min. and max

- Requested Dew Point

THE CHOICE

- Installation environmental conditions

- End-user air quality requirements

- Supply voltage

- Technical documentation

THE CHOICE

For a correct sizing of the dryers it is also usefull to know:

THE RANGE - AD from 7 to 3780

AD 1400 up to 3780AD 650 up to 1300

AD 115 up to 470

AD 7 up to 60

Aluminium Extrusion : AD 7 up to 60

- compact execution

- simple design

- reduced foot print

FAD: 7,2 up to 60 m³/h. ( at 7 bar. )

std dew point: - 40°C.

derating 0,7: - 70 °C.

max. working pressure: 16 bar.

working pressure range: 4 - 16 bar.

Every unit has supreme application versatility.

All units can handle all electrical supplies and have all necessary approvals for pressures up to 16 bar.

- Desiccant: Molecular sieve supplied as standard , meaning -70°C. Pressure Dew Point (PDP) possible simply by reducing the inlet flow. ( see the correction factor )

- Purge nozzles: 3 extra nozzles included with each model for efficient performance at different working pressures.

- Maximum inlet pressure: 16 bar (all models)

- Max inlet temperature: 50°C

- Max ambient temperature: 50°C

- Electrical supply: 110-230/1/50(all models) 110-230/1/60

12-24 VDC


Versation, with Multi-Port system:

3 different air input

3 different air outlet.

This arrangement ensure easy and fast installation.


- It can be installed horizontally or vertically ( the filters have to stay in vertically position ).- it can stand on the floor or be mounted on a wall *

* Optional mounting kit available: code 8092 2608 53


The after filters are integrated in the desiccant cartridges:0.01 micronn.a. mg/mc

All units include a loose pre filter:0.01 micron0.01 mg/mc

- one pre-filter delivered loose with the dryer

( it have to be assembled directly on the dryer )

- one post-filter integrated on dryer

ELECTRONIC CONTROL SYSTEM

Each unit is fitted with an electronic control system, housed in

an IP65 box, which enables:

• Complete management of the dryer and cycle status

• Automatic fault diagnosis, including alarms

• Integrated timer solenoid drain for pre-filter



- 40°C. dew point with Activated Alumina

FAD: 115 up to 468 m³/h. (at 7 bar*)

max. working pressure: 14.5 bar.

working pressure range: 4 – 14.5 bar.

floor mounted kit as standard

Available in:

Timer Control and DP management system (Sensor ) as option

STANDARD

*For working pressure different from 7 bar use the correction factors.

- 70°C. dew point with Molecular Sieves

FAD: 81 up to 328 m³/h. (at 7* bar)

max. working pressure: 14.5 bar.

working pressure range: 4 – 14.5 bar.

floor mounted kit as standard

OPTION: - 70°C. derating 0,7

code at -70°C: 0000 0208 51



- Different desiccant have different levels of water attraction

- Greater is the attraction, better pressure dew point is possible, but more purge is

need to regenerate the desiccant.

- Most desiccant cannot provide a - 70°C.

- Desiccant that can provide a - 70°C. is much more expens ive

We don’t want the customer to pay for something that’s not needed

We balance performance with capital investiment and ong oing running cost

through purge air.

OPTION: - 70°C.

Molecular SievesSTANDARD: - 40°C.

Activated Allumina

WHY USE DIFFERENT DESICCANT ?

SensorTimer

Elect. Timer Control DP management system (Sensor)

OPTION : code 0000020850

IP54: leds are penetrating through cover IP65: the leds are under the cover

Purge air flow is fixed and it is about 15 % of the AD dryer capacity.

Regeneration cycle control by a fix time:

x sec. for drying cycle

x sec. for regeneration + pressurization cycle

Timer


Timer


It is done by measuring PDP of compressed air on the dryer outlet and switching the colums only when desiccant in active tower is saturated.

As most of the time compressor and dryer runs < 100% load, this result in significantextension of drying time = reduction in purge air consumption; saving on dryer runningcosts.

The elec. PDP control extending drying part of dryer’s cycle.

Regeneration + pressurization time stays fixed.

Sensor


OPTION : code 0000020850

Sensor


Pressure gauge: tower A

Pressure gauge: tower B


TIMER CARD – FREEZE CONTACT ( X3 connection )

If the compressor goes to unload, the dryer will finish its cycle over the drying tower and then freeze.

When the compressor goes to load again, the dryer restart over the other tower.

Contact closed: freeze

Contact open: not freeze


Air Outlet

Air Inlet

Purge control connectios ( as option )


Purge Nozzle

Air Outlet

Elect. cubicle


High efficiency silencer withintegrated safety valve

SILENCER

Air Inlet


DIMENSION (mm.)

A B H n. column

AD115 - 145 550 177 998 1

AD160 550 177 1243 1

AD215 - 250 550 378 999 2

AD325 550 378 1243 2

AD360 550 540 998 3

AD470 550 540 1243 3

AB

H


3 5

AD115 – 470 SF - DF

P.S. Filters are delivered loose with the dryer and theyhave to be mounted on the air distribution line.

Oil is affecting the adsorbing material reducing the efficiency.

