3.8m³/min Modular Air Compressor Desiccant Dryer System

Our compressed dry air system dew point is -20℃, -40℃, etc. Of course, if you need the lower dew point, we can also customize it. For twin tower adsorption air dryer, we can reach -70℃ dew point. But this air compressor dryer system is modular type. The lowest is -40℃.

Regenerative desiccant air dryer is different from refrigerant dryer. It does not use the principle of freezing and dehumidification. But use the adsorbents to remove water. Common desiccant beads are activated alumina and molecular sieves. This adsorption air dryer includes two types. That is, heatless and heated air dryer.

1. Technical sheets of air compressor desiccant dryer

2. Why choose our modular type adsorption compressed dry air system? ① More energy saving:

The air compressor desiccant dryer has low air consumption. The air consumption of the modular heatless dryer is generally 7%. But the double tower heatless dryer is generally 13%. In addition, its structure is simple. So the air pressure loss is lower. Compared to traditional adsorption air dryer, it can reduce operation cost by 30%~60%.

② Stable performance:

The air compressor dryer system uses high quality adsorbents. So the performance is stable. It adopts a decentralized adsorption unit structure. It can greatly increase effective adsorption area. Thus, the dew point is more stable.

③ More hygienic:

The main material uses magnesium-aluminum alloy. Also do anti-rust treatment by oxidation. So it can effectively prevent secondary pollution. Especially suitable for the food and pharmaceutical industry. Life expectancy can be up to 30 years;

④ Intelligent control:

This compressed dry air system uses PLC. Friendly human-computer interface. So it can realize remote control. The operation is simple and easy to understand. The air supply is continuous and stable. No intermittent air cuts.

⑤ Small size and light weight

The overall structure is compact. Beautiful appearance design. The modular desiccant dryer is easy to transport and install. We can also install it in narrow spaces. So does not take up a lot of production space.

Besides, modular adsorption dryer is not pressure vessel. So it doesn’t require annual re-inspection. Significant time and cost savings;

⑥ The later maintenance cost is low.

Firstly, compared to the twin tower air dryer, fewer valves are used. So the failure rate is lower. Large desiccant dryers use air cylinders. Maintenance is simple and convenient. Also, the cost of the adsorbent is low. So there are fewer replacements later. For example, 3.8m³/min heatless module air compressor desiccant dryer requires 35KG adsorbents. But 3.8m³/min heatless twin tower desiccant dryer requires 60KG adsorbents.

3. Why modular desiccant air compressor dryer system is more energy saving?

Take a 110KW air compressor as an example. The 5-year electricity consumption of several compressed dry air systems is as follows:

① Double tower heatless adsorption dryer: Air consumption is about 13%.
So energy consumption=11012436513%*5=CNY626340.

② Twin tower micro-heat regenerative air dryer: air consumption is about 7%. And electric heating wire power is 4KW.
So energy consumption=1101243657%5+4124365*5=CNY512460.

③ Combination desiccant air compressor dryer system: the air consumption is 5%. And the power of refrigerated dryer is 4.5KW.
So energy consumption=1101243655%5+4.5124365*10=CNY438000.

④ Modular air compressor desiccant dryer: the air consumption is 5%. And the electricity consumption is 5 years:
1101243655%*5=CNY240900.

Modular air compressor dryer system composes of several cavities. It is equivalent to this situation: several small adsorption towers take adsorption at the same time. So it can maintain stable compressed air dew point.

And this structure has benefits. It increases the surface area where the adsorbent and compressed air contact. The contact time will also increase. So the water absorption effect is multiplied. Finally, it greatly reduces the regeneration air consumption.

It is not like a traditional twin tower compressed dry air system. The double-tower air dryer has a dead angle of adsorption. Short contact time with desiccant. Besides, the contact is insufficient. Insufficient drying and regeneration. To achieve the dew point, it needs much air to purge the adsorbents. Therefore, the regeneration air consumption is large.

