US20100319371A1 - Method and apparatus for drying compressed gases - Google Patents

Method and apparatus for drying compressed gases Download PDF

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US20100319371A1
US20100319371A1 US12/770,014 US77001410A US2010319371A1 US 20100319371 A1 US20100319371 A1 US 20100319371A1 US 77001410 A US77001410 A US 77001410A US 2010319371 A1 US2010319371 A1 US 2010319371A1
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column
compressed air
dryer
adsorption
temperature
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Luciano Bellemo
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Parker Hiross SpA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/26—Drying gases or vapours
    • B01D53/261—Drying gases or vapours by adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/26—Drying gases or vapours
    • B01D53/265—Drying gases or vapours by refrigeration (condensation)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04151—Purification and (pre-)cooling of the feed air; recuperative heat-exchange with product streams
    • F25J3/04157—Afterstage cooling and so-called "pre-cooling" of the feed air upstream the air purification unit and main heat exchange line
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04151—Purification and (pre-)cooling of the feed air; recuperative heat-exchange with product streams
    • F25J3/04163—Hot end purification of the feed air
    • F25J3/04169—Hot end purification of the feed air by adsorption of the impurities
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04151—Purification and (pre-)cooling of the feed air; recuperative heat-exchange with product streams
    • F25J3/04163—Hot end purification of the feed air
    • F25J3/04169—Hot end purification of the feed air by adsorption of the impurities
    • F25J3/04181—Regenerating the adsorbents
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04763—Start-up or control of the process; Details of the apparatus used
    • F25J3/04769—Operation, control and regulation of the process; Instrumentation within the process
    • F25J3/04775—Air purification and pre-cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/402—Further details for adsorption processes and devices using two beds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0407—Constructional details of adsorbing systems
    • B01D53/0423—Beds in columns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0407—Constructional details of adsorbing systems
    • B01D53/0438—Cooling or heating systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0407—Constructional details of adsorbing systems
    • B01D53/0446—Means for feeding or distributing gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0462—Temperature swing adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/047—Pressure swing adsorption
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/02—Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum
    • F25J2205/04—Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum in the feed line, i.e. upstream of the fractionation step
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/60—Processes or apparatus using other separation and/or other processing means using adsorption on solid adsorbents, e.g. by temperature-swing adsorption [TSA] at the hot or cold end
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/84—Processes or apparatus using other separation and/or other processing means using filter
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2245/00—Processes or apparatus involving steps for recycling of process streams
    • F25J2245/40—Processes or apparatus involving steps for recycling of process streams the recycled stream being air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00—Refrigeration techniques used
    • F25J2270/90—External refrigeration, e.g. conventional closed-loop mechanical refrigeration unit using Freon or NH3, unspecified external refrigeration

Definitions

  • the present invention refers to an improved method for drying compressed gas, in particular compressed air, and an apparatus of a hybrid kind for carrying out such method.
  • compressed air is known to contain a certain percentage amount of moisture in the form of water vapour. Under the circumstances, if the temperature of compressed air decreases below the dew point, the water vapour content thereof is caused to condense under formation of water droplets.
  • both generally high concentrations of water vapour and the presence of liquid in compressed air are generally known as being the main cause of corrosion and premature breakdown of piping systems, leading eventually to a malfunction or even full unserviceableness of the machines and apparatus that use compressed air.
  • Refrigeration-based compressed-gas dryers substantially comprise two heat exchangers, i.e. a heat-recovery arrangement and an evaporator.
  • a refrigerant medium is used to cooling purposes, which is caused to flow, i.e. circulated in the evaporator being part of a refrigerating circuit.
  • Adsorption-type compressed-gas dryers are used whenever the need arises for a dew point under pressure to be obtained, which is lower than 0° C., e.g. ⁇ 40° C. In this case, no use can in fact be made of a refrigeration-based compressed-gas dryer, since icing, i.e. ice formation, would occur in the evaporator.
