U.S. patent application number 13/102929 was filed with the patent office on 2012-11-08 for modular construction compressed air/gas dryer system with filtration.
Invention is credited to John A. Carlin, Allan Hoerner.
Application Number | 20120279252 13/102929 |
Document ID | / |
Family ID | 47089303 |
Filed Date | 2012-11-08 |
United States Patent
Application |
20120279252 |
Kind Code |
A1 |
Carlin; John A. ; et
al. |
November 8, 2012 |
MODULAR CONSTRUCTION COMPRESSED AIR/GAS DRYER SYSTEM WITH
FILTRATION
Abstract
A modular compressed-gas dryer including in series: an inlet
module, a precooler/reheater module, an evaporator module, and a
sump module. The modules form columns where at least one column has
a filtration chamber. Further provided are a gas outlet and
gastight seals between modules. The system creates a first and
second set of heat transfer passages where refrigerant passes
through the second set in a heat exchange relationship in a
direction perpendicular to incoming gas passing in the first set.
The filtration chamber conducts chilled gas from the first set to a
third set of heat transfer passages. The third set extends through
the precooler/reheater in heat exchange relationship with the first
set. Chilled gas passes in heat exchange relationship in a
direction perpendicular to the incoming gas so that the incoming
gas chilled in the evaporator exchanges heat with the incoming gas
in the precooler/reheater.
Inventors: |
Carlin; John A.; (Buffalo,
NY) ; Hoerner; Allan; (Alden, NY) |
Family ID: |
47089303 |
Appl. No.: |
13/102929 |
Filed: |
May 6, 2011 |
Current U.S.
Class: |
62/524 |
Current CPC
Class: |
F28F 2280/00 20130101;
F28D 2021/0064 20130101; F28F 9/001 20130101; F28F 3/025 20130101;
F28F 9/26 20130101; F28D 2021/0038 20130101; F28F 9/22 20130101;
F28D 21/0014 20130101; B01D 53/265 20130101; F28D 9/0062 20130101;
F28D 2021/0066 20130101; F28D 7/16 20130101; F28F 17/005 20130101;
F28F 2275/205 20130101 |
Class at
Publication: |
62/524 |
International
Class: |
F25B 39/02 20060101
F25B039/02 |
Claims
1) A modular compressed-gas dryer system comprising: a flow through
gas system, including in series, a) an inlet module for introducing
incoming gas into said system; b) a precooler/reheater module for
housing a gas-to-gas heat exchanger; c) an evaporator module for
housing a refrigerant-to-gas heat exchanger; d) a sump module for
collecting and draining condensate from said system; e) wherein
said modules together form a plurality of columns for creating gas
flow through passages where at least one of said columns has a
filtration chamber for housing a filter; f) a gas outlet for
discharging outgoing gas; g) a sealing means interposed between
respective modules to ensure a gastight seal; h) a first set of
heat transfer passages extending through said heat exchangers in
which said incoming gas passes serially through said heat
exchangers in a first direction; i) a second set of heat transfer
passages extending through said evaporator module in heat exchange
relationship with said first set of heat transfer passages through
which a charge of refrigerant passes in a heat exchange
relationship with said incoming gas and in a direction
substantially perpendicular to said first direction of said
incoming gas to produce chilled gas; j) a filtration passage within
said filtration chamber for conducting said chilled gas through
said filter from said first set of heat transfer passages to a
third set of heat transfer passages; k) said third set of heat
transfer passages extending through said precooler/reheater module
in heat exchange relationship with said first set of heat transfer
passages and through which chilled gas passes in heat exchange
relationship with said incoming gas and in a direction
substantially perpendicular to said first direction of said
incoming gas; and l) so that said incoming gas is chilled in said
evaporator module and chilled gas therefrom exchanges heat with
said incoming gas in said precooler/reheater module to precool said
incoming gas and to raise the temperature of said chilled gas to a
temperature for ultimate use upon discharge.
2) The modular compressed-gas dryer system of claim 1 wherein said
series of modules are removably held together by a multiplicity of
rods and bolts and wherein said sealing means is a gasket and
mating interlocking edges between each module.
3) The modular compressed-gas dryer system of claim 1 wherein said
filtration chamber houses a replaceable filter.
4) The modular compressed-gas dryer system of claim 3 wherein said
filter is a coalescing filter.
5) The modular compressed-gas dryer system of claim 1 wherein said
gas-to-gas heat exchanger is a tube-and-shell heat exchanger.
6) The modular compressed-gas dryer system of claim 5 wherein said
tube-and-shell heat exchanger is equipped with a baffle
assembly.
7) The modular compressed-gas dryer system of claim 1 wherein said
heat exchangers are constructed as corrugated sheet units having
vertical channels and horizontal channels.
8) The modular compressed-gas dryer system of claim 1 further
comprising a sensor port for insertion of a level sensor and a dew
point port for insertion of a dew point sensor.
9) A modular compressed-gas dryer system comprising: a flow through
gas system, including in series, a) an inlet module for introducing
incoming gas into said system; b) at least one precooler/reheater
module for housing a gas-to-gas heat exchanger; c) at least one
evaporator module for housing a refrigerant-to-gas heat exchanger;
d) a sump module for collecting and draining condensate from said
system; e) wherein said modules together form a plurality of
columns for creating gas flow through passages where at least two
of said columns have a filtration chamber for housing a filter; f)
a gas outlet for discharging outgoing gas; g) a sealing means
interposed between respective modules to ensure a gastight seal; h)
a first set of heat transfer passages extending through said heat
exchangers in which said incoming gas passes serially through said
heat exchangers in a first direction; i) a second set of heat
transfer passages extending through said evaporator module in heat
exchange relationship with said first set of heat transfer passages
through which a charge of refrigerant passes in a heat exchange
relationship with said incoming gas and in a direction
substantially perpendicular to said first direction of said
incoming gas to produce chilled gas; j) a third set of heat
transfer passages extending through said precooler/reheater module
in heat exchange relationship with said first set of heat transfer
passages and through which chilled gas passes in heat exchange
relationship with said incoming gas and in a direction
substantially perpendicular to said first direction of said
incoming gas; k) at least one filtration passage within said at
least two of said columns having a filtration chamber for
conducting said gas from any one of said modules to one of said
heat transfer passages; and l) so that said incoming gas is chilled
in said evaporator module and chilled gas therefrom exchanges heat
with said incoming gas in said precooler/reheater module to precool
said incoming gas and to raise the temperature of said chilled gas
to a temperature for ultimate use upon discharge.
10) The modular compressed-gas dryer system of claim 9 wherein said
series of modules are removably held together by a multiplicity of
rods and bolts and wherein said sealing means is a gasket and
mating interlocking edges between each module.
11) The modular compressed-gas dryer system of claim 9 wherein said
gas-to-gas heat exchanger is constructed as a tube-and-shell heat
exchanger.
12) The modular compressed-gas dryer system of claim 11 wherein
said tube-and-shell heat exchanger is equipped with a baffle
assembly.
13) The modular compressed-gas dryer system of claim 9 wherein said
heat exchangers are constructed as corrugated sheet units having
vertical channels and horizontal channels for directing gas and
refrigerant.
14) The modular compressed-gas dryer system of claim 9 wherein each
of said at least two of said columns having a filtration chamber
houses a replaceable filter.
15) The modular compressed-gas dryer system of claim 14 wherein one
said at least two of said columns having a filtration chamber
houses a replaceable filter and conducts said gas from said inlet
module to a first of said at least one precooler/reheater
modules.
16) The modular compressed-gas dryer system of claim 15 wherein one
said replaceable filter is a particulate/coalescing filter.
17) The modular compressed-gas dryer system of claim 14 wherein one
said at least two of said columns having a filtration chamber
houses a replaceable filter and conducts said gas from said sump
module to said at least one precooler/reheater module.
18) The modular compressed-gas dryer system of claim 17 wherein one
said replaceable filter is a coalescing filter.
