Which Dryer is the Most Energy Efficient? - Pneumatech

March 5, 2019

Pneumatech's refrigerated and desiccant dryers are used in hundreds of different applications around the world. From food factories, to automotive shops, to textiles, our dryers provide clean, dry compressed air for many different products. If you are shopping our dryers to help reduce your energy costs, you may be asking, "Which dryer is the most energy efficient?" All of our dryers help save on energy costs, but depending on your dew point needs, there are 2 models in particular that will help boost your savings.

+ 40° F Dewpoint

If you don't have very low dewpoint requirements, you will most likely need a refrigerated dryer. Refrigerated air dryers use the same cooling principal as typical air conditioning units. Using the refrigeration system and passing compressed air through a heat exhanger, the air is cooled to approximately 40° F. As the air cools, water droplets begin to form in the air due to condensation much like the water droplets that form on the outside of a cold drink. The moisture laden air then undergoes a mechanical separation process where the liquid or “condensate” is separated from the air stream. The air is then rewarmed using the incoming air which lowers the relative humidity of the air and traps any remaining moisture in a vapor form. Pneumatech's AC Series - Cycling Dryers are the most energy-efficient in the refrigerated range. These dryers use a Cycle Saver algorithm that starts and stops the dryer to save energy while keeping the relative humidity of the compressed air below 50% to prevent the formation of liquid water. No-air-loss drains are also used on the AC Series to save you money by preventing the loss of valuable compressed air associated with other types of drains.

Selecting the appropriate dryer for your application is essential during the chilly winter months. The last thing you need is a freeze in your compressed air system that causes expensive downtime. Choosing the right dryer will help you avoid these frustrating problems.

If you’re asking yourself, “What kind of air dryer do I need?” we’re here to help!

What Is the Job of an Air Dryer in Compressed Air Systems?

An air dryer’s job is to suppress the dew point of your compressed air by removing moisture from it. Then it will chill the air to 40 degrees.

Air with moisture content can be detrimental to plant operation. It can cause contamination, erosion, and operation downtime. Therefore, having the best air dryer for your application is vital.

What Kind of Air Dryer Do I Need?

As you know, an air dryer is an essential component of any compressed air system, but did you know that there are different types of dryers to choose from? We’ll explain their differences, so you’ll know what kind of air dryer you need for your application.

Refrigerated vs. Desiccant Air Dryer

Each type of air dryer has its own principle of operation. Two of the main types of air dryers are refrigerated and desiccant air dryers. Choosing between these two dryers is dependent on the acceptable amount of moisture content or pressure dew point requirements for your application. We’ll compare refrigerated vs. desiccant air dryers.

Refrigerated Air Dryers

Typically, refrigerated air dryers are adequate for general-purpose compressed air applications. They offer a pressure dew point (PDP) between 35 and 40 degrees. They use a refrigeration compressor and heat exchange to cool the compressed air and remove the water. Refrigerated air dryers are one of the more affordable drying technologies.

There are two types of refrigerated air dryers – cycling and non-cycling.

Cycling Refrigerated Air Dryers

• • Energy-efficient 
  • Used for higher flows where the flow rate varies from shift to shift
  • Cycles on and off to deliver the correct PDP at the right time

Non-Cycling Refrigerated Air Dryers

• • Less expensive
  • Constantly running, do not turn on and off
  • Run at the same load as long as they’re turned on and running

Desiccant Air Dryers

Desiccant air dryers use hygroscopic materials to capture moisture from the air. The materials are known as desiccants and are dry, solid particles that work using the principle of adsorption. Desiccant dryers are used when your application requires extremely dry compressed air or when the air supply runs in cold environments. They can achieve dew points as low as -100 degrees.

There are two types of desiccant air dryers – heated and non-heated.

Heated Desiccant Air Dryers

• • Use heat to remove water vapor from the desiccant material that isn’t in use at that point in the cycle
  • Require large amounts of steam or electricity to operate

Non-Heated Desiccant Air Dryers

• • Use dry air generated by the dryer to remove water vapor from the desiccant material
  • Does not rely on excessive outside services (steam, electricity, gas, etc.) for heat

TMI Compressors Is Here To Help

During winter, choosing a suitable dryer for your application is more crucial than ever. The last thing you need is expensive downtime, resulting in a freeze in your compressed air system. These annoying issues can be prevented by picking the correct air dryer.

The specialists at TMI Compressors are here to assist you. If you’re unsure of the type of dryer your application calls for or if you need assistance sizing the ideal dryer for your system, give us a call today!