4. How does modular air compressor desiccant dryer system work?

Heatless modular compressed dry air system has multiple aluminum cavities. Each group has two cavities. Each cavity is fully with desiccant beads. It’s to dry the moist compressed air. Then one cavity is working (drying), beads will absorb moisture. At this time, the other side will regenerate by PSA.

During regeneration, some dry air expands to atmospheric pressure. Take away the moisture in the adsorbents. So the desiccant beads can regenerate. We usually use it with refrigerant dryer and precision filters. Thus, it will enhance the performance and reliability of air compressor desiccant dryer system.

When Group A is adsorbing, the intake valve A1 opens. At the same time, muffler exhaust valve B1 closes. And the outlet check valve C1 of air compressor desiccant dryer system also opens. Compressed air enters the downpipe from A1. Then enter the upper trachea after adsorption. The dry air flows to the air consumption section through C1. Part of the dry air enters Group B through regeneration valve D1. So Group B start regeneration.

When Group B is regenerating, intake valve A2 is closed. Muffler exhaust valve B2 of compressed dry air system opens. At the same time, the outlet check valve C2 closes. The regeneration air enters the upper air pipe through valve D2. And the air performs analytical regeneration on the desiccant beads. Finally, it will discharge the moisture from the muffler exhaust valve B2.

5. How to use the modular adsorption compressed dry air system?

Select the appropriate machines. That is, air receiver and filters, refrigerant dryer and modular adsorption dryer. Among them, the air storage tank is necessary. And it must be installed between the air compressor system and the modular desiccant dryer.

Normal product usage conditions are as follows:
Ambient temperature: ≤40℃;
Intake temperature: ≤38℃;
Inlet pressure: 0.6MPa～1.0MPa;

(1) Install the modular air compressor desiccant dryer system

① Firstly, install the modular adsorption compressed dry air system. And place it directly on a level and firm concrete floor.

② Secondly, install the pipeline from the air compressor outlet to the inlet of the modular desiccant dryer. It needs to do rust-proof treatment to the pipes. And avoid bends in the pipes that cause the water to be stored.

③ Thirdly, install the bypass piping. This is to facilitate future maintenance.

④ The installation site should avoid rain. If outdoors, pls build a shelter. At the same time, reserve space for maintenance. So it will be convenient to fix the air compressor desiccant dryer system.

⑤ Please put the power plug into a 220/380V dedicated socket. Or connect the protection switch. Besides, there must be a leakage circuit breaker.

⑥ In 50HZ area, please control the power frequency at 210V-230V, 360-400V. In 60HZ area, control at 208-230V, 360V-400V.

⑦ Be sure to ground the wire before using the desiccant dryer.

⑧ When setting the leakage circuit breaker, please refer to the maximum operating current.

⑨ Modular adsorption compressed dry air system is mechanical equipment. And avoid strong vibrations during loading, unloading, handling and installation.

⑩ Electrical Installation
Electrical wiring may become loose due to vibration during transportation. So please tighten it with a tool.

Please set a power switch separately. Do not share a starting power source with other equipment.

The voltage fluctuation is within ±5%.

Configuration cable should avoid too small or too long cross-section to avoid voltage drop.

(2) Precautions for operation of modular adsorption dryer

Check before starting air compressor desiccant dryer system:

① Check the power supply: whether the voltage and the number of phases meet the requirements. Besides, the electrical wiring is correct or not.

② Confirm whether the working pressure and temperature meet the selection requirements.

③ Confirm that there is air storage tank before the adsorption dryer. If no, ask the user why.

④ Should install the modular desiccant dryer on a suitable foundation with bolts.

⑤ Confirm that the installation center distance of each dryer is greater than 500mm.

⑥ Confirm to install filters separately for each compressed dry air system. And installation should be correct.

⑦ Each filter should have a separate drain pipe. Fix it under the filter with a pipe joint.

⑧ Check whether the inlet bypass valve closes and the outlet bypass valve opens.