19) The modular compressed-gas dryer system of claim 9 wherein said
at least one precooler/reheater module for housing a gas-to-gas
heat exchanger is two precooler/reheater modules for housing two
gas-to-gas heat exchangers; and wherein said at least one
evaporator module for housing a refrigerant-to-gas heat exchanger
is two evaporator modules for housing two refrigerant-to-gas heat
exchangers; and wherein said at least two of said columns have a
filtration chamber for housing a filter is two filtration chambers
each housing a filter.
20) The modular compressed-gas dryer system of claim 9 further
comprising a sensor port for insertion of a level sensor and a dew
point port for insertion of a dew point sensor.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This patent application relates to a compressed air/gas
dryer system for generating clean, dry air for use in industrial
processes. More specifically this patent application relates to a
refrigerant compressed air/gas dryer system comprising modular
construction and a replaceable filter.
[0003] 2. Background
[0004] The atmospheric air that surrounds us is contaminated with
varying concentrations of hydrocarbons, solid particles and water
vapor. When compressed to a working pressure of 100 pound-force per
square inch gauge (PSIG), the concentration of these contaminants
is increased by a factor of eight to one. If these contaminants are
not removed prior to entering a process distribution system they
will damage air operated equipment, slow down or stop production,
corrode the inside of pipes, spoil product, ruin processes, and
drive up energy costs.
[0005] Moisture is a serious problem in compressed air systems.
Since atmospheric air always contains some amount of moisture,
measured in terms of relative humidity. Relative humidity is the
ratio of moisture in the air compared to the capacity of moisture
that volume of air is capable of holding at a specified
temperature. When air is compressed, friction causes the actual air
temperature to rise, greatly increasing its ability to hold
moisture. At 100 PSIG the quantity of moisture commonly held in
eight cubic feet of air is reduced in an area 1/8 its original
size. The result of compression is hot, wet, dirty air.
[0006] A good general rule is that for every twenty degrees
Fahrenheit (20.degree. F.) the temperature of air decreases, its
ability to hold moisture is reduced by 50%. As air passes through a
plant piping system, the ambient conditions cause the compressed
air to cool, causing the formation of liquid water. This water,
coupled with particulate matter and oil/lubricant carry-over will
cause numerous problems. The water will wash away lubricants from
tools and machinery, spoil paint applications, rust the general
system, and, if exposed to unfavorable ambient temperatures,
freeze.
[0007] Particulate matter consists of atmospheric particles that
are drawn into a plant piping system through the air compressor
intake. Some air system components, along with scale build-up in
piping, may introduce additional particulate matter. Particulates
traveling through the air system will cause pressure drop to
increase, valves and orifices to clog, and product to be spoiled.
Particulate matter will clog orifices and valves, damage gear
driven equipment, increase system pressure drop and contaminate
product.
[0008] Airborne hydrocarbons, compressor oils and lubricants are
harmful to all downstream equipment and processes. Today's high
performance compressor lubricants can cause additional problems,
and need to be removed before they cause irreversible damage. They
will cause valve and gasket materials to fail, and wreak havoc on
processing equipment. Residual oils and lubricants will cause valve
wear, spoiled product and system contamination.
[0009] Therefore, it is essential to treat process air before it
can do any damage to a process system. By drying and filtering
compressed air, operation efficiency can be maximized, and
equipment productivity and longevity can be greatly increased.
[0010] Presently, refrigerated compressed air/gas dryer systems
utilize some basic components. For example, there is usually a heat
exchange unit used to pre-cool air entering the dryer system and to
reheat dry air before the air leaves the dryer. Various systems
also use an evaporator for circulating refrigerant to promote
condensation of water vapor followed by a means to drain-off the
resultant condensation. Dryer systems are further equipped with a
filter to clean the compressed air/gas before the air/gas enters
the dryer system and/or as the air/gas leaves the dryer system.
Additionally, some systems utilize a filter as an intermediate
stage component; such as after the evaporator and before the
reheater. These traditional dryer systems are large and bulky due
to the interconnection of the various components comprising the
dryer system. To date, there are no dryer systems contained within
a single pressurized housing that efficiently allows the passage of
compressed air/gas to flow through the system and exit both dry and
filtered. Many prior attempts have been made to mitigate the
problems associated with drying gas. For example:
[0011] U.S. Pat. No. 5,794,453 discloses an apparatus for removing
condensate from a gas. The system has a chiller to cool the gas
followed by a separator to remove the condensed liquid. The dried
gas is then sent through a reheater before exiting the apparatus.
While this apparatus dries and reheats the gas, there are
significant drawbacks to this design. First, there is no filtration
of the gas to remove particulates or to further condense any
remaining water vapor in the gas following chilling. Secondly, the
device is inefficient as the hot incoming air is cooled only
through the chiller, thus requiring more energy to run and a
greater amount of refrigerant to cool the gas.
[0012] U.S. Pat. No. 6,470,693 describes a gas compressor
refrigeration system. The system has a chiller to cool the gas
followed by a separator to remove the condensed liquid. The dried
gas is then sent through a reheater before exiting the apparatus. A
closed-loop refrigerant system which supplies heat to the reheater
and is then recharged to cool the gas in the chiller. While this
apparatus dries and reheats the gas, there are significant
drawbacks to this design. First, there is no filtration of the gas
to remove particulates or to further condense any remaining water
vapor in the gas following chilling. Secondly, the device is
inefficient as the hot incoming air is cooled only through the
chiller, thus requiring more energy to run and a greater amount of
refrigerant to cool the gas.
[0013] U.S. Pat. No. 7,343,755 presents a gas drying system having
a recuperator, a moisture separator, and a refrigerated section
housed in a single unit. The recuperator has a pair of fluid flow
paths in thermal communication such that incoming hot air is cooled
by, and in turn warms, cooled air exiting the system. The incoming
air is further chilled in the refrigerated section to cause water
in the air to condense into liquid water. The liquid water is then
separated from the gas in the separator section. While this
apparatus dries and reheats the gas, there is no filtration of the
gas to remove particulates or to further condense any remaining
water vapor in the gas following chilling.
[0014] Importantly none of the example provided above, even
combined, construct in a single, compact housing, all the necessary
elements to dry and clean compressed air/gas, namely to precool
incoming gas, to chill the gas to 33.degree. F., to drain off
resulting condensation and to coalesce any remaining water
molecules, to remove particulates in the gas, to sense the liquid
level (of coalesced condensate) and drain off as necessary, and to
reheat exiting gas. Further, none of the above examples employ
filtration, and more specifically, filtration using a replaceable
filter. Additionally, none of the examples are modularly
constructed which prevents them from being disassembled for
maintenance and repair. These examples must be completely removed
and replaced, adding greatly to the size and cost of such
systems.
[0015] Thus, there is clearly an unmet and long-felt need for a
free-standing, cost effective, refrigerated compressed air/gas
dryer system that dries and filters compressed air/gas in a single
pressurized housing where the housing further comprises a
replaceable coalescing filter; eliminating the need for bulky
interconnecting means between subcomponents. Ideally, such a
refrigerated compressed air/gas dryer system that dries and filters
compressed air/gas in a single pressurized housing would be
compatible with a variety of existing dryer systems.
[0016] It should be understood that there are other conventional
components that, when combined with the refrigerant compressed
air/gas dryer system of the present disclosure, fully comprise a
finished dryer which is ready for use. Such additional conventional
components include a condensing unit (refrigerant compressor,
condenser that is either air or water cooled, receiver,
accumulator, pressure switches), drain solenoids & valves,
cabinetry, controls and wiring, etc.
SUMMARY OF THE INVENTION
[0017] It is accordingly an object of the present disclosure is to
provide a compressed air/gas dryer system which is comprised of an
air inlet compartment, a precooler/reheater compartment, and
evaporator compartment and a sump compartment housed in a single
pressurized housing.
[0018] A further object of the present disclosure is to provide a
compressed air/gas dryer system which is housed in a single
pressurized housing and which further comprises an intermediate
stage replaceable coalescing filter.
[0019] Still another object of the present disclosure is to provide
a compressed air/gas dryer system where there is a unidirectional
air/gas flow circuit through the pressurized housing and a
unidirectional refrigerant flow circuit within the evaporator
compartment.
