Data Sheet Thl-1500 Air Dryer Delair

delair
Compressed Air Drying

Systems
ISO 9001:2000
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Moisture Removal
Understanding Air’s Moisture Holding Capacity:
The air surrounding us always contains a certain

amount of humidity in the form of water vapour.
The maximum amount of water vapour, which
can be held in air is governed by the volume and
temperature. The higher the temperature, the
more water vapour can be held in the air in
vapour form and vice versa. For a constant
volume, only the temperature influences the
ability of holding water in vapour form.
Saturated Air means that the air contains the
maximum possible amount of water in vapour
form. Any excess water vapour will condense in
the form of water.
When air contains less water than what it can at
saturation point, it is expressed as the relative
humidity of air.
Dewpoint is the temperature at which air is fully
saturated and below which the water vapour will
condense.
# 1 in Compressed Air Drying

ISO 9001:2000
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Compression
of air
leads to
100% saturated air

ISO 9001:2000
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Compressed air compression at 100

PSIG
140oC
Compressed air after the aftercooler at

100 PSIG
40oC
Compressed air after expansion to

atmospheric pressure

ISO 9001:2000
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Cause
Pollutants found in
compressed air
• Humidity
• Dust
• Oil
• Gases, vapours, fumes
• Bacteria, viruses
Source
• Components in the air
sucked in by the
compressor
• Elements added to the
air by the compressor
ISO 9001:2000
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Common Problems
faced by
compressed air users
Sluggish operation of Rusting of pipes and
pneumatic tools and fittings leading to
gauges leakage
Malfunction of Blisters on painted

instrumentation surface
like
l Analyzer l Recorder
l Relay l Indicator
l Integrator l Test stand
Contaminated food- Chemicals, pharmaceuticals–

Processing and Spoilage of materials during
packaging pneumatic conveying

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The moisture
menace
Air sucked into a

Compressor contains
water vapour

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Remaining Water
Compressor Lubricants
Corrosive Sludge
• Ruins air-operated tools

• Contaminates food packaging
• Fouls up spraying processes
• Several other problems

ISO 9001:2000
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Other
contaminants
Oil
Typically, 5-25 mg/m3 added by the compressor
Dust
100 mg/m3 is the typical dust content in an
industrial area
Oil + dust + gases + bacteria =
• Clogged nozzles in pneumatic

instruments
• Spoilt food and pharma products
• Degraded brewery products etc.

ISO 9001:2000
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Installation of an
Aftercooler
OUTLET
AIR
6.3 GM/KG
OF AIR
AFTER COOLER
INLET AIR
AT 40°C
INLET AIR
AT 30°C
60% RH
(16 GM/KG
OF AIR)
30 K.W.
COMPRESSOR
80 L/SEC
60%
Removes at best only

60% of captive moisture

ISO 9001:2000
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Quality air
Appropriate air quality gives
• Optimal compressed air economy
• Low running costs
• Low maintenance costs
• Reliability
• Better product
To achieve quality air

contaminants present in
the compressed air
must be removed

ISO 9001:2000
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Removal of
compressed air
contaminants
Contaminant Can be removed by
Moisture
... as free water Separators, mechanical filters,
coalescing filters, air dryers
... as aerosol mist Coalescing filters, air dryers
... as vapour Air Dryers
Oil
... as free oil Separators, mechanical filters,
coalescing filters
... as aerosol mist Coalescing filters
... as vapour Adsorbents and activated carbon
Scale
... as particles Mechanical filters, coalescing
filters (by impingement)
Dust (most types)
Pollens
Bacteria (90-100%)
... as particles Coalescing filters (by impingement)

ISO 9001:2000
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Moisture removal
Totally dependent on
reduction of dewpoint
HIGHER TEMPERATURE
= DRY AIR
104°F (40°C)
SATURATED Commonly accepted
dewpoint is 10° below
COMPRESSED AIR prevailing ambient
FROM AFTERCOOLER Dewpoint Ambient
LOWER TEMPERATURE
=CONDENSATION

ISO 9001:2000
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Understanding
moisture content of air
DEWPOINT CONVERSION CHART

ISO 9001:2000
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The only positive
means of
lowering dewpoints
of compressed air
is by
installation of a
Quality Air Dryer

ISO 9001:2000
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Understanding
filteration
Filter Media Principle
1. Ceramics Separates liquids (droplets
and mist) through narrow
channels. A high quality and
economic filter media.
Selectivity: 2-5 µ..
2. Sintered metal Principle same as ceramics.

