Industrial Utility Efficiency    

Air Treatment

Compressed air dryers need to get the ball handed to them on the 25 yard-line by a compressor providing low enough temperature, and high enough pressure for the dryer to take it to the design dew point. If not, the dryer is not able to work properly. Once the dryer gets the right moisture level, it needs to operate properly. Heat exchangers, drains, switching valves, etc., all have to work with the proper control sequence to provide reliable dew point to the plant.
Nitrogen is primarily used as a clean, dry inert gas where the reduction of Oxygen is required for certain products and processes. It is widely used in the food and beverage, electronics, laser cutting, chemical and oil & gas industries. The cost of producing Nitrogen by separating compressed air using Pressure Swing Adsorption (PSA) is significantly impacted by the treatment of the compressed air supply. The introduction of Adsorption Media Tube (AMT) technology in order to dry the compressed air prior to separation offers the potential to reduce compressed air energy costs up to 25%.
The Compressed Air and Gas Institute (CAGI) will be issuing a series of articles discussing moisture in the compressed air system and will provide a brief overview of the compressed air drying technologies available.
Triethylene glycol (TEG) dehydrators are the most prevalent technology for removing water vapor from natural gas . Molecular sieve dryers are also quite common in gas processing plants. Molecular sieve units have operating processes similar to industrial heat-regenerated compressed air dryers. Natural gas, however, often needs to be purified at the wellhead before reaching the processing plant. Deliquescent dehydrators are normally used, in remote locations where no power supply exists, to dry small gas volumes located between the wellhead and these main treatment plants. The most common applications are instrument gas, fuel gas, sales gas, and emissions mitigation.
Compressed Natural Gas (CNG) is an alternative fuel source (to diesel and gasoline) with far-reaching benefits to North America. Strategically important benefits include energy independence, improved air quality, job creation, and lower and more stable fuel prices. This article discusses natural gas desiccant dryer requirements in Natural Gas Vehicle (NGV) refueling stations, compares deliquescent to desiccant dryers and reviews two on-site field gas upgrading examples in displacing diesel fuel.
  In an ideal world, industrial air or gas supply lines would be free of particulate, water, oil and other contaminants. In the real world, however, supply lines typically deliver some contaminants along with the air or gas they were designed to carry. Left unchecked, these contaminants will cause efficiency losses, maintenance headaches and the premature failure of pneumatic components.
Energy efficiency and sustainability solutions are often associated with more obvious initiatives--such as installing compact fluorescent bulbs—but those solutions fail to dig deeper for the “hidden gems” that can have a much greater impact. For manufacturing and building engineers or anyone else dealing with high potential energy consumption and inrush current demands, compressed air systems are one of the first places to look for significant energy savings and greater sustainability.
What are the conditions inside your pipes, is it cloudy and hot with showers or cool and dry? Could there be snow and blowing snow and excessive icing conditions? Are there smog and dust storm conditions or is the air as fresh as a mountain breeze. All these conditions are commonly experienced inside compressed air systems. What you get is determined by your selection of system equipment, ambient conditions and how well your system is maintained.
Desiccant compressed air dryers offer a simple solution where very dry compressed air is required however there are some key issues which must be considered to make their operation reliable. In particular, excessive flow, low pressure, silencer back pressure and purge air must be carefully monitored and controlled. This paper discusses common issues affecting the reliability of compressed air desiccant dryers which lead to loss of performance.
Condensate drains are possibly the least glamorous and most ignored component of a compressed air system but nevertheless, a most important part. No matter how much you spend on that fancy new compressed air system, VFD’S pin-stripes and flashing lights notwithstanding, not spending a little effort with your drain choice could cause you no end of headaches and increased operating costs for years to come. Contaminants can enter a system at the compressor intake or be introduced into the airstream by the system itself. Lubricant, metal particles, rust, and pipe scale are all separated and filtered out, but it’s the drains that have to operate properly for the filters and separators to be successful in completing their task.  
In the 1970s, the use of filtration in air quality management in pharmaceutical production, hospitals, and medical device manufacturing facilities became increasingly important and increasingly of interest to regulatory agencies. The air quality field was growing. From the air moving into and out of clean rooms to the protection of surgical environments to the expansion of the global medical drug industry, compressed air began to play a larger role—a role that continues undiminished (and, in fact, has increased substantially) today.