Air dryer BPHE

In the world of industrial operations, ensuring the quality of compressed air is vital for maintaining system efficiency and preventing damage to equipment. Refrigerated air dryers play a crucial role in separating humidity from compressed air, effectively enhancing the performance of pneumatic systems. The AL series Air Dryer, utilizing brazed plate heat exchangers (BPHE), stands out as an innovative solution designed specifically for this purpose. By employing advanced cooling technologies, the AL series efficiently removes moisture from compressed air, leading to improved operational reliability and longevity of equipment.

This document delves into the functionality, applications, benefits, design specifications, and the operational efficiency of the AL series Air Dryer, illustrating its significance in the realm of compressed air drying.

How Refrigerated Air Dryers Work

Refrigerated air dryers are engineered to separate humidity from compressed air through a process that involves cooling. The cooling effect is generated by the evaporation of a refrigerant within an evaporator. As the compressed air passes through the evaporator, it cools down, reducing its capacity to hold moisture. This results in condensation, which is subsequently collected and expelled through a separator.

An essential component of the air dryer system is the heat recovery air-to-air heat exchanger. This device reheats the now-dry air back to ambient temperature, optimizing energy efficiency and preventing temperature drops in the air supply. The overall process ensures that the air leaving the dryer is not only free of moisture but also at a suitable temperature for further use.

The typical pressure drop on the air side of the system is between 20-30 kPa (approximately 3-4 psi), which is a crucial factor to consider when integrating these dryers into existing compressed air systems.

Applications

The AL series Air Dryer is primarily utilized in various industrial settings where compressed air is an essential component of operations. Some of the key applications include:

• Manufacturing Industries: Ensuring dry air for tools and equipment, preventing corrosion and malfunction.
• Food and Beverage Processing: Maintaining air quality to prevent contamination in production processes.
• Pharmaceutical Manufacturing: Guaranteeing clean and dry air to meet stringent regulatory standards.
• Automotive and Aerospace: Providing compressed air for pneumatic tools and systems where moisture can lead to defects.
• Textile Production: Supplying consistent and dry air to improve product quality and machine reliability.

These applications highlight the versatility and necessity of the AL series Air Dryer in maintaining operational efficiency across various sectors.

Benefits

The AL series Air Dryer offers a multitude of benefits, making it a preferred choice for industries requiring reliable moisture removal from compressed air. Here are some of the key advantages:

1. Compact Design

The AL series features a compact design that allows for easy integration into existing systems, saving valuable space in industrial environments. This feature is particularly important in settings where real estate is limited.

2. Easy Installation

The air dryers are designed for straightforward installation, minimizing setup time and reducing the associated costs. This ease of installation is crucial for businesses looking to implement new technologies without lengthy downtimes.

3. Self-Cleaning Properties

The brazed plate design minimizes fouling, allowing the air dryer to maintain efficiency over time. This self-cleaning characteristic reduces the need for frequent maintenance, enhancing overall system reliability.

4. Low Level of Service and Maintenance Required

With a robust construction and efficient design, the AL series requires minimal service and maintenance, translating to lower operational costs and reduced downtime for users.

5. Pressure and Leak Tested

All units undergo rigorous pressure and leak testing to ensure reliability and safety. This quality assurance process guarantees that the air dryers meet the highest industry standards before deployment.

6. Gasket-Free Design

The absence of gaskets reduces the risk of leaks and eliminates the need for gasket replacements during maintenance, further enhancing the reliability and ease of use of the AL series Air Dryer.

Design Specifications

The AL series Air Dryer is engineered with a focus on performance and efficiency. Here are the key design specifications:

Air Side Parameters

• Pressure: 7 bar(g)
• Dew Point Temperature: 3°C
• Pressure Drop (∆P): 20 kPa
• Inlet Temperature (T in): 35°C
• Outlet Temperature (T out): 27°C

Refrigerant Parameters

• Type: R134a
• Evaporating Temperature (T evap): 0°C
• Superheat (SH): 5K

Maximum Working Pressures

• Air Side: 16 bar(g) at 20°C
• Refrigerant Side: 35 bar(g) at 20°C

These specifications ensure that the AL series Air Dryer operates effectively within a wide range of conditions, making it suitable for various industrial applications.

Material Specifications

The construction materials used in the AL series are selected to ensure durability, corrosion resistance, and optimal performance:

• Main Parts: Stainless Steel – Provides excellent resistance to corrosion and wear, ensuring a long service life.
• Brazing Material: Copper – Known for its excellent thermal conductivity and strength, ensuring effective heat transfer between components.

Separator Efficiency Rate

The efficiency of the separator in the AL series Air Dryer is paramount for effective moisture removal. The separator is designed to capture droplets with an impressive efficiency rate of 95%, ensuring that the air exiting the dryer is consistently dry and suitable for use in various applications.

Mounting

The AL series Air Dryer is equipped with stud-bolts for secure mounting, providing flexibility in installation while ensuring stability and safety in operation.

Understanding Dew Point

The term “dew point” is critical in the context of air drying. It refers to the temperature at which water vapor in the air begins to condense into liquid water. For optimal operation, the dew point is typically maintained slightly above the freezing point of water, around 2-5 °C (35-40 °F). This careful control of dew point is essential in preventing moisture-related issues in compressed air systems, ensuring that the air delivered to the application is both dry and effective.

Conclusion

The AL series Air Dryer is an essential component for any industry that relies on compressed air for operations. Its advanced design, compactness, and low maintenance needs make it a highly efficient solution for separating humidity from compressed air. By leveraging the power of brazed plate heat exchanger technology, the AL series provides reliable and effective moisture control, contributing to improved system performance and longevity.

As industries continue to evolve and seek ways to enhance efficiency while reducing energy consumption, the AL series Air Dryer stands out as a valuable asset. Its ability to operate under various conditions, coupled with a focus on durability and efficiency, makes it the ideal choice for businesses aiming to maintain high standards in air quality.

For those looking to improve their compressed air systems and ensure the reliability of their operations, the AL series Air Dryer is the clear choice. Contact us today to learn more about how our air dryers can meet your specific needs and enhance your operational efficiency.