Consists of small metal balls.
Generally applied for less
stringent demands and long
standing time required.
3. Fibre structure Media for fine filteration.

(Boro Silicate Glass) Works on mechanical
Micro fibres filteration principle or coalescing
filters by direct interception, inertial
impaction and diffusion.
Selectiveity: Down to 0.01 µ..
4. Activated carbon Enables oil vapours to be

removed by adsorption on
activated carbon.

ISO 9001:2000
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Methods of drying
compressed air
REFRIGERATION
Removes moisture by cooling the air
below its dewpoint and condensing
the moisture
SORPTION
Removes moisture by passing air over
materials capable of extracting moisture
ADSORPTION ABSORPTION
Adsorbs water on the Removes moisture by
surface of sorbent chemically combining
without undergoing with water
change

ISO 9001:2000
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Refrigeration Dryers
AIR-TO-AIR HEAT EXCHANGER
AIR OUT
COUNTER FLOW
AIR IN
REFRIGERANT-TO-AIR HEAT EXCHANGER
PARALLEL FLOW
EXPANSION VALVE
LIQUID RECEIVER
CONDENSER COMPRESSOR
FAN
• Compressed air cooled to required dewpoint temperature

• Condensed water vapour discharged
• Cooled compressed air warmed by passing through an
air-to-air heat exchanger

ISO 9001:2000
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Delair
DI / FDI SERIES
This is how it works
AIR COOLED OPTION
DI Series: 27 models
Pressure dewpoint achievable: 3°C
Capacitites: 18 m3/hr to 540 m3/hr
Operating pressure: 7 bar (g)

ISO 9001:2000
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Delair
DI / FDI SERIES
This is how it works
WATER COOLED OPTION
DI Series: 27 models
Pressure dewpoint achievable: 3°C
Capacitites: 540 m3/hr to 6000 m3/hr
Operating pressure: 7 bar (g)

ISO 9001:2000
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Delair
• Unique, patented foamed-in air-
to-air heat exchanger
Reduces energy needs by 60%
• Unique load equaling device

Gives correct outlet dewpoint
• Compact design, easy to install
• Digital dewpoint readout
• Automatic electronic drain
• Fully automatic operations
…. better by design

ISO 9001:2000
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Methods of
regeneration
Saturated adsorbent can be
regenerated by
1. CHANGING THE ISOTHERM

(Thermal or Temperature Swing
Involves heating the adsorbent by hot gas.
2. CHANGING THE RELATIVE PRESSURE

(Pressure Swing)
Part of the treated (dried) gas is expanded,
which divides its relative pressure by the
pressure ratio. This removes the adsorbate.
3. COMBINATION OF PRESSURE SWING AND

TEMPERATURE SWING.

ISO 9001:2000
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Purge flow of a dryer

Myth and Reality
MYTH
Heatless dryers use 5 to 7% of the total air flow rate as
purge air
REALITY
Minimum purge (theoretical) possible is
1
x 100%
[Pressure (bar-g) + 1]
Typical example: Air at 7 bar (g)

1
Minimum purge = x 100 = 12.5%
7+1
In reality it is always higher
However, reduced purge % can be combined with heated

dryers
Typical : 3% purge + imbedded heaters = Delair
PDPA range

ISO 9001:2000
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delair – Adsorption
Dryers Heatless
DC Series
The principals of heatless, compressed air dryer
(regeneration by purge air) is based on the physical
property of desiccants to adsorb and desorb water
vapour.
OUTLET DRY AIR
INLET WET AIR
DC Series : 12 models
Pressure dewpoint achievable : < (–) 40°C
Capacities: 6 m3/hr to 1128 m3/hr