[0020] Yet another object of the present disclosure is to provide a
compressed air/gas dryer system which is comprised of an air inlet
compartment, a precooler/reheater compartment, and evaporator
compartment and a sump compartment housed in a single pressurized
housing where each compartment is an independent module which can
be sequentially dismantled and reassembled.
[0021] A further object of the present disclosure is to provide a
means to measure the level of collected liquid water (condensation)
and to evacuate condensation from the system.
[0022] Another object of the present disclosure is to provide a
compressed air/gas dryer system which has `layered` horizontal
compartments, when assembled, comprise vertical column chambers for
adding filters.
[0023] The above and other objects are accomplished in accordance
with the present disclosure which comprises an air/gas dryer system
having a plurality of vertical compartments formed by layering a
plurality of modular units. The system has an inlet module with an
air inlet port for admission of air/gas into the dryer system.
Inlet air passes into a precooler/reheater module which cools the
air from the inlet module while, without allowing communication
between incoming and outgoing air, simultaneously warms outgoing
air which is directed out of the system through an air outlet port.
Precooled air then passes into an evaporator module having inlet
and outlet ports for circulating refrigerant/coolant within a
refrigerant flow circuit. The air is further cooled, by way of the
refrigerant, until the air temperature nears 33.degree. F. Cooling
the air causes the water vapor within the air to condense into
liquid water and collect in the sump module where it can then be
drained out of the system. The air then passes into a filter
compartment which is a dedicated vertical compartment that spans
the precooler/reheater and evaporator modules. The filter
compartment contains a coalescing filter which further dries the
air and removes any particles. Liquid water captured by the filter
is removed via a filter drain port on the evaporator module. The
coalescing filter is replaceable and is accessed by an entry port
on the top plate of the inlet module. The system may further
comprise a dew point sensor port directly below the evaporator
module and a condensation level sensor port on the Sump module. The
air/gas dryer system further has a mechanical mounting means
located next to the air inlet & air outlet ports and on the
bottom side of the bottom plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present disclosure and the manner in which it may be
practiced is further illustrated with reference to the accompanying
drawings wherein:
[0025] FIG. 1 is a perspective view of one embodiment of a
compressed air/gas dryer system of the present disclosure with the
dryer system having four modules forming three chambers along a
common axis.
[0026] FIG. 2 is an exploded view of the major components
comprising one embodiment of the present disclosure.
[0027] FIG. 3 is an enlarged exploded view of the sump module and
the bottom plate taken generally from boxed region 33 in FIG.
2.
[0028] FIG. 4 is a detailed view of one embodiment of a
precooler/reheater heat exchange unit of the present
disclosure.
[0029] FIG. 5 is a detailed view of an additional embodiment of a
precooler/reheater heat exchange unit of the present disclosure
including various baffle techniques.
[0030] FIG. 6 shows a top left perspective view of baffle
assemblies utilized in one embodiment of a precooler/reheater heat
exchange unit of the present disclosure.
[0031] FIG. 7 shows a side view of examples of baffle assemblies
utilized in one embodiment of a precooler/reheater heat exchange
unit of the present disclosure.
[0032] FIG. 8a is a perspective view of a refrigeration evaporator
heat exchange unit used in one embodiment of the present
invention.
[0033] FIG. 8b is an enlarged view of a refrigeration evaporator
heat exchange unit used in one embodiment of the present disclosure
taken generally from boxed region 8b in FIG. 8a.
[0034] FIG. 8c is a perspective view of refrigeration evaporator
heat exchange units used in one embodiment of the present
invention.
[0035] FIG. 9a is a flow schematic illustrating a representative
example of the air and refrigerant flow pattern through one
embodiment of a compressed air/gas drying system of the present
disclosure.
[0036] FIG. 9b is a flow schematic illustrating a representative
example of the air and refrigerant flow pattern through a preferred
embodiment of a compressed air/gas dryer system of the present
disclosure.
[0037] FIG. 10 is an exploded view of the major components
comprising a preferred embodiment of the present disclosure.
[0038] FIG. 11a is a perspective view of a precooler/reheater heat
exchange unit of the present disclosure.
[0039] FIG. 11b is an enlarged view of a precooler/reheater heat
exchange unit taken generally from boxed region 11 in FIG. 11a.
[0040] FIG. 11c is a perspective view of another embodiment of a
precooler/reheater heat exchange unit of the present
disclosure.
[0041] FIG. 12 is a detailed enlarged exploded view of a
precooler/reheater heat exchange unit of the present
disclosure.
[0042] FIG. 12a is a detailed enlarged exploded view of the heat
exchanger unit taken generally from boxed region 112 in FIG.
12.
[0043] FIG. 13 is a side elevational view of a preferred embodiment
of a compressed air/gas drying system of the present disclosure
showing the symmetrically constructed cell columns and the rod/bolt
pattern of the three column cell, single row configuration.
[0044] FIG. 13A is a top view of a top plate of a preferred
embodiment of a compressed air/gas drying system of the present
disclosure taken generally along line 13A-13A in FIG. 13.
[0045] FIG. 13B is a top view of the inlet module of a preferred
embodiment of a compressed air/gas drying system of the present
disclosure taken generally along line 13B-13B in FIG. 13.
[0046] FIG. 13C is a top view of the precooler/reheater module of a
preferred embodiment of a compressed air/gas drying system of the
present disclosure taken generally along line 13C-13C in FIG.
13.
[0047] FIG. 13D is a top view of the evaporator module of a
preferred embodiment of a compressed air/gas drying system of the
present disclosure taken generally along line 13D-13D in FIG.
13.
[0048] FIG. 13E is a top view of the sump module of a preferred
embodiment of a compressed air/gas drying system of the present
disclosure taken generally along line 13E-13E in FIG. 13.
[0049] FIG. 14 is a perspective illustration showing the bottom
plate and rod-and-bolt fasteners of an embodiment of a compressed
air/gas dryer system of the present disclosure.
[0050] FIG. 15 is a perspective illustration showing the bottom
plate and sump module, of a compressed air/gas dryer system of the
present disclosure.
[0051] FIG. 16a is a perspective illustration showing the bottom
plate, sump module, filter, and gasket configuration for an
embodiment of a compressed air/gas dryer system of the present
disclosure.
[0052] FIG. 16b is a perspective illustration showing the bottom
plate, sump module, filter, and gasket configuration for an
embodiment of a compressed air/gas dryer system of the present
disclosure.
[0053] FIG. 17a is a perspective illustration showing the bottom
plate, sump module, filter, and gasket configuration for an
embodiment of a compressed air/gas dryer system of the present
disclosure.
[0054] FIG. 17b is a perspective illustration showing the bottom
plate, sump module, filter, and gasket configuration for an
embodiment of a compressed air/gas dryer system of the present
disclosure.
[0055] FIG. 18a is a perspective illustration showing the bottom
plate, sump module, precooler/reheater module, and refrigeration
evaporator module for an embodiment of a compressed air/gas dryer
system of the present disclosure.
[0056] FIG. 18b is a perspective illustration showing the bottom
plate, sump module, precooler/reheater module, and refrigeration
evaporator module for an embodiment of a compressed air/gas dryer
system of the present disclosure
[0057] FIG. 19 is a perspective view of an additional embodiment of
a compressed air/gas dryer system of the present disclosure with
the dryer system having four modules forming two chambers along a
common axis.
[0058] FIG. 20 is a perspective view of one embodiment of a
compressed air/gas dryer system of the present disclosure with the
dryer system having four modules forming four chambers along a
common axis.
[0059] FIG. 21 is a perspective view of one embodiment of a
compressed air/gas dryer system of the present disclosure with the
dryer system having four modules forming five chambers along a
common axis.
[0060] FIG. 22 is a perspective view of one embodiment of a
compressed air/gas dryer system of the present disclosure with the
dryer system having four modules forming six chambers where a first
row of three chambers lies parallel with a second row of three
chambers.
[0061] FIG. 23 is a perspective view of the precooler/reheater and
evaporator modules each welded in a single piece construction.