⑨ The dryer installation site should be well ventilated. So it can remove the heat easily from the room. The surroundings should be tidy and clean. The ambient temperature must not exceed the limit temperature of the dryer.

⑩ Check whether the pressure gauges are normal. Besides, the readings should be the same in the standby state.

⑪ It should install and tighten the muffler before starting air compressor desiccant dryer system.

⑫ Confirm whether the remaining air in the pipeline has been released.

After checking the above items, then you can start the modular desiccant dryer.

Shutdown sequence: firstly close the air compressor and the inlet valve. Then turn off the modular adsorption compressed dry air system.

(3) Modular Air Compressor Desiccant Dryer System Adjustment

Our desiccant compressed dry air system has passed adjustment and test before leaving factory. Normally users can directly turn on and use it according to the manual.

If any abnormalities during use, please contact our company in time. Under the guidance of our company’s personnel, adjust certain valves. Do not operate blindly to avoid damage to the dryer parts.

Specific adjustment process:

① Turn on the external power switch;

② Confirm that the inlet and exhaust shut-off valves of the dryer are closed;

③ Confirm that all condensate is drained. If liquid water enters the dryer, check whether the control system is affected. Besides, need to issue a report.

④ Charge the pressure on one side of air compressor desiccant dryer systen. Then the cycle starts. And the pressure gauge can indicate；

⑤ For the desiccant dryer with -20°C dew point, you need to close the exhaust valve. Then run the compressed dry air system for at least 4 hours to activate.

For the adsorption air dryer with -40°C dew point, also need to close the exhaust valve. Then run the air compressor dryer system for at least 8 hours to activate.

For the regenerative air dryer with -70°C dew point, also close the exhaust valve. And then run the dryer for at least 24 hours to activate. Then slowly open the exhaust shut-off valve of the dryer until the fully open position. And air compressor desiccant dryer starts to supply air.

6. Modular desiccant compressed dry air system maintenance

① Firstly, check the time program. The two drying towers switches. At the same time, check whether the drain valve of the filter works normally;

② Secondly, check whether the muffler discharge is smooth. Observe whether the filter pressure difference indicator exceeds the standard;

③ Thirdly, check whether the pressure difference before and after air compressor desiccant dryer system is too high;

④ Check whether the desiccant is polluted or powdered.

1) Improper operation or low-pressure operation will cause high-speed airflow to wash the desiccant. As a result, a large amount of dust falls off. At this time, should get out the desiccant beads. Sieve and refill them.

2) Sometimes, the intake air humidity is too high. Liquid water will shock the adsorbent. Or work overtime without switching action. The desiccant beads will be oversaturated or even soaked in water. This will form a compaction and fail. At this time, should eliminate fault immediately.

Gradually dehumidify in the power-on state. Wait until it restores the original dryness.

3) Sometimes, the filter fails. Or there is no oil removal filter. So the lubricating oil enters the compressed dry air system. This blocks the capillary channels on the adsorbent surface. It causes the adsorbent to reduce or lose its adsorption capacity. At this time, we must replace desiccant beads.

⑤ Regularly clean or replace the pre-filter element. So it can ensure inlet air standards;

⑥ Soak the muffler in warm soapy water every 3~4 months. Blow dry before use. Usually replace it once a year;

⑦ Make a work record card on air compressor desiccant dryer system. It includs, operating pressure, inlet pressure, air usage, adsorption, regeneration cycle, replacement of filter elements, etc.

⑧ Adsorbent replacement cycle: about one and a half years (about 8000~12000 hours). Repalce according to the situation.