ISO 9001:2000
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Adsorption Dryers
SWITCHING
VALVES
DRYING REGENERATING
DESICCANT DESICCANT
PRESSURE PRESSURE
VESSEL VESSEL
SWITCHING
VALVES
Regenerative Dryer
• It consists of two pressure vessels filled with desiccant
• One tower dries the air, while the other is being regenerated
• Switching of towers is automatic through valves
• Desiccants used:
• Activated Alumina
• Molecular Sieve
• Silica Gel

ISO 9001:2000
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Dryers Heat regenerated
(No less)

ISO 9001:2000
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Dryers Heat regenerated
Reduced purge
Working principle based on combined pressure

+ temperature swing

ISO 9001:2000
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Dryers Energyless
Energyless dryer uses the heat of

compression to regenerate the desiccant.
Hot compressed air before ‘aftercooling’ is
used to regenerate the desiccant.

ISO 9001:2000
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Criteria for
selection of
the right dryer
• Degree of dryness
required
• First Cost
• Operating Cost
• Pressure drop through

the dryer and accessories
• Maintenance
• Reliability

ISO 9001:2000
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Choice of
desiccants
SILICA GEL MOLECULAR SIEVE
Pore size: 4 to 20 Pore size: 3 to 5
Angstroms Angstroms
Low cost Uniform structure
Highly reactive to Most effective at low RH
liquid water Pressure drop is low
Desiccant fines cause Best for high
excessive pressure drop temperature/
Best for atmosperic air very low dewpoint drying
drying
ACTIVATED ALUMINA DELSORB

Pore size: 4 to 20 The delair choice
Angstroms High efficiency
High cost Specially graded for size
Resilience to liquid water. Low pressure drop
Does not fracture
Homogenous air flow
Very little pressure drop
Regenerates at low
Can obtain dewpoints to temp.
-100oF
Certified performance
Best for compressed air
application Ensured long life
Available grade:
Delsorb 10

ISO 9001:2000
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3 Steps to
economic dryer selection
1. Check your application
2. Check your first cost v/s

operating cost
3. Check our range

ISO 9001:2000
delair
3 Steps to
COMPANY
economic dryer selection

1 Check your application
Pressure Refrigera-
Application dewpoint tion Dryer Adsorption
Dryers
* Plant Air * Paint spraying * Food

* General instrumentation 2°C
* Controls to Best Yes
* Pneumatic tools 10°C
* Chemicals * Healthcare
* Instrument ‘glove
boxes’ * Dry Air for
ozone generators
* Purging of refrigeration 0°C
coils and systems to X Best
* Vacuum breaking operations –20°C
* Climatic chambers
* Paint curing
* Instrumentation and
controls * Plastics
* Pneumatic transportation –20°C
* Chemicals * Cables and to X Best
wave guides –40°C
* Pharmaceuticals
* Packaging
* Specialised instrumentation
* Electronic assemblies –40°C Best
* Wind tunnels and X (for low
* Space research below air flow)
* Dry boxes – Cryogenics
* Gas liquification
A B

ISO 9001:2000
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Operating Cost Comparison

A B C
REFRIGERATED HEATLESS HEAT REGENERATED
1. Capacity 1000 1000 1000

(Typ) M 3/hr
2. Mode (Typ) DI 970 DC 132 DB 24 S (D)
3. Inlet temp. 38°C 38°C 38°C
4. Pressure Bar (g) 7 7 7
5. P.D.P. 2°C (–) 40°C (–) 40°C
6. Atmospheric (–) 23.3°C (–) 57°C (–) 57°C

dewpoint
7. Purge m3/hr – 190 m3/hr –
8. Eqv hp/kw loss – 20.7 K –
9. Operating kw 2.9 kw 20.7 kw 12 kw