[0062] FIG. 24 is a perspective view of the precooler/reheater and
evaporator modules as welded components.
[0063] FIG. 25 is a perspective view of the components of a further
embodiment wherein the precooler/reheater exchanger and evaporator
exchanger are welded in a single piece construction.
[0064] FIG. 26 is a perspective view of the precooler/reheater
exchanger and evaporator exchanger as a single unit with the
precooler/reheater and evaporator modules welded components.
DESCRIPTION OF SPECIFIC EMBODIMENTS
[0065] At the outset, it should be clearly understood that
reference numerals are intended to identify the information found
in the block diagrams in the several drawing figures, as may be
further described or explained by the entire written specification
of which this detailed description is an integral part. The
drawings are intended to be read together with the specification
and are to be construed as a portion of the entire "written
description" of this disclosure as required by 35 U.S.C.
.sctn.112.
[0066] Refrigerated compressed air/gas dryer systems utilize some
basic components to produce clean, dry and compressed air.
Typically a dryer system, will intake at the inlet wet, hot and
dirty compressed air/gas which is at approximately 100 PSI and at
100.degree. F., with a relative humidity of 100%. The precooler
cools the air temperature down to about 70.degree. F. and the
evaporator further cools air temperature down to the desired dew
point target of approximately 33/34.degree. F. The air leaves the
evaporator and the liquid water condensate falls out of the air and
the cold dryer air/gas is filtered and further dried by the
coalescing filter and enters the reheater section where it is
warmed (from the incoming hot air) to about 80.degree. F.
Fahrenheit as it exits the dryer system as clean dry air, ready for
use as compressed air/gas for industry. For example, a heat
exchange unit is typically used to pre-cool air entering the dryer
system and to reheat dry air before the air leaves the dryer.
Various systems also use an evaporator for circulating refrigerant
to promote condensation of water vapor followed by a means to
drain-off the resultant condensation. Systems are further equipped
with a filter to clean the compressed air/gas before the air/gas
enters the dryer system and/or as the air/gas leaves the dryer
system. Additionally, some systems utilize a filter as an
intermediate stage component; such as after the evaporator and
before the reheater. However, there are no dryer systems contained
within a single pressurized housing that efficiently allows the
passage of compressed air/gas to flow through the system and exit
both dry and filtered.
[0067] The preferred embodiment of the present disclosure provides
for a modularly constructed single pressurized vessel apparatus,
with integral filtration, which allows a flow of both
refrigerant/coolant and compressed air/gas to pass through the
single structure system to achieve clean, dry and compressed air
with greater economy and reduced cost of manufacturing. Increased
efficiency further reduces the physical size of the pressurized
system, as well as the physical size cabinetry in which the system
is installed.
[0068] Adverting now to the drawings, with reference to FIG. 1 a
preferred embodiment of the present disclosure of a modular
compressed air/gas dryer system is indicated generally by numeral
10. Modular dryer system 10 is comprised of a modular housing. In a
preferred embodiment, this modular housing is comprised of four
individual horizontal modular units. The housing is comprised of
inlet module 20 capped with top plate 12. Below inlet module 20 is
a heat exchange precooler/reheater module 30, followed by heat
exchange evaporator module 40, sump module 50, and bottom plate 14,
sequentially which, when combined form a single housing creating
three distinct vertical columns which direct the flow through the
system. Columns 1 and 2 are passageways that direct the flow of air
through the system from the inlet module to the sump module. Column
3 directs the passage of air from the sump module to the air
outlet. Preferably, the housing is of an aluminum cast and/or
aluminum extrusion construction. However, any suitable material can
be used to form the housing including, but not limited to, another
metal, an alloy, or a suitable polymeric material. Top plate 12 is
equipped with filter access cap 18, while inlet module 20 is
equipped with air inlet port 22, precooler/reheater module 30 has
air outlet port 32, and evaporator module 40 has
refrigerant/coolant inlet port 44, refrigerant/coolant outlet port
46, filter drain port 49 with a level sensor port 149 for insertion
of a level sensor and a sump module 50 having a dew point port 51
for insertion of a dew point sensor. The sump drain, filter drain
and liquid level sensor each afford a means to evacuate any
collected condensate from the system. Bottom plate 14 is configured
with threaded holes configured to accept a standard mounting means
(not shown) such as threaded bolt which allows pressurized the
modular dryer system 10 to be secured to a cabinet structure (not
shown).
[0069] It is important to understand that each of the ports
discussed above have appropriate fittings which are germane to its
respective technology (such as compressed air and refrigeration
technology and plumbing for the drains) that will be installed when
the dryer system 10 is implemented. For example, the
refrigerant/coolant ports 44 and 46 have conventional refrigeration
fittings typical to that technology such as `flair` fittings or
`rotolock` fittings because of the unique physical properties of
refrigerants. Likewise in a preferred embodiment air inlet port 22
and air outlet port 32 are each configured with NPT (National Pipe
Thread) pipe threads, straight thread and O-ring or a flange and
gasket. Thus the ports are compatible with conventional compressed
air/gas piping. In the preferred embodiment the remaining ports are
fitted with conventional NPT (National Pipe Thread) or a flange
with gasket. The typical connecting means to for the various inputs
and outputs are constructed with a threaded type fitting (such as
compressed air/gas into the system and out of the system and the
port to drain the condensation out of the system to a sewer).
[0070] FIG. 2 is an exploded perspective illustration of one
embodiment of a compressed air/gas dryer system of the present
disclosure. In this embodiment, dryer system 10 has four modules
which create three vertical columns with each module having three
chambers. Inlet module 20 is capped with top plate 12. Below inlet
module 20 is precooler/reheater module 30, followed by
refrigeration/coolant evaporator module 40, sump module 50, and
bottom plate 14, sequentially. Layered between each module is
gasket 16, as well as between top plate 12 and module 20 and
between bottom plate 14 and module 50. Gaskets 16 ensure pressure
tight seals at the junctions between modules, and plates and
modules. Gaskets such as depicted in FIG. 2 are necessary to ensure
a tight leak proof modular system. Top plate 12 and bottom plate
14, along with each of the gaskets 16 between each module and
plate, are preferably held together via a rod & bolt system to
create a pressure tight/air tight unit. Each of the three column
chambers controllably allows air to flow within each of the four
modular levels. The dryer operation and air flow will be discussed
in the detailed description of FIG. 9.
[0071] Top plate 12 of the compressed air/gas dryer system has a
filter access hole 17 into which is removably fitted filter access
cap 18. Cap 18 is equipped with an airtight seal means such as a
threaded portion which mates with corresponding threads in hole 17,
and/or an O-ring seal typically made out of rubber or a synthetic
polymer. An airtight seal is formed when gasket 16 is sandwiched
between the top plate and inlet module 20. Inlet module 20 is
equipped with air inlet port 22 through which wet contaminated air
is introduced to the dryer system. In this particular embodiment
where three vertical columns are present, inlet module further has
inlet pass-through hole 24 which allows inlet air to be split
between two columns as it passes to precooler/reheater module
30.
[0072] Precooler/reheater module 30 is secured to inlet module 20
and a pressure tight seal is created by gasket 16.
Precooler/reheater heat exchange units 35 are inserted into two
chambers of module 30 proximate to air outlet port 32. Dried and
filter air passes from the filter chamber through
precooler/reheater pass-through holes 34 and exits the system
through outlet port 32. Inlet air passes through precooler/reheater
heat exchange units 35 and enters refrigeration evaporator module
40.
[0073] Evaporator module 40 is secured to precooler/reheater module
30 and a pressure tight seal is maintained by gasket 16. Evaporator
heat exchange units 42a and b are positioned within the two
chambers of module 40 immediately below precooler/reheater heat
exchange units 35 in module 30. Refrigerant/coolant enters
evaporator module 40 via refrigerant inlet port 44 and flows
between the two halves of evaporator heat exchange units 42a and b
through pass-through hole 48. Exchangers 42a and 42b have a top and
bottom retainer flange 41. Vertical baffle 43 extends from the top
to the bottom of the exchanger. Air directed into module 40 from
module 30 travels within evaporator heat exchange units 42a and b
and passes into sump module 50.