  • Distinction is generally made between two main kinds of adsorption-type compressed-gas dryers: (i) adsorption-type compressed-gas dryers using regeneration under cold conditions, which are usually employed to cope with medium-to-low flow rates (for example, up to 10-20 m 3 /min), and (ii) adsorption-type compressed-gas dryers using regeneration under hot conditions, which are usually employed to cope with medium-to-large flow rates (for example, higher than 10 to 20 m 3 /min).
  • the dryers include two under-pressure reservoirs (columns), which contain solid material capable of adsorbing water-vapour molecules. Their operation is a cyclic one, since—while a column is working in the adsorption mode—the other one is either working in the regeneration mode or simply waiting for the first one to complete its working cycle.
  • the working cycle of each column includes the following steps: (i) adsorption, in which compressed air is let into a column, where it flows through the mass of adsorbing material to eventually reach the desired dew point; (ii) depressurization of the column concerned; (iii) regeneration of the adsorbing material, in which the dry compressed air generated in the column working in the adsorption mode expands into a calibrated orifice down to atmospheric pressure, flows into the column working in the regeneration mode, and causes water to be de-adsorbed; and (iv) pressurization, in which the pressure in the column is brought up again to the value required for a new adsorption cycle to be able to start.
  • This kind of dryer is characterized by its being relatively simple in construction, but involving a remarkable usage of compressed air and, hence, energy.
  • each column typically includes the following steps: (i) adsorption; (ii) depressurization; (iii) heating up, in which air taken in from outside is heated up and delivered onto the adsorbing material in the column so as to cause water to be de-adsorbed therefrom; (iv) cooling down, in which the adsorbing material in the column is cooled down to a temperature that is as close as possible to the temperature of the air to be dried; and (v) pressurization.
  • This kind of dryer has a lower specific energy usage (i.e. compressed-air usage as added to energy usage) than an adsorption-type dryer with cold regeneration, but is certainly more complex from a construction point of view and, therefore, more expensive.
  • Compressed-gas dryers of a hybrid type can also be found on the market, which are generally intended to handle medium-to-high flow rates (i.e. 20 to 150 m 3 /min).
  • medium-to-high flow rates i.e. 20 to 150 m 3 /min.
  • an adsorption-type dryer using hot regeneration downstream from a refrigeration-based dryer there is provided an adsorption-type dryer using hot regeneration.
  • the refrigeration-based dryer enables more than 80 percent of the water contents in the compressed air to be removed, as well as a dew point under pressure of +3° C. to be reached.
  • the adsorption-type dryer may advantageously be sized in view of working under less demanding conditions, so as to go down to a dew point of ⁇ 40° C.
  • another purpose of the present invention is to provide a hybrid-type compressed-gas dryer, which has such small size as to be able to be contained within a single casing.
  • Yet another purpose of the present invention is to provide a hybrid-type compressed-gas dryer, which involves installation and maintenance costs that are sensibly lower than the ones connected with prior-art dryers of the same kind.
  • Still another object of the present invention is to provide an improved method for drying compressed air, which enables energy usage to be sensibly reduced, with a corresponding energy saving effect, under decreasing load conditions, since a small percentage of dry compressed air is used in the heating and cooling phases of the adsorbing material in the columns, and the outlet temperature of the regeneration air is controlled during such phases.
  • FIG. 1 shows a block diagram of a refrigeration-based compressed-gas dryer according to the prior art
  • FIG. 2 shows the operation schematics of an adsorption-type compressed-gas dryer using cold regeneration according to the prior art
  • FIG. 3 shows the operation schematics of an adsorption-type compressed-gas dryer using hot regeneration according to the prior art
  • FIG. 4 shows a block diagram of a hybrid-type compressed-gas dryer according to the prior art
  • FIG. 5 shows an operation schematics of a hybrid-type compressed-gas dryer, featuring an air flow from the bottom upwards during the regeneration phase, according to the present invention.
  • FIG. 6 shows an operation schematics of a hybrid-type compressed-gas dryer, featuring an air flow from top downwards during the regeneration phase, according to the present invention.