SF 0.01 µm 0.01 mg/mc

DF 1 µm n.a. mg/mc

INSTALLATION


If the X3 connection is NOT used, the installation sequenceis: compressor - air receiver - dryer

If the X3 connection is used, the installation sequence is: compressor - dryer - air receiver

INSTALLATION



- FAD: 648 up to 1296 m³/h. (at 7* bar)



FAD: 774 up to 1548 m³/h. (at 12.5* bar)

max. working pressure: 14,5 bar.

working pressure range: 11 – 14,5 bar.


STANDARD

Available in:

Timer Control and DP management system (Sensor)

Welded Vessels : AD 650 up to 1300


FAD: 454 up to 907 m³/h. (at 7* bar)

FAD: 542 up to 1084 m³/h. (at 12.5* bar)

* For working pressure different from 7 bar use the

correction factors.

OPTION: - 70°C. derating 0,7( there is one part number for each size )


DP management ( Sensor )

Timer Control

IP54: leds are penetrating through cover IP65: the leds are under the cover


TIMER CARD – FREEZE CONTACT ( X3 connection )

If the compressor goes to unload, the dryer will finish its cycleover the drying tower and then freeze.

When the compressor goes to load again, the dryer restartover the other tower.

Contact closed: freeze

Contact open: not freeze


Pressure gauge tower A

Pressure gauge tower B

PDP sensor on dryer outlet( only in Sensor version )

PDP display

( only in Sensor version )


Stainless steel non-return valve

Purge nozzle for regeneration

Galvanized pipes


The AD range of dryers uses a self cleaning, integrated nozzle to control the amount of purge air used.This simple device is not only very reliable, but also maintenance free and self cleaning.

Regeneration air flow quantity is fixed and

can not be modified.

It is defined by requirements of the

application.

Purge Nozzle


Stainless steel3 - way inlet valve

Pneumatic actuator

Stainless steel inlet valve used to ensure long service

3 - way inlet valve


Air Inlet

Pneumatic actuators

High efficiency silencer withintegrated safety valve

At the cycle reversal, the humid tower in pressure is discharged causing noise.

Mufflers reduce this noise during tower depressurizing and during purge.

Silencer


Fork lift slots

Holes for anchoring

Air Outlet

Air Inlet


DIMENSION (mm.)

A B H

AD 650 - 800 960 754 1716

AD 1080 1064 833 1832

AD 1300 1118 859 1869

AB

H


3 4 5

AD650 - 1300 MF SF - DF

Oil is affecting the adsorbing material reducing the efficiency.

P.S. Filters are delivered loose with the dryer and theyhave to be mounted on the air distribution line.

MF 0.1 µm 0.1 mg/mc

SF 0.01 µm 0.01 mg/mc

DF 1 µm n.a. mg/mc

INSTALLATION


If the X3 connection is not used, the installation sequence is: compressor - air receiver - dryer

If the X3 connection is used, the installation sequence is: compressor - dryer - air receiver

INSTALLATION



FAD: 1404 up to 3780 m³/h. (at 7* bar)


( for AD3780 is at 9 bar.)


STANDARD

* For working pressure different from 7 bar use the correction factors.

Available in:

Timer Control and DP management system (Sensor)



FAD: 983 up to 2646 m³/h. (at 7* bar)

* For working pressure different from 7 bar use the correction factors.

OPTION: - 70°C. derating 0,7


DP management ( Sensor )

Timer Control


FEW CONNECTIONS

for a quick and low cost installation

INSTALLATION

Every 4000 running hours or yearly:

replace the filters cartridges and silincers.

Every 40000 running hours or 5 years:

replacement of the desiccant cartridges.

MAINTENANCE : AD7 up to 3780

Without PDP sensor :

With PDP sensor :

Same maintenance plus:

Every 8000 running hours or yearly :

recalibration of the PDP sensor.

- Compact execution

- Easy transportation

- Low pressure drop

- Low operational costs

- Easy maintenance

- Wide range and many available versions

- Reliability of a big name

SUMMERY

ADVANTAGES

Adsorption dryers are necessary in all processes where a

Dew Point in pressure lower than zero centigrade is needed

SUMMARY

APPLICATION

APPLICATIONS

ISO 8573.1

DEGREE OF PURITY OF AIR BY ISO 8573.1

They are NOT in competition

Each dryers has :

- his application

- a specific market

ADQ - AD

SUMMARY COMPETITION

- No 3 way valves used, instead butterfly valves are installed which only have a partial opening, causing pressure drop.

- None of the valves are stainless steel, so are susceptible to corrosion and accelerated wear.

- Towers are tall and thin – beware high speeds and short contact time

- Blow off silencers do not have an integrated safety valve

- The purge rate is quite high when you compare the real technical data. Typically the units are consuming around 19%-20% of the inlet flow.

- Unit must be removed from pipe work in order to perform maintenance

- PDP control included as standard but not a digital readout of the PDP

- The dryer can be mounted vertically but NOT horizontally- The unit can only be floor mounted, wall mounting is not possible- No multi port inlet and outlet connections, single inlet/outlet only- Design includes integrated pre and after filters

69

THANK YOU FOR YOUR ATTENTION

Date post:	30-Jun-2018
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Roberto Costa Product Manager - e-compresoare.ro · If the temperature falls below its dew point,...

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