[0074] Sump module 50 is secured to evaporator module 40 and a
pressure tight seal is maintained by gasket 16. Base plate 14 is
secured to sump module and a pressure tight seal is maintained by
gasket 16. Sump drain port 15 in base plate 14 allows removal of
any collected moisture during the air drying process. Module 40 has
refrigerant/coolant inlet port 44, refrigerant/coolant outlet port
46 and filter drain port 49 with a level sensor port 149. Air
leaves evaporator module 40 and passes into the sump module through
the two chambers via pass-through holes 56 located directly beneath
the two chambers of module 40 housing evaporator heat exchange
units 42a and b. A dew point sensor port 51 is located on sump
module 50 housing directly below the first chamber of evaporator
heat exchange units 42a and b. The air then passes through
pass-through holes 56 and is directed upwardly through coalescing
filter seat 54. Coalescing filter 52 is seated within seat 54 using
an airtight sealing means such as but not limited to a threaded
connection or a threaded connection with an O-ring seal made from
rubber or another suitable material such as synthetic polymer, or
bayonet style connection. Coalescing filter 52 extends upwardly
into evaporator module 40, precooler/reheater module 30 and inlet
module 20. Liquid water (condensate) captured by the filter element
(water molecules coalesce into droplets and travel down the filter)
is collected within the evaporator module and is removed through
evaporator drain port 49 located at the base of the filter seat.
Filter 52 is removably attached to seat 54 and is accessed by
removing cap 18 from top plate 12. This arrangement allows for the
filter to be quickly and easily changed without necessitating the
complete dismantling of the dryer system. Sump module 50 further
has, a dew point port 51 for measuring and sensing the dew point
value of the air/gas being dried.
[0075] FIG. 3 presents an enlarged exploded view of the sump module
50 and bottom plate 14 taken generally from boxed region 33 in FIG.
2. As shown, bottom plate 14 has a recessed edge 13 which
orientates and seats gasket 16. Sump module 50 has an interlocking
edge 58 located at the bottom of the module. Interlocking edge 58
interlocks with edge 13 which prevents blow-out of gasket 16 when
the dryer system is pressurized, and ensures an airtight/pressure
tight seal between the module and the base plate. The top of sump
module 50 has recessed edge 55 for seating a gasket 16 (not shown).
Gasket 16 is fully captive between each of the modules of the
modular dryer system. The recessed edge/interlocking edge
configuration allows each level of the dryer system to be
interlocked.
[0076] FIG. 4 is an illustration of a precooler/reheater heat
exchange unit 35 having a top tubesheet 36 and a bottom tubesheet
38 attached to the heat exchanger. The tubesheets seat in an
airtight manner at the top and bottom of the precool/reheat chamber
of module 30. Located between the tubesheets are a multiplicity of
hollow parallel tubes 37. In practice heat exchanger units 35
perform two functions; a pre-cool function and a reheat function.
The pre-cool function allows air flow from inlet module 20 (see
FIG. 2) to pass down through the inside of tubes 37 of the tube
array. The relatively cooler air from the coalescing filter chamber
cools the relatively warmer inlet air passing in the tube array
from the inlet module to the evaporator module.
[0077] The reheat function, allows air flow from the filter chamber
to pass through pass-through holes 34 (see FIG. 2) as the air is
directed to the air outlet port 32. The air is reheated by passing
around and between the outside of the tubes in the array. The
relatively warmer air from the inlet module passing within the
tubes warms the relatively cooler air coming from the coalescing
filter chamber.
[0078] FIG. 5 is an alternative precooler/reheater heat exchange
unit arrangement. In this example, precooler/reheater heat exchange
unit 35 retains the top tubesheet 36, bottom tubesheet 38, and
multiplicity of tubes 37, with all of the mechanical
characteristics thereof, of the precooler/reheater heat exchange
unit arrangement illustrated in FIG. 4. However, in the embodiment
of FIG. 5, baffles 39 are operatively arranged in and among tubes
37 to control the direction of airflow from the filter chamber as
the air passes to the air outlet port. Baffles 39 direct the flow
of air to create multiple passes, thus having multiple
opportunities to transfer heat within the exchanger.
[0079] FIG. 6 shows a top left perspective view of examples of
baffle assemblies utilized in one embodiment of a
precooler/reheater heat exchange unit. FIG. 7 shows a side view of
examples of a baffle assemblies utilized by one embodiment of a
precooler/reheater heat exchange unit. Note that for clarity
purposes, the tubesheets 36 and 38 and the various horizontal
baffles 39 do not show the holes through which the tubes pass. As
can be seen, there are two different baffle assembly arrangements,
39a and 39b. Using these configurations, the direction of flow
comprises a `two-pass` or `multi-path` system. By incorporating
various baffle assembly arrangements the heat exchangers can be
configured to achieve optimal heat exchange performance.
[0080] FIG. 8a is a perspective view of refrigeration evaporator
heat exchange unit 42. FIG. 8a shows the basic shape of heat
exchange units 42a and b having channels that are both vertical and
horizontal. FIG. 8b is an enlarged view of a refrigeration
evaporator heat exchange unit used in one embodiment of the present
disclosure taken generally from boxed region 8b in FIG. 8a. A
vertical flow channel array 410 allows the air to pass from top to
bottom through the heat exchange units 42a and b, and horizontal
flow channel array 412 allows refrigerant/coolant to pass from side
to side. Vertical baffle 43 extends from the top to the bottom of
the exchanger for controlling the flow of refrigerant/coolant. FIG.
8c shows the exchange units 42a and b assembled with a top and
bottom retainer flange 41. Since refrigerant/coolant is completely
surrounding the heat exchange units 42a and b (within the chamber
columns of the module 40), the baffle in this case will impede the
flow outside the exchanger and force the flow through the
horizontal channels 412.
[0081] The evaporator heat exchange unit functions as a
refrigerant/coolant-to-air heat exchange device. The retaining
flanges are disposed within the evaporator module chambers in a
like manner as the precooler/reheater heat exchange unit described
above and form an airtight seal such that the precooled air coming
from the tube array 37 (see FIGS. 4 and 5) is directed into the
evaporator heat exchange unit vertical channels 410 and does not
leak around the unit. During use, refrigerant/coolant is supplied
to the evaporator heat exchange unit through refrigerant inlet port
44 and circulates until it passes through exchanger 42a and to
exchanger 42b via notch pass-through 48 in module 30 housing, to a
second subunit before being recovered at refrigerant outlet port
46. The passage of expanded refrigerant at, for example 34.degree.
F., causes the compressed air/gas received from the
precooler/reheater module to quickly cool down to a dew point
suitable for vapors within the air/gas to condense and fall into
the sump module.
[0082] FIG. 9a is a flow schematic showing the paths of the air and
refrigerant flow patterns through a preferred embodiment of the
modularly constructed compressed air/gas dryer system of the
present disclosure. The side cross sectional view illustrates an
embodiment having four stacked modular levels 20, 30, 40, and 50
and three columns 1, 2, and 3. For the sake of clarity airflow is
depicted by solid black line arrows, refrigerant flow is depicted
by framed in white arrows and water exiting the system is depicted
by hashed arrows.
[0083] Contaminated hot wet compressed air/gas, represented as
arrow 100 enters inlet module 20 through air inlet 22. A portion of
air as illustrated by arrow 100 passes through pass-through hole 24
such that contaminated air is confined to columns 1 and 2. Air then
enters the tubes of precooler/reheater heat exchange units 35 (see
FIG. 5) within precooler/reheater module 30 where cooling of the
air progressively increases as the air moves through the exchange
units in the general direction of arrows 110 and 115. The
pre-cooled air flow as illustrated by arrow 120 then enters the
evaporator heat exchange unit within evaporator module 40.