  • FIG. 1 this can be noticed to schematically illustrate—in the form of a block diagram—a refrigeration-based compressed-gas dryer according to the prior art, which comprises two heat exchangers, i.e. a heat-recovery arrangement ( 10 ), or gas-to-gas heat exchanger, and an evaporator ( 40 ).
  • a heat-recovery arrangement 10
  • gas-to-gas heat exchanger or gas-to-gas heat exchanger
  • evaporator 40
  • the compressed air to be dried is initially pre-cooled in a pre-cooling section ( 20 ) of the heat-recovery arrangement ( 10 ); it then exits such pre-cooling section and keeps cooling down to a further extent in a cooling section ( 50 ) of the evaporator ( 40 ) until it reaches the desired dew point.
  • a refrigerant or coolant medium that evaporates in an evaporation section ( 60 ) of the same evaporator.
  • Such evaporating coolant medium is circulated in a refrigerating circuit ( 70 ).
  • the compressed air is caused to flow into a condensate separator arrangement ( 80 ), or air condenser, in which condensed water vapour is collected and separated from the air.
  • the resulting condensate is then discharged through a proper drain provision ( 90 ).
  • the air exiting the condensate separator arrangement ( 80 ) flows through the heating section ( 30 ) of the heat-recovery arrangement ( 10 ) so as to pre-cool the compressed air flowing through the pre-cooling section ( 20 ).
  • the condensate separation efficiency of the condensate separator arrangement ( 80 ) is high enough (>99.5%)
  • the dew point under pressure substantially coincides with the temperature of the compressed air exiting the evaporator ( 40 ), and—for a refrigeration-based compressed-gas dryer—it typically lies anywhere between 3° C. and 7° C.
  • FIG. 2 shows the operation schematics of an adsorption-type compressed-gas dryer using cold regeneration according to the prior art.
  • the compressed air flows into a strainer or filter ( 110 ), in which possible oil contained in the air is removed down to a concentration of approx. 0.01 ppm; it then flows through the pipe ( 120 ) and eventually enters a four-way valve ( 130 ) to be selectively delivered—via two conduits ( 135 , 136 )—into one of two columns ( 160 , 170 ) under pressure, which contain adsorbing material.
  • the other column When one of the columns is working in the adsorption mode, the other column is de-pressurized by opening a valve ( 140 ) and exhausting the air outside through a silencing or muffling filter ( 150 ).
  • the dried compressed air exits the columns ( 160 ) or ( 170 ), as the case may be, by flowing through the pipe conduits ( 190 ) or ( 200 ) and the non-return valves ( 210 ) or ( 220 ), respectively, another piping ( 230 ) and a dust filter ( 240 ), to eventually be let again into the operating or working cycle of the industrial plant.
  • the adsorbing material contained in the columns ( 160 ) or ( 170 ) For the adsorbing material contained in the columns ( 160 ) or ( 170 ) to be regenerated after adsorption, use is made of part of the dried compressed air that flows out of one of the columns and—to regeneration purposes—is in fact delivered into the other column via a piping ( 180 ), in which there is provided a calibrated orifice ( 185 ). Then, the resulting moisture-laden air, carrying the moisture it has de-adsorbed from the adsorbing material, is exhausted outside via the pipe conduits ( 135 ) or ( 156 ), the valves ( 130 ) or ( 140 ), and the filter ( 150 ).
  • This particular kind of compressed-gas dryer is certainly characterized by a substantial simplicity in its construction, but involves a remarkably high compressed-air and, hence, energy usage.
  • ISO7183 standards saturated compressed air at an inflow temperature of 35° C. and pressure of 7 bar(g)
  • manufacturers state that the orifice ( 185 ) is calibrated so as to let—during the regeneration phase—a percentage of air therethrough that amounts to 21% with reference to the total flow rate of dried compressed air exiting the dust filter ( 240 ) during the regeneration phase. With reference to the whole cycle, such percentage amounts to 16.7%.
  • FIG. 3 shows the operation schematics of an adsorption-type compressed-gas dryer using hot regeneration according to the prior art.