7. Modular air compressor desiccant dryer system troubleshooting (1) Dew point does not meet requirements

The possible reasons are below:

① The adsorbent is insufficient. Or the desiccant beads are broken and fail.
② The regeneration air volume of compressed dry air system is insufficient. Or the switching of regeneration towers is abnormal
③ The air inlet temperature of air compressor desiccant dryer is too high.
④ The intake air has high oil content. So the desiccant beads fail.
⑤ Low working pressure results in low adsorption capacity;
⑥ The switching period of modular adsorption air dryer is too long;

How to solve the problems:

① Add adsorbent or replace.
② Adjust to a reasonable air volume. Adjust regeneration towers to switch normally.
③ Adjust the process configuration. Improve the cooling effect of the cooler.
④ Improve the oil filtering effect. Replace the desiccant beads.
⑤ Properly increase the intake pressure;
⑥ Reasonably adjust the switching cycle of compressed dry air system;

(2) Too high dew point

The reasons are as follows:

① The regeneration air volume of air compressor desiccant dryer system is too small;
② Improper switching cycle of adsorption towers;
③ The desiccant beads are polluted;

The solutions for reference:

① Adjust the throttle valve. Therefore, increase the amount of regeneration air;
② Reset the switching cycle of compressed dry air system;
③ Replace the adsorbent. At the same time, exclude the cause of contamination;

(3) Excessive pressure drop (more than 3% of inlet pressure)

The possbile causes are below:

① The desiccant beads are seriously damaged;
② The compressed air filters blocking;
③ Adsorbent has exceeded the lifetime. Or they has been prematurely broken into powder;

How to solve the problems:

① Remove the damaged adsorbent and refill it;
② Check and clean the clogged filter. Or change the filter replacement;
③ Sieve or replace the desiccant beads;

(4) The regeneration tower pressure reset is abnormal

The reasons are as follows:

① Too much regeneration air in the air compressor desiccant dryer system;
② Check valve is broken or leaking;
③ Main solenoid valve leaking;

How to solve problems:

① Adjust the throttle valve in the compressed dry air system. Then reduce the amount of regeneration air;
② Replace leakage valve or valve core parts;

(5) The pressure of the regeneration tower does not return to zero. Or the pressure of the two towers drops at the same time

Below are the possible reasons:

① The muffler or the muffler pipe has blockage;
② Pneumatic valves have failure. Or there is serious leakage;
③ The amount of regeneration air is too large;
④ Not smooth regeneration air outlet pipeline in the air compressor desiccant dryer system;

Below are the solutions:

① Clean the mufflers in the compressed dry air system;
② Check and replace damaged parts;
③ Appropriately reduce the amount of regeneration air;
④ Check the exhaust pipe, mufflers, etc.;

8. How to install filters to air compressor desiccant dryer system?

The filters can improve our compressed air quality. At the same time, it can protect our desiccant beads.

(1) Install the pre-filter before adsorption air dryer

That is, install water-removal and oil-removal filters. Add them front of the air compressor desiccant dryer system. If there is a lot of liquid water, it will affect the dryer effect. This results in an increase in the outlet dew point. In addition, oil mist can seriously pollute the desiccant beads. It will also raise the dew point. At the same time, it will shorten the service life of the adsorbent. After filtration, the liquid microparticle content will reach 0.01 μm. And the residual content of oil vapors will reach 0.01ppm.

(2) Install the post filter on the compressed dry air system

The desiccant beads are under pressure and shock for a long time. It will generate some adsorbent dusts. So we need to ensure the quality of the downstream compressed air. Then it is necessary to install the post filter on the air compressor desiccant dryer system. Here we use the dust-removal filter.

9. FAQ

Q1: What are desiccant beads in your air compressor desiccant dryer system?

A1: High-efficiency activated alumina + high-efficiency molecular sieve. Both are from China famous brand.

Q2: How long does air dryer desiccant last?

A2: It is about 8000~12000 hours. The specific replacement time bases on the compressed air quality.

Q3: Is it necessary to equip the compressed dry air systemwith filters?

A3: Sure. In fact, there are two advantages to install the compressed air filters. Firstly, it can ensure the compressed air quality. Secondly, it can extend the lifetime of desiccant dryer and adsorbent.

Q4: What’s the dew point of the modular air compressor desiccant dryer system?

A4: For modular adsorption air dryer, the dew point can be -20℃ and -40℃.