[0084] Refrigerant/coolant enters evaporator module 40 via
refrigerant inlet port 44 (as shown in FIG. 1) and flows in the
direction of arrows 180 into a first evaporator heat exchange unit
and flows into a second evaporator heat exchange unit through
pass-through hole 48. All refrigerant is circulated and distributed
throughout evaporator module 40 and enters cavities 146 & 148
from refrigerant that flows in the general direction of arrows 183
and 185. Refrigerant accumulates on the leading side of the
evaporator heat exchanger in cavity 146 and after it moves through
the heat exchanger it is collected on the after side of the
evaporator heat exchanger in cavity 148. A similar process occurs
for the air flow precooler/reheater module 30 as air fills cavities
136 & 138. The cavities allow for even distribution of airflow
and refrigerant.
[0085] Refrigerant quickly cools the air which flows in the
direction of arrows 120 and 125 and causes vapor to condense and
drip into sump module 50. Collected water 191 drains from the
system through sump drain port 15 in the general direction of arrow
190. Removal of condensate is one of the objectives of the dryer
system. When air leaves module 40 it is cooled and dried air
traveling in the direction of arrow 130 and the air passes through
pass-through holes 56 and enters column 3 in the general direction
of arrow 131.
[0086] Column 3 has coalescing filter 52 seated at the top of sump
module and extending upwardly through evaporator module 40 and
partway into precooler/reheater module 30. Cooled dry air passes
into coalescing filter 52 in the general direction of arrows 140
thereby removing particles in the air while any remaining moisture
coalesces into droplets that fall down the outer surface of filter
52 and collect at the bottom of column 3 of the evaporator module.
Liquid condensate 196 is then removed through filter chamber drain
port 49 in the general direction of arrow 195. The cleaned, dry
cold air then passes in the general direction of arrow 145 into
precooler/reheater column 2 through first pass-through hole 34.
[0087] Relatively cooler air leaves evaporator module 40 and enters
precooler/reheater module 30 in the general direction of arrow 145
and passes through a first precooler/reheater heat exchanger in the
general direction of arrow 150. Cooler air coming from the
coalescing filter chamber is gradually warmed as it moves in the
general direction of arrow 155. Air then passes in the general
direction of arrow 155 through a second pass-through hole 34 into a
second precooler/reheater heat exchange subunit. The air flow from
the second precooler/reheater heat exchange subunit is directed to
the air outlet port 32. The air is reheated by passing around and
between the outside of the tubes in the precooler/reheater heat
exchangers. The tubes in the heat exchangers contain air flowing in
the general direction of arrow 110 entering the system on the
precooler side of the exchanger. The heat exchange occurs when the
relatively warmer air from the inlet module passing within the
tubes warms the relatively cooler air coming from the coalescing
filter chamber; and the relatively cooler air coming from the
coalescing filter chamber cools the relatively warmer air coming
from the inlet module. The air flowing in the general direction of
arrow 160 merges in cavity 138 before exiting dryer system as air
flowing in the general direction of arrow 170 through outlet port
32.
[0088] In another preferred embodiment of the present disclosure
having a baffle configuration assembly such as depicted in FIGS. 6
and 7, the baffle configuration causes the air to take multiple
paths around the baffles and tubes causing the air to become warmer
and exit the system in the general direction of arrow 165. The
clean, dry, filtrated, warmed compressed air then exits the system
through air outlet port 32 in the general direction of arrow
170.
[0089] FIG. 9b is a flow schematic showing the paths of air and
refrigerant flow patterns through a another preferred embodiment of
the modularly constructed compressed air/gas dryer system of the
present disclosure. This preferred embodiment of the modularly
constructed compressed air/gas dryer system is utilizing a single
precooler/reheater heat exchange unit 300 (as shown in FIG. 10) and
an evaporator heat exchanger 400 (as shown in FIG. 10) as opposed
to a pair of precooler/reheater heat exchange units 35 and
evaporator exchange units 42a and b utilized in the preferred
embodiment of the present disclosure illustrated in FIG. 2.
[0090] Hot and wet compressed air/gas flowing in the direction of
arrow 100 enters inlet port 22, passes through the precooler
generally in the direction of arrows 110 and 115, and continues
through the evaporator in the general direction of arrows 120 and
125 where it exits into the sump in the general direction of arrow
130. The moisture in the air turns to liquid water 191 (condensate)
and exits the system in the general direction of arrow 190 through
sump drain port 15. The cold dry air flowing in the general
direction of arrow 131 continues up into column 3 and passes
through coalescing filter which collects and filters-out
particulates in the air. The large liquid condensate in air flowing
in the direction of arrow 130 is drained-off and out sump drain
port 15. As the air flow continues into the filter chamber and pass
through the filter, any remaining smaller water molecules will
coalesce and trickle-down to outer surface of the filter and
collect at the base. A liquid level sensor (when installed into
sensor port 149, see FIG. 1) detects a specified level, this would
allow the dryer system to activate the drains (electrical drain
solenoids are not shown) and evacuate any collected condensate.
[0091] Remaining water molecules coalesce and are drained out port
49 as condensate in the general direction of arrow 195. The
cleaned, dried filtered air generally traveling in the direction of
arrow 145 exits column 3 and passes through pass-through 34 into
air distribution cavity 136 of precooler/reheater module 306.
Distribution cavity 136 serves to equally deliver air to the
approach side of the reheater section of the precooler/reheater in
the general direction of arrow 150. The air leaves the reheater in
the general direction of arrow 160 and enters air after cavity 138
where it exits through outlet port 32 as dry clean filter air in
the general direction of arrow 170. Refrigerant/coolant circuit (in
evaporator module 406) receives refrigerant/coolant from
refrigerant inlet port 44 (see FIG. 1). The circuit has a
refrigerant distribution cavity 146 on the approach to the
evaporator heat exchanger, and a refrigerant after cavity 148 to
collect refrigerant/coolant before exiting the evaporator module
via port 46.
[0092] FIG. 10 is an exploded view of an additional preferred
embodiment of modular compressed air/gas dryer system 500 of the
present disclosure. The embodiment illustrated in FIG. 10 is
identical to the embodiment illustrated in FIG. 2 except for a few
modifications. Precooler/reheater module is operatively arranged
such that a single precooler/reheater heat exchange unit 300 can be
inserted within the module. This single unit design has top
retainer flange 360 and bottom retainer flange 380 which fit in an
air tight manner within precooler/reheater module 306. Modified
gaskets 19 are configured to accommodate a single
pre-cooler/reheater heat exchange unit and a single evaporator heat
exchanger to ensure pressure tight seals at the junctions between
modules, and plates and modules. Gaskets such as depicted in FIG.
10 are necessary to ensure a tight leak proof modular system. An
array of vertical channels 370 and horizontal channels 375 are
interleafed to one another to create airflow channels to make up
the heat exchange unit.
[0093] Evaporator heat exchanger 400 has top flange 460 and bottom
flange 480. An array of vertical channels 470 and horizontal
channels 475 are interleafed allowing the exchange of heat from air
flowing through the vertical channels and refrigerant flowing
through the horizontal channels. Evaporator module 406 is
operatively arranged with a cavity to house a single evaporator
heat exchanger 400.
[0094] FIG. 11a is a perspective view of a precooler/reheater heat
exchange unit of the present disclosure. Heat exchanger 300 is
sandwiched between outer plate 314 and corner support 316. FIG. 11b
is an enlarged view of a precooler/reheater heat exchange unit
taken generally from boxed region 11 in FIG. 11a. FIG. 11b shows an
enlarged view of vertical channels 370 and horizontal channels 375.
The channels are formed from corrugated sheets of aluminum that are
oriented within the heat exchanger to have layers of vertical
channels 370 and horizontal channels 375 which are positioned on
opposite sides of an isolation barrier sheet 318 which is a flat
sheet of aluminum interleafed between each vertical and horizontal
channeled sheet. The sheets have a horizontal straight edge 372 and
a vertical straight edge 376 opposite its respective corrugated
pattern 371 (as shown in FIG. 12).
[0095] FIG. 11c is a perspective view of another embodiment of a
precooler/reheater heat exchange unit of the present disclosure.