  • the compressed air flows into a strainer or filter ( 110 ), in which possible oil contained in the air is removed down to a concentration of approx. 0.01 ppm; it then flows through the pipe ( 120 ) and eventually enters a four-way valve ( 130 ) to be selectively delivered—via two pipe conduits ( 135 ) or ( 136 )—into one of two columns ( 160 ) or ( 170 ) under pressure, which contain adsorbing material.
  • the other column is de-pressurized by opening a valve ( 140 ) and exhausting the air outside through the silencing or muffling filter ( 150 ).
  • air is taken in from outside with the aid of a blower ( 280 ); it is then heated up by means of an electric heater ( 270 ) and selectively delivered into the two columns ( 160 ) or ( 170 ) via a valve ( 260 ) provided in a series arrangement with the four-way valve ( 250 ).
  • the resulting moisture-laden air i.e. carrying the moisture it has de-adsorbed from the adsorbing material, is exhausted outside via the pipe conduits ( 135 ) or ( 156 ) and a valve ( 145 ).
  • the process for cooling down the adsorbing material is started, in which the valve ( 260 ) and the valve ( 145 ) are shut, accordingly, while one of the valves ( 186 ) or ( 187 ), as appropriate, and the valve ( 140 ) are on the contrary opened.
  • the dried compressed air expands down to atmospheric pressure and flows from an adsorption column over to the other one via the four-way valve ( 250 ).
  • the cooling air which gets heated up in the process, flows out from one of the pipe conduits ( 135 ) or ( 136 ), as the case may be, passes through the four-way valve ( 130 ) and is exhausted outside via the valve ( 140 ) and the muffling filter ( 150 ).
  • a percentage of compressed air typically lying anywhere between 5 and 10% is used to cooling purposes.
  • the cooling-down phase is aimed at bringing the adsorbing material in the columns down to a temperature lying as close as possible to the temperature of the air to be dried.
  • This kind of compressed-gas dryer is rather complex and, therefore, expensive from a construction point of view, but involves a specific energy usage that is certainly lower than the one of the afore-considered compressed-gas dryer using cold regeneration.
  • power consumption amounts to 0.49 kW/(m 3 /min) in this case, to which there shall be added the usage of compressed air needed for cooling (approx. 2% of total flow rate), which corresponds to additional 0.12 kW/(m 3 /min), leading to a total of 0.61 kW/(m 3 /min).
  • compressed-gas dryers using hot regeneration are typically used in applications involving flow rates in excess of 10 to 20 m 3 /min.
  • FIG. 4 shows a block diagram of a hybrid-type compressed-gas dryer according to the prior art.
  • this apparatus is comprised of a refrigeration-based dryer that includes two heat exchangers ( 10 , 40 ), a refrigerating circuit ( 70 ), a condensate separator arrangement ( 80 ) and a condensate drain arrangement ( 90 ); downstream from this refrigeration-based dryer there is connected an adsorption-type dryer using hot regeneration ( 300 ) similar to the above-described one.
  • the compressed air is in this case allowed to flow back into the heating section ( 30 ) of the heat-recovery exchanger ( 10 ) of the refrigeration-based dryer.
  • these compressed-gas dryers of the hybrid type are advantageous from an energy-usage point of view, but keep being complex from a construction point of view, involving both considerable sizes and very high costs.
  • FIG. 5 shows the operation schematics of a hybrid-type compressed-gas dryer according to the present invention.
  • the inventive hybrid-type compressed-gas dryer is comprised of a refrigeration-based dryer of a traditional kind, downstream from which there is connected an adsorption-type dryer ( 300 ), whose construction and operating mode are situated halfway between the ones of an adsorption-type dryer with cold regeneration and the ones of an adsorption-type dryer with hot regeneration.
  • This valve group ( 130 ) is preferably comprised of a four-way valve, which may be replaced by a plurality of appropriately coordinated one-way valves. If the column ( 160 ) is working in the adsorption mode, the compressed air flows through the sections ( 130 a and 130 b ) of the valve ( 130 ) and the pipe conduit ( 135 ) to eventually flow into the column ( 160 ).
