How do you dry air for an ozone generator?

What is an air dryer system?

An air dryer is a piece of equipment that separates the moisture from the industrial processed air, more commonly known as de-humidifying. By drawing out the humid air and compressing it, the air temperature is raised and then the air is cooled, condensing the water vapor from the unit. 

How does an air dryer work?

The moist, warm air enters the air dryer and is cooled down quickly to just above freezing. This condenses the water vapor into liquid water, which is then trapped and emitted via discharge lines.

Are there different types of air dryers? 

There are four essential utilities needed in the manufacturing industry: 

• Water
• Electricity
• Natural Gas
• Compressed 

While compressed air isn’t considered a utility by the rest of the world, in the world of manufacturing, it is a utility, and just as important as the others. Those four utilities are important in the operation of the four different types of air dryers used in manufacturing, which are:

• Refrigerated Air Dryers

This is the most popular and most used type. It functions much like the refrigerator in a home kitchen with a cooling process that prevents moisture with a key difference. Where the home refrigerator cools perishable foods, keeping them preserved, a refrigerated air dryer retains the air quality in a manufacturing setting. 

• Desiccant Air Dryers

Desiccant agents are used in some air dryers for drying compressed air, also referred to as adsorption. Adsorption is the process of moisture attaching itself to the desiccant whereas absorption, a drying agent absorbs moisture.

• Chemical Air Dryers

Chemical air dryers pass compressed air over a layer of deliquescent chemicals, saturating those chemicals with excess moisture pulled from the air. These chemicals attract water naturally such as calcium chloride, lithium, and sodium. 

• Membrane Air Dryers

Membrane air dryers are used for applications where gas separation is required and dehumidification, commonly used in the food production sector. As compressed air enters a membrane air dryer, it moves over semi-permeable membrane fibers. Specific materials are allowed to pass, like oxygen, separating it from the needed gas.  

What is the most efficient type of air dryer?

For areas that require extremely low dew points, a desiccant air dryer is the most efficient. This will maintain the ambient temperature when it drops below freezing to prevent ice from forming in the applications and pipes. It is recommended to use a desiccant air dryer that is equipped with a PPR (Pulse Purge Regeneration).

What are the common problems with air dryers? 

Air dryers are a critical piece of equipment in the manufacturing industry to keep costs down, and more often than not, they are neglected. Some of the common problems with air dryers are: 

• Clogged/Failed Drains 

This will compromise a refrigerant air dryer’s performance because the water can’t escape and will get into the pneumatic system, similar to a clogged gutter system. A clogged or failed drain will force the compressed air into the pneumatic component and lowers the quality of the air.

• High Inlet and/or Ambient Temps

This is the next most common problem with air dryers. If there is any variation in the temperature, it can send the PSIG, Inlet temperature, and Ambient temperature in the wrong direction, hindering the air dryer’s performance.

• Improper Air Dryer Size

Like the size of your water heater or HVAC system, if they are the wrong size, you won’t get optimum service from an air dryer. Consulting with the dryer sizing chart is important to ensure you have the right size for your industry’s needs. 

• Infrastructure

Compressed air is like water, it follows the path with the least resistance. It is important to consider this when choosing an air dryer. If the components are oversized, the pressure is reduced across the equipment.