(Total) (Compressor) (Purge) (Heater+Blower)
10. Cost differential (Rs.) – 10,00,000 –

for over capacity
compressor
(Approx.)
11. Dryer cost (Rs.) 1,95,000 1,80,000 4,50,000
12. Total capital 2,55,000 2,70,000 4,50,000

cost (Rs.)
13. Operating cost (Rs.) 348 2484 1440

per day (24 hrs.) at
Rs. 5 KW
14. Operating cost A vs B Rs. 2136/ B vs A Rs. 2136 C vs A Rs. 1092

difference per day day saving (loss) (loss)
(Rs.) A vs C Rs. 1092/ B vs C Rs. 1044 C vs B Rs. 1044
day saving (loss) (gain)
Payback period
A vs B 70 days N.A. N.A.
A vs C 467 days N.A. N.A.
(15 months)
C vs B N.A. N.A. 343 days
(12 months)

ISO 9001:2000
delair
COMPANY
Check-list for
a good dryer
DRYER COMPONENTS
REFRIGERATION
• Heat exchanger
• Control Systems
• Space design (Floor space)
• Filters
DESICCANT
• Desiccant
• Valves
• Vessels -- code/design/size
• Controllers
• Filters
• Pipeline and valve sizing
• Purge

ISO 9001:2000
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COMPANY
Delair Dryers
To achieve
Quality Air
Delair provides total
solutions
l Design l Engineering
l Production l Installation
in Compressed Air
Dryers
delair . . . Better by design

ISO 9001:2000
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COMPANY
Dryer
installation options
Option A
Dryer after air receiver
COMPRESSOR
WITH
AFTERCOOLER
PRE AFTER
FILTER FILTER
DRYER WITH
AIR BY-PASS
RECEIVER
• Flow through dryer can be more than maximum flow of compressor

• Inlet temperature dryer lower than outlet temperature of aftercooler
Options B
1000 CFM PLANT AIR
1000 CFM
AT 2°C PDP
REFRIGERATION
DRYER
AIR
COMPRESSOR RECEIVER

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delair

Compressed Air Drying

The air surrounding us always contains a certain

# 1 in Compressed Air Drying

# 1 in Compressed Air Drying

Compressed air compression at 100

Compressed air after the aftercooler at

Compressed air after expansion to

# 1 in Compressed Air Drying

Malfunction of Blisters on painted

Contaminated food- Chemicals, pharmaceuticals–

# 1 in Compressed Air Drying

Air sucked into a

# 1 in Compressed Air Drying

• Ruins air-operated tools

# 1 in Compressed Air Drying

Oil + dust + gases + bacteria =

• Clogged nozzles in pneumatic

• Spoilt food and pharma products

• Degraded brewery products etc.

# 1 in Compressed Air Drying

Removes at best only

# 1 in Compressed Air Drying

• Low running costs

• Low maintenance costs

To achieve quality air

# 1 in Compressed Air Drying

# 1 in Compressed Air Drying

# 1 in Compressed Air Drying

DEWPOINT CONVERSION CHART

# 1 in Compressed Air Drying

The only positive

Quality Air Dryer

# 1 in Compressed Air Drying

2. Sintered metal Principle same as ceramics.

3. Fibre structure Media for fine filteration.

4. Activated carbon Enables oil vapours to be

# 1 in Compressed Air Drying

# 1 in Compressed Air Drying

REFRIGERANT-TO-AIR HEAT EXCHANGER

• Compressed air cooled to required dewpoint temperature

# 1 in Compressed Air Drying

This is how it works

AIR COOLED OPTION

# 1 in Compressed Air Drying

This is how it works

WATER COOLED OPTION

# 1 in Compressed Air Drying

• Unique load equaling device

• Compact design, easy to install

• Digital dewpoint readout

• Automatic electronic drain

• Fully automatic operations

# 1 in Compressed Air Drying

1. CHANGING THE ISOTHERM

2. CHANGING THE RELATIVE PRESSURE

3. COMBINATION OF PRESSURE SWING AND

# 1 in Compressed Air Drying

Purge flow of a dryer

Typical example: Air at 7 bar (g)

In reality it is always higher

However, reduced purge % can be combined with heated

# 1 in Compressed Air Drying