  • the compressed air exits the column through the pipe conduit ( 190 ), flows through the non-return valve ( 210 ) and the pipe conduit ( 230 ) to eventually flow out through the dust filter ( 240 ) and back to the heat-recovery arrangement ( 10 ) in the heating section ( 30 ) of the refrigeration-based dryer ( 100 ). From the latter, the dried compressed air is then let again into the operating or working cycle of the industrial plant.
  • the column ( 170 ) is de-pressurized by opening the valve ( 140 ).
  • the compressed air is exhausted outside through the muffling filter ( 150 ) and the pressure in the column ( 170 ) reaches down to the value of atmospheric pressure.
  • the electric heating element ( 275 ) may be switched on, i.e. energized either at the beginning of the regeneration phase, i.e. concurrently with the opening of the valve ( 140 ), or it may be switched on, i.e. energized in advance so as to ensure that the compressed air flowing through the pipe conduit ( 180 ) is able to flow out at a high temperature right from the beginning.
  • the air exiting the pipe conduit ( 180 ) at a high temperature flows through the pipe conduit ( 200 ) and into the column ( 170 ), exchanges heat with both the adsorbing material and the vessel containing it, flows eventually out through the pipe conduit ( 136 ), passes through the sections ( 130 c and 130 d ) of the four-way valve ( 130 ) and is exhausted outside by flowing through the valve ( 140 ) and the muffling filter ( 150 ).
  • a high temperature e.g. at 130 to 200° C.
  • Controlling the temperature of the air that is heated up by the electric heating element ( 275 ) is done by having a temperature probe (T 2 ) sensing the air temperature at the outlet of the electric heating element, and switching the same heating element on and off, or modulating the power output thereof, accordingly.
  • T 2 a temperature probe sensing the air temperature at the outlet of the electric heating element
  • the heating and cooling phases that are carried out in the columns ( 160 and 170 ) perform the regeneration process thereof, i.e. the process aimed at regenerating the adsorbing material after an adsorption process.
  • the heating phase can be interrupted, i.e. cut off based on:
  • the electric heating element is switched off and the dry compressed air keeps expanding through the orifices ( 188 ) and ( 189 ), flowing through the column ( 170 ), and exiting through the valve ( 140 ) and the muffling filter ( 150 ).
  • the cooling phase can be terminated, i.e. cut off based on: a pre-set time that depends on rated design specifications;
  • the valve ( 140 ) closes so as to allow the column ( 170 ) to reach up to the same pressure as the one prevailing in the column ( 160 ), so that it becomes ready to start a new adsorption cycle.
  • the column pressurization stage may be allowed to continue for a much longer time than the minimum time required (approx. 1 minute) to take the greatest possible advantage out of the adsorption capacity of the other column working in the adsorption mode.
  • the main feature of the novel hybrid-type compressed-gas dryer according to the present invention is represented by the regeneration phase thereof, which comprises both the heating and the cooling of the columns containing the adsorbing material.
  • the dry air used for regeneration represents the highest operating cost and, for this cost to be reduced, the need arises for the rate of air flowing through the column being regenerated to be reduced. However, if such flow rate is decreased below a certain value, which is characteristic of each column and the amount of water to be de-adsorbed, very detrimental condensation effects may follow.
  • the hot air entering the upper portion of the column to be regenerated undergoes an increase of the water-vapour content thereof, i.e. takes in moisture, but, as it keeps flowing downwards along the column, it cools down, thereby causing the water vapour it took in by de-adsorption in the upper portions to condense.
  • the water content to be removed from moisture-laden compressed air in a hybrid dryer is 7.6 times lower (with an inflow dew point of 3° C., instead of 35° C., and a pressure of 7 bar(g)) than in an adsorption dryer of the traditional type, it may be reasonably contemplated for also the specific kg/(m 3 /min) amount of adsorbing material to be reduced by approximately the same factor. This is possible also due to the fact that—as this has been thoroughly confirmed experimentally—a height of just a few dozen centimetres of adsorbing material is sufficient (for a same diameter of the column) for a pressure dew point, i.e. a dew point under pressure of ⁇ 40° C. to be reached—as against a height of 1 to 1.5 metres in traditional dryers—when entering the adsorption dryer at a temperature of approx. 3° C.