FIG. 11c shows top retainer flange 360 and bottom retainer flange
380 affixed as if it were inserted into module 306. It is to be
expressly understood that the vertical and horizontal channels are
completely isolated from one another when the exchanger 300 is
installed into the assembly according to the teaching of the
present disclosure.
[0096] FIG. 12 is an exploded view of heat exchanger 300 showing
the construction and direction of channels of the inner sheets.
Heat exchanger 300 is made up of an assembly of aluminum sheets
having channels which are positioned to allow air to flow both
vertically and horizontally through the heat exchanger. The sheets
are oriented within the heat exchanger to have layers of vertical
channels 370 and horizontal channels 375 which are positioned on
opposite sides of an isolation barrier sheet 318 which is a flat
sheet of aluminum interleafed between each vertical and horizontal
channeled sheet.
[0097] FIG. 12a is a detailed enlarged exploded view of the heat
exchanger unit taken generally from boxed region 112 in FIG. 12.
Vertical channels 370 and horizontal channels 375 are formed
conventionally by sheets of aluminum which are pressed in a press
and die to result in a corrugation pattern 371. The corrugated form
makes the channels which help transfer heat between the channel
layer and the isolation barrier 318 by isolating and directing air
flow. The outer panels 314 encase and seal the assembly of aluminum
sheets as the layers of vertical and horizontal corrugated forms
and isolation barrier sheets are retained by corner support 316 and
notch 320 in corner support 316 receives the corner edges of the
vertical channels 370, horizontal channels 375 and isolation
barriers 318. The entire assembly is conventionally fused together
by any number of processes, for example dipped and brazed,
soldered, sonic weld, ultrasonic weld, microwave bonding fusion
bonding, etc. The preferred method of sealing/fusing the present
disclosure is a braze bonding process using an appropriate alloy to
fuse an approximate 0.0156 inch thick aluminum material for the
channeled aluminum sheets, and a 0.03125 inch thick aluminum
material for the flat isolation barriers. In like manner, outer
panels 314 are made of an approximate 0.125 inch thick (or thicker)
aluminum material which are--braze bonded to the inner channels and
barriers with the corner supports 316. The resulting structure can
withstand several hundred degrees of temperature and several
thousand pounds per square inch shear pressure. Further, all heat
exchangers described in this disclosure are preferably bonded via
brazing methods. It is important to understand that the corrugated
aluminum heat exchanger described herein is most suitable in a
compressed air/gas environment. In the preferred embodiment of the
present disclosure the two sides of the exchanger are configured to
withstand the pressures and temperatures typically found in such
environments.
[0098] In operation, inlet air enters module 306 through inlet
module 20 through air inlet and passes to evaporator module 406 by
going within the vertical channels 370. Air leaving the system
through air outlet port 32 is directed by horizontal channels 375
without contact or mixing with the inlet air. Similarly, evaporator
module 406 is designed to fit a single evaporator heat exchange
unit 400 within the module as shown in FIG. 10. The construction of
an evaporator heat exchanger 400 is identical to the
precooler/reheater heat exchanger 300 presented above except it is
installed into an evaporator module 406 housing. Heat exchanger 400
is comprised of vertical channel array 470 and horizontal channel
array 475, top retaining flange 460, and bottom retaining flange
480 as shown in FIG. 10. Heat exchanger 400 is installed in module
406 in like manner as exchanger 300 is installed into module 306
housing, with both being completely air pressure tight.
[0099] Air entering evaporator module 406 from precooler/reheater
module 306 passes through the evaporator heat exchange unit 400
where the air is rapidly cooled to about 34.degree. F. thereby
causing moisture within the air to condense and fall into sump
module 50. The air is rapidly cooled by action of a refrigerant
circulating within evaporator heat exchange unit 400. Refrigerant
is supplied via refrigerant inlet port 44 and removed through
refrigerant outlet port 46 as was discussed previously. In all
other respects, additional preferred embodiment of modular
compressed air/gas dryer system 500 of the present disclosure is
constructed and operates in the manner described above with
reference to the dryer system 10 (See FIGS. 1 and 2).
[0100] FIG. 13 is a side elevational view of a preferred embodiment
of a compressed air/gas drying system of the present disclosure
showing the symmetrically constructed cell columns and the rod/bolt
pattern of the three column cell, single row configuration. FIG.
13A is a top view of a top plate of a preferred embodiment of a
compressed air/gas drying system of the present disclosure taken
generally along line 13A-13A in FIG. 13.
[0101] FIG. 13B is a top view of the inlet module of a preferred
embodiment of a compressed air/gas drying system of the present
disclosure taken generally along line 13B-13B in FIG. 13. The top
views 13A through 13E show the openings of each module. FIG. 13C is
a top view of the precooler/reheater module of a preferred
embodiment of a compressed air/gas drying system of the present
disclosure taken generally along line 13C-13C in FIG. 13. FIG. 13D
is a top view of the evaporator module of a preferred embodiment of
a compressed air/gas drying system of the present disclosure taken
generally along line 13D-13D in FIG. 13. FIG. 13E is a top view of
the sump module of a preferred embodiment of a compressed air/gas
drying system of the present disclosure taken generally along line
13E-13E in FIG. 13.
[0102] FIGS. 14 through 18 are perspective illustrations showing
each skeletal level of the present disclosure, starting from the
bottom plate and gradually building a complete system including the
various levels in its modular construction. FIG. 14 is a
perspective illustration showing the bottom plate and rod-and-bolt
fasteners of a compressed air/gas drying system of the present
disclosure showing the symmetrically constructed cell columns
outlined by a multiplicity of rod/bolts 8 mounted to bottom plate
14. As can be readily observed in FIG. 14, three sets of four
rod/bolts 8 create the skeleton of a three column cell. In
operation, modular construction affords serviceability of each
independent module, filter, gasket and heat exchanger. The
removability of the rods and bolts allows for easy disassembly and
reassembly of the dryer modular unit. During the lifetime of the
modular dryer, cleaning and repair is easily accomplished because
every part of the modular unit is replaceable.
[0103] FIG. 15 is a perspective illustration showing the bottom
plate and sump module 50 of a compressed air/gas dryer system of
the present disclosure. Sump module 50 is configured so that its
three circular cavities can accommodate any combination of heat
exchanger design, such as a single precooler/reheater heat exchange
unit 300 and a single evaporator heat exchanger 400 (as shown in
FIG. 10) or two precooler/reheater heat exchange units 35 and two
evaporator heat exchange units 42a and b (as shown in FIG. 2), to
achieve the desired dryer function. It should be understood to one
skilled in the art that the dryer system of the present disclosure
can utilize any combination of heat exchanger. Again, it is
important to understand that this flexibility can support a number
of system functions and capabilities.
[0104] FIG. 16a is a perspective illustration showing the bottom
plate, sump module, filter, and gasket configured to accommodate an
embodiment of a compressed air/gas dryer system of the present
disclosure having two precooler/reheater heat exchange units 35 and
two evaporator heat exchange units 42a and b (as shown in FIG.
2)
[0105] FIG. 16b is a perspective illustration of another embodiment
of a compressed air/gas dryer system of the present disclosure
showing a multiplicity of rod/bolts 8 mounted to bottom plate 14,
sump module 50 having coalescing filter 52, and modified gasket 19
configured to accommodate a single precooler/reheater heat exchange
unit 300 and a single evaporator heat exchanger 400 (as shown in
FIG. 10). It should understood that although this sequence of parts
is one example of how to build a compressed air/gas drying system
of the present disclosure it should be obvious to one skilled in
the art of mechanical assembly that such interlocking modules would
have gaskets appropriately layered to achieve a fully assembled,
air-tight final configuration.
[0106] FIG. 17a is a perspective illustration of an embodiment of a
compressed air/gas dryer system of the present disclosure having a
multiplicity of rod/bolts 8 mounted to bottom plate 14, sump module
50 having coalescing filter 52, gasket 16 and two
precooler/reheater heat exchange units 35 and two evaporator heat
exchange units 42a and b attached thereto.
