Unlock the Power of Dry Air with Desiccant Dryers in Compressed Air Systems
November 13, 2024
Atmospheric air always contains some moisture in the form of water vapor. In compressed air, it has the potential to cause problems. For critical installations where a higher dew point / dry air is required adsorption dryers are best suited as solution to keep up the application needs.
Types of compressed air contaminants
Taking the atmosphere first, in a typical metropolitan environment these are something like 140*10 dirt particles per cubic meter. Approximately 80% of them are less than 2 microns and are not removed by the compressor intake filter. In addition to this there are hydrocarbon vapors from unburnt fuels and industrial processes and water vapor. All these are drawn into the compressor and their concentration increased by compression process. Inside the compressor, wear particles and lubricating oil are added to the air. Also, degraded & oxidized oil from an oil injected compressor travels in the distribution system.
Ultimately, untreated air can lead to premature failure of pneumatic equipment, product rejections, leakages in distribution channels and subsequently shorter life due to corrosion. Choosing right desiccant dryer is therefore essential to protect production processes, maintain the quality of end products and minimize energy costs.
Benefits of Using Desiccant Dryers
- Low Dew Point: Desiccant dryers can achieve dew points as low as -40°C, which is essential for preventing water condensation, especially in cold environments.
- Protection of sensitive equipment: Dry air prevents corrosion and maintains the integrity of pneumatic controls and instrumentation.
- Improved product quality: Moisture-sensitive manufacturing processes, such as in pharmaceuticals or electronics, benefit from the consistent quality of dry air.
Considerations for Desiccant Dryers
- Energy consumption: Desiccant dryers can be more energy-intensive than refrigerated dryers due to the regeneration process.
- Maintenance: Regular replacement of desiccant material and filters is necessary to maintain dryer efficiency.
- Cost: The initial investment and operating costs are generally higher compared to other types of dryers.
Regeneration Process
Regeneration of the desiccant material is vital for the continuous operation of the dryer. This can be achieved through:
- Pressure Swing Adsorption (PSA): Fluctuating pressure levels within the towers to release moisture.
- Heated regeneration: Using heated air to purge moisture from the desiccant.
- Blower purge: Employing an external blower to provide heated air for regeneration.
Industry Applications
1. Manufacturing Industry
Application: Used for drying compressed air to prevent contamination and corrosion in pneumatic equipment.
Benefits:
- Ensures quality production by reducing moisture-related defects.
- Extends the lifespan of machinery and tools.
- Maintains consistent air quality for smooth operations
2. Food and Beverage industry:
Application: Helps maintain the quality and shelf life of food products.
Benefits:
- Preserves food freshness by controlling humidity levels.
- Prevents clumping in powdered ingredients.
- Enhances food safety by minimizing microbial growth.
Examples:
- Food processing plants
- Beverage production facilities
- Dairy processing companies
3. Pharmaceutical industry:
Application: Essential for maintaining the integrity of sensitive pharmaceutical products.
Benefits:
- Protects the efficacy of medications by controlling moisture levels.
- Ensures compliance with regulatory standards for drug manufacturing.
- Safeguards against degradation of active ingredients.
Examples:
- Pharmaceutical production facilities
- Drug manufacturing companies
- Pharmaceutical packaging businesses
- Medical device production companies
- Surgical instrument manufacturers
- Healthcare equipment suppliers
4. Electronics industry:
Application: Crucial for preventing moisture-related damage to electronic components.
Benefits:
- Reduces the risk of short circuits and malfunctions in electronic devices.
- Extends the lifespan of sensitive electronic equipment.
- Maintains product reliability and performance.
Examples:
- Electronics assembly plants
- Semiconductor fabrication facilities
- Electronics manufacturing service providers
5. Chemical industry:
Application: Helps in drying gases and controlling humidity in chemical processes.
Benefits:
- Enhances the efficiency of chemical reactions by maintaining dry conditions.
- Minimizes the risk of corrosion in pipelines and storage tanks.
- Improves the quality of chemical products by controlling moisture content.
Examples:
- Chemical processing plants
- Petrochemical refineries
- Specialty chemical manufacturers
Takeaway
Atlas Copco desiccant dryers protect the reliability during production process and the quality of your products. The high-performance dryers remove the moisture from your compressed air with a standard pressure dew point of -20°C/-5°F, -40°C/-40°F and -70°C/-100°F..
For critical installations where a higher dew point / dry air is required adsorption dryers are best suited as solution to keep up the application needs. In conclusion, desiccant dryers are an effective solution for providing high-quality, dry compressed air. However, their use should be evaluated based on the specific requirements of the application, considering the balance between the need for dry air and the associated costs.