  • a reduction in the amount of adsorbing material used has the effect of favouring also a reduction in power usage per cycle. In fact, it just cannot be avoided to heat up the adsorbing material and the vessel containing it to regeneration temperature, so as it just cannot be avoided to cool them down, so that a reduction in the amount of such material means that it takes a smaller amount of energy to heat up the material to regeneration temperature, as well as a smaller amount of dry, cold compressed air to cool it down.
  • a heating method that does not call for the whole amount of adsorbing material to be heated up to regeneration temperature, in that just a minimum amount of heat is delivered into the column as strictly necessary to de-adsorb, and allow it to flow out of the column being regenerated, the amount of water that had been adsorbed in the previous adsorption phase.
  • Such minimum amount of heat is represented by a minimum by-passed flow of dry compressed-air that is heated up by the electric heating element to a pre-established temperature, and that is allowed to flow for a minimum time as pre-established or determined by the outlet temperature of the regeneration air. This minimum amount of heat corresponds to a flow rate amounting to approx. 4 to 6% of dry compressed air heated up to a temperature of approx.
  • the upper portion (close to the column inlet) will have changed to the inlet temperature of the dry regeneration air, whereas the lower portion (close to the column outlet) will be at such temperature as to ensure that all previously absorbed water is removed and let out of the column, wherein this temperature may typically vary within a range from approx. 30° C. to approx. 80° C.;
  • a cooling method that does not call for the whole amount of adsorbing material to be cooled down to the temperature of the drying air flowing into the column.
  • the dry air “pushes”, i.e. drives the heat that had built up in the upper portion of the column downwards, whereby this heat keeps practically going on in regenerating the adsorbing material in the column portions lying therebelow throughout the cooling period, without any additional heat and dry compressed air being wasted, actually.
  • the cooling process is stopped prior to reaching down to a temperature (T 3 ) in the outlet section of the column, which is equal to the inlet temperature (i.e. approx. 3° C.), e.g.
  • the capacity of the adsorbing material is at its maximum in the upper sections of the column (regeneration just ended) and, as a result, it is such as to succeed in ensuring that the desired dew point is reached, actually. In the following few minutes, even the lower sections of the column cool down, so that the adsorption capacity of the column is restored to its optimum.
  • the electric heater ( 275 ) is still quite hot and is gradually cooled by the dry air flowing therethrough. In this way, the dry air heats up and carries such heat into the column without wasting it, actually.
  • the cycle time of the novel hybrid-type compressed-gas dryer according to the present invention is situated somewhere halfway between the cycle time of an adsorption-type compressed-gas dryer using cold regeneration and the cycle time of an adsorption-type compressed-gas dryer using hot regeneration.
  • a further alternative embodiment might be based on the use of a single calibrated orifice associated to a single electric heating element. This would enable costs to be certainly cut, however at the expense of the overall apparatus efficiency.
  • Yet another alternative embodiment is based on reversing the flow direction of the air within the columns ( 160 ) and ( 170 ) during the adsorption phase and the regeneration one, so that the compressed air is able to flow from top downwards during the adsorption phase, as this is best shown in FIG. 6 .
  • the problem of fluidization during the adsorption phase is definitely done way with.
  • valves ( 141 ) and ( 142 ) may be added for connection upstream to the lower portion of the column ( 170 ) and ( 160 ), respectively, and downstream from the inlet of the muffling filter ( 150 ).
  • the valve ( 141 ) or, as the case may be, ( 142 ) is opened at the beginning of the column de-pressurization phase, and is kept in the open state thereof for a pre-established period of time so as to allow pressure to be released from the column ( 160 ) or ( 170 ), respectively, while keeping the valve ( 140 ) shut.
  • valve ( 141 ) or, as the case may be, ( 142 ) is closed, the valve ( 140 is opened and the electric heating element ( 275 ) is energized to have the afore-described heating phase started.