[0107] FIG. 17b is a perspective illustration of another embodiment
of a compressed air/gas dryer system of the present disclosure
showing a multiplicity of rod/bolts 8 mounted to bottom plate 14,
sump module 50 having coalescing filter 52, modified gasket 19 and
a single precooler/reheater heat exchange unit 300 and a single
evaporator heat exchanger 400 attached thereto.
[0108] FIG. 18a is a perspective illustration showing the bottom
plate, sump module 50, precooler/reheater module 30, and
refrigeration heat exchange evaporator module 40 for an embodiment
of a compressed air/gas dryer system of the present disclosure
configured to accommodate two precooler/reheater heat exchange
units 35 and two evaporator heat exchange units 42a and b (as shown
in FIG. 2)
[0109] FIG. 18b is a perspective illustration of the bottom plate,
sump module, precooler/reheater module, and refrigeration
evaporator module for an embodiment of a compressed air/gas dryer
system of the present disclosure configured to accommodate a single
precooler/reheater heat exchange unit 300 and a single evaporator
heat exchanger 400 (as shown in FIG. 10). It should be understood
that any of the dryer systems disclosed above, can be disassembled
for repair, cleaning or replacement of subcomponents (by removing
the rod and bolts) during the life of the system.
[0110] FIG. 19 is another alternative embodiment of the present
disclosure comprised of a two cell column arrangement having four
modular levels. Note that one of the cell columns is a chamber
configured to accommodate a coalescing filter and the other cell
column is a chamber configured to accommodate a single
precooler/reheater heat exchange unit 35 and a single evaporator
heat exchange unit 42a (as shown in FIG. 2).
[0111] FIG. 20 shows another embodiment of a compressed air/gas
dryer system of the present disclosure showing comprising a four
cell columns configuration with four modular levels. In this case,
the dryer system is configured to accommodate two levels of
replaceable filters. As can be appreciated, the current disclosure
is made to accommodate various sized and shaped types of filters.
The various column configurations are for illustrative purposes
only and are not meant to be limiting. In addition, the filters
used in the system of this disclosure are made from various
`grades` of refinement such as microns of filtration or different
combinations of the same, for example. The type of filter used to
construct the dryer system is dependent on circumstance, for
instance the two filters can be different `types` of filtration
such as a particulate/coalescing pre-filter and a coalescing
intermediate stage filter. In a further alternative, the dryer
system of the instant disclosure can use an intermediate coalescing
filter with an after-filter arrangement.
[0112] FIG. 21 is another embodiment of the present disclosure
wherein the dryer system has five cell columns in a single row and
four modular levels. This alternate embodiment of a compressed
air/gas dryer system of the present disclosure is configured to
accommodate three different filtration means, e.g.,
particulate/coalescing pre-filter, coalescing intermediate stage
filtration, and an after-filter.
[0113] FIG. 22 is another alternative embodiment of the present
disclosure where the dryer system has a two row configuration made
up of four modular levels. In this alternative embodiment, the
compressed air/gas dryer system is configured to accommodate a
`doubled` capacity by having more cell columns, with more
precooler/reheater heat exchanger elements, more evaporator heat
exchanger elements and more intermediate coalescing filter elements
than the compressed air/gas dryer system accommodating a single and
a double heat exchange module.
[0114] FIG. 23 is an exploded view of another preferred embodiment
of the precooler/reheater and evaporator modules each welded in a
single piece construction. In this embodiment of the present
disclosure precooler/reheater heat exchanger 300 is welded to
chamber housing 392 and outlet frame 394. Once air outlet frame 394
is attached to exchanger 300 it creates an after cavity 138. Each
individual element welded together results in a single piece
construction. This embodiment differs from a preferred embodiment
in that it eliminates the necessity of inserting the heat exchanger
into a module such as precooler/reheater module 306 as shown in
FIG. 10. Top member 390 and bottom member 395 are welded to
precooler/reheater heat exchanger 300. In this embodiment
precooler/reheater heat chamber housing 392 is directly welded to
exchanger 300. Both precooler/reheater heat chamber housing 392 and
air outlet frame 394 are configured to have a distribution cavity
136 and after cavity 138 respectively. Although the structures
differ in the modular construction as shown in FIGS. 2 and 10 the
structures function alike.
[0115] In addition, this embodiment differs from a preferred
embodiment in that it eliminates the necessity of inserting the
heat exchanger into a module such as heat exchange evaporator
module 406 as shown in FIG. 10. In like manner, evaporator heat
exchanger 400 is configured with top member 490, bottom member 495,
evaporator chamber housing 492, refrigerant outlet frame 494, all
welded together in a singular construction resulting a heat
exchanger which functions the same as a heat exchanger would
contained within evaporator module 406.
[0116] FIG. 24 is a perspective view of precooler/reheater 307 and
evaporator 407 shown assembled in a single piece construction from
their component parts as depicted in the exploded view of FIG. 23.
Precooler/reheater module 307 and evaporator module 407 are each a
single piece construction module having the same function of
precooler/reheater module 306 and evaporator module 406 with their
constituent heat exchangers inserted in their respective cavities
as described herein and illustrated in FIG. 10. This welded
singular construction is advantageous for reducing fabrication cost
but does not have the advantages of easy replacement parts of that
of replaceable modular system described herein.
[0117] FIG. 25 is an exploded view of an additional preferred
embodiment of modular compressed air/gas dryer system 607 of the
present disclosure wherein the precooler/reheater exchanger and
evaporator exchanger are welded in a single piece construction
600.
[0118] FIG. 26 is a perspective view of an additional preferred
embodiment of modular compressed air/gas dryer system 607 of the
present disclosure wherein precooler/reheater exchanger and
evaporator exchanger are constructed as a single construction.
Modular compressed air/gas dryer system 607 comprises outer panel
314 extending the full height of both exchangers, giving the unit a
seal that is air and pressure tight, and completely isolating the
heat exchangers from one another. Top member 390 and bottom member
495 are mounted to the heat exchangers, which facilitate the
mounting of precooler/reheater heat chamber housing 392 and
evaporator chamber housing 492; and refrigerant outlet frame 494
and air outlet frame 394. Once these components are fixedly mounted
to each other by welding or other like method, they form a single
constructed unit having the same function of the modules 306 and
406 as described herein and illustrated in FIG. 10. It should be
understood that in order to ensure a complete pressure tight seal
of the evaporator section contained in the compressed air/gas dryer
system 600, the manufacturing evaporator components chamber housing
492 and refrigerant outlet frame 494 are welded to the heat
exchanger before components precooler/reheater heat chamber housing
392 and air outlet frame 394. In this manner mechanical welding can
be on all four surfaces around cavities 146 and 148. It should be
further noted that the precooler/reheater heat chamber housing 392
and air outlet frame 394 can only be welded to the heat exchanger
on the top and side surfaces around cavities 136 and 138. However a
pressure tight weld 496 and 498 is will ensure the unit is
completely air tight. A minor passage of clean dried air from the
filter chamber into distribution cavity 136 instead of passing
through pass-through 34 is relatively inconsequential.
[0119] Although the disclosure has been described in several
embodiments and configurations, with reference to certain preferred
embodiments, it will be appreciated by those skilled in the art
that modifications and variations may be made without departing
from the spirit and scope of the disclosure. It should be noted
that the above preferred embodiment depicts typically a 1000
standard cubic feet per minute (scfm) dryer system capacity. To
achieve a smaller or larger capacity dryer system (for example 500
scfm or 1200 scfm), a simple change in the inlet port 22 and outlet
port 32 sizing would make such dryer system modifications. Still
further, again by example, a smaller or larger capacity can be
achieved by altering the `height` of precooler/reheater module 30
and evaporator module 40. The height change would either extend or
shorten the contact time the air or refrigerant is making to
various surfaces within the heat exchangers, thus modifying the
capacity to suit any desired scfm. And it is obvious that using any
of the considerations shown in FIGS. 19 through 22 can dramatically
change desired scfm capacity and functionality configurations by
simply adding (or subtracting) column chambers. It should be
understood that applicant does not intend to be limited to the
particular details described above.
* * * * *