  • Yet another advantage that is generally ensured by the novel hybrid-type dryer according to the present invention lies in the energy saving effect under partial load conditions, owing to the possibility given for the need to be done away with of having a dew-point meter installed and used (quite expensive in the case of small-capacity equipment), as this is the case in current adsorption-type dryers.
  • This can be achieved by controlling, i.e. sensing the temperature (T 3 ) and cutting off the heating phase when the temperature (T 3 ) is sensed to be in excess of a pre-set value, which might be situated anywhere in the range between 30° C. and 60° C. depending on the type of adsorbing material used, the cooling phase when the temperature (T 3 ) is sensed to have moved down below a pre-set value, which might be situated anywhere in the range between 10° C. and 30° C., as appropriate.
  • the amount of adsorbed water, which has therefore to be de-adsorbed is correspondingly small, so that—during the heating phase—the above-cited temperature (T 3 ) is able to rise at a much quicker rate than in normal or rated load conditions. If this heating phase is cut off based on the sensed value of this temperature (T 3 ), i.e. by having such temperature sensed, dry compressed air can be effectively prevented from being wasted to heating purposes. In the same way, if the temperature (T 3 ) reaches down to the desired value at a quicker rate during the cooling phase, switching over to the column pressurization phase sooner means saving on energy.
  • Controlling the operating or working cycles of the apparatus according to the present invention can therefore be done in a variety of manners, such as in particular:
  • variable heating and cooling times according to or as a function of the temperature values being sensed by the probe (T 3 ), and fixed pressurization times.
  • a further cycle control option is based on working with heating and cooling times that vary in accordance with or as a function of the temperature values being detected by the sensor (T 3 ), and a pressurization time that varies in accordance with or as a function of the dew point of the compressed air exiting the dryer ( 300 ).
  • a dew-point sensor which controls the interchanging sequence of the columns ( 160 , 170 ) in the operative state thereof. This mode of operation is particularly advantageous in view of the ability to save energy to a still further extent when the equipment is working under partial load conditions.
  • novel hybrid-type dryer according to the present invention will be provided with a single control unit (not shown in the Figures) adapted to receive the signals being output by the temperature probes (T 1 -T 3 ) and control the totality of the valves provided in the equipment based on the respective operating programmes.
  • Adsorption dryer Adsorption dryer Hybrid dryer with with according to cold regeneration hot regeneration invention Total specific power 1 0.51 0.33 usage, kW/(m 3 /min) (1)
  • novel hybrid-type dryer according to the present invention differs from prior-art ones in following features:
  • novel hybrid-type dryer according to the present invention is characterized by specific energy consumption data that fall into a line with the rated ones of current hybrid dryers, i.e. approx. 0.33 kW/(m 3 /min).

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CN113350965A (zh) * 2021-06-25 2021-09-07 烟台宏远氧业股份有限公司 一种医用空气加压氧舱的空气净化设备

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DE102012112040B4 (de) 2012-12-10 2014-12-24 Parker Hannifin Manufacturing Germany GmbH & Co. KG Hiross Zander Division Vorrichtung und Verfahren zum Trocknen von Gasen
ITPN20130009A1 (it) 2013-02-07 2014-08-08 Parker Hannifin Mfg S R L Apparato ibrido perfezionato per deumidificare un gas compresso
FR3011915B1 (fr) * 2013-10-10 2018-10-12 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procede et appareil de separation d'air par distillation cryogenique pour la production d'azote gazeux
RU2568704C1 (ru) * 2014-07-17 2015-11-20 Андрей Владиславович Курочкин Способ осушки сжатого газа
US10603627B2 (en) * 2018-01-17 2020-03-31 Ingersoll-Rand Industrial U.S., Inc. Hybrid low dew point compressed air dryer
US10888815B2 (en) * 2018-07-27 2021-01-12 Saudi Arabian Oil Company Drying compressed gas
CN109260908A (zh) * 2018-09-30 2019-01-25 深圳市贝腾科技有限公司 干燥过滤装置

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EP2263778B1 (en) 2016-03-23

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