Tag: compressed air dryer

How Do Membrane Dryers Work?

Published on by Russ BowmanLeave a comment

Water and water vapor can cause big problems in a compressed air system. That’s why compressed air dryers are a critical component of those systems. There are a few different types, and they all have their pros and cons. My colleague Jordan Shouse summed up the selection process pretty succinctly in a past blog: Compressed Air Dryers : What are they Good For? I particularly enjoyed his reference to Edwin Starr’s famous protest song, War (What Is It Good For?)

While they are all indeed “good for (as Jordan said) absolutely A LOT”, I wanted to take (another) deeper dive into one particular type. Membrane dryers are among the newer types of compressed air dryers. As the name suggests, they use a semi-permeable membrane whose structure allows molecules of certain fluids to pass through faster than others, thereby separating those certain fluids from the primary volume. Membrane separation technology is commonly used in:

  • Water purification and desalination (removal of particulates and salts)
  • Nitrogen separation (removal of oxygen and other trace gases)
  • Removing moisture from compressed air (removal of water vapor)

A membrane dryer is made of a cylinder containing very small polymer tubes that have a special coating inside. This coating allows the above-mentioned water & water vapor to pass through more readily than the nitrogen, oxygen, and other trace gases found in the atmospheric air that the compressor has drawn in.

As compressed air enters the cylinder, it’s directed through the polymer tubes, which allow water (but not air) to pass through their walls due to the difference in partial pressure between the gases (e.g., compressed air & water vapor) on the inside, & outside, of the tubes. Air flow, traveling in the opposite direction outside the tubes, sweeps the water out. The higher the sweep air flow rate, the lower the dew point of the compressed air out.

The advantages of membrane dryers are:

  • No moving parts to wear or break.
  • No electricity required.
  • Easy to install.
  • Unaffected by environmental contamination.
  • Compact design.

While environmental contamination isn’t a concern, they are very sensitive to internal contamination, like oil & oil vapor. Membrane dryers are commonly supplied with coalescing filters to minimize any issues there.

One disadvantage (kind of) is their limited flow capacity: the highest capacity membrane dryers are capable of passing around 200 SCFM, meaning they can only be used in small-to-mid-sized systems. I said “kind of” above because, if a certain part of the compressed air system requires a different level of dry air than the rest of the plant, membrane dryers are an inexpensive and easy way to provide that. That’s “kind of” an advantage, in that situation, actually.

Another disadvantage (kind of) is the amount of purge air they lose. Remember, membrane technology means certain fluids will pass through faster & more readily – but not exclusively – so they’re going to lose some of that brand new compressed air along with the water vapor. And the lower you want the dew point to be, the more purge air will be lost. However, the purge air loss is minimal when they’re discharging air dried to a dew point in the 40°F range, and that’s perfectly acceptable in many industrial compressed air systems.

I want to help you get the most out of your compressed air system, so when you think of compressed air, think EXAIR! If you’ve got questions, we’re here to help. Give me a call.

Russ Bowman, CCASS

Application Engineer
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Dew Point and Water in Compressed Air: Understanding the Effects

Published on by John BallLeave a comment

In systems, it is important to understand the type of medium that is being used.  For most EXAIR products, this will be compressed air.  As the air compressor draws in ambient air, it also brings in dust, contamination, and moisture into the system.  If untreated, the pneumatic system will have to contend with these foreign “invaders” that will affect the performance of your pneumatic devices.  One of the most common problems is water.

Water enters the compressed air system from the water vapor already present in the ambient air, which is referred to as the dew point or relative humidity.  When you take ambient air and compress it, the amount of “elbow room” for the water vapor decreases.  This causes the water vapor to condense and create liquid water.  It would be similar to a water-soaked sponge.   As you compress it with your hands, the sponge will not be able to hold on to the water.  Similarly, as the air is compressed, water will start to form and fall out into the compressed air system.  Water is a by-product of a compressed air system.

Visual depiction of the impact of water vapor contained amongst air particles and how this reduces available volume during compression.

The definition for determining if liquid water is present in your system is called the pressure dew point.  Dew point is the temperature at which water vapor will condense and form water droplets.  If the dew point temperature and the air temperature are equal, then the air is considered 100% saturated (water vapor will start to condense to form water droplets).  In compressed air systems, air dryers are used to reduce the dew point temperature.  This means that unless the ambient temperature falls below the dew point temperature, water vapor will not condense into a liquid state.

There are two major types of compressed air dryers; refrigerated and desiccant.  The refrigerated air dryers are the most common, and the dew point is measured at about 39oF (4oC).  So, unless the air temperature gets close to freezing, i.e., the piping system that goes outside in cold weather, water should not be present.  Desiccant air dryers can achieve dew points as low as -40oF (-40oC).  This compressed air is very dry and can be used for medical systems, food and beverage processing, and instrument air.  The reason is that bacteria cannot survive in compressed air that is that dry.  The other types are dewpoint reducing systems, which include membrane and deliquescent dryers. 

Good engineering practice calls for point of use filtration and moisture removal, such as that provided by EXAIR Filter Separators.

For most pneumatic devices, a Filter Separator with an auto-drain should be used as a minimum amount of protection.  Even with systems that have compressed air dryers as described above, they are mechanical devices.  So, failures can occur.  You should review your compressed air system to ensure that your pneumatic system, including EXAIR products, is operating at peak efficiency.  This will include your supply system, compressed air leaks, and blow-off devices. 

Moisture-laden compressed air can cause issues such as increased wear on the pneumatic tools, the formation of rust in piping and equipment, quality defects in painting processes, and frozen pipes in colder climates.  Regardless of what products you’re using at the point-of-use, a compressed air dryer is undoubtedly a critical component of the compressed air system.  Providing clean, dry air to EXAIR Products or other pneumatic devices will help to extend the life of your equipment.  If you wish to discuss more about your compressed air system or how EXAIR can provide a more efficient way to use that compressed air, an Application Engineer will be happy to assist you.

John Ball
International Application Engineer


Email: johnball@exair.com
Twitter: @EXAIR_jb

Refrigerated Air Dryers

Published on by John BallLeave a comment

Whenever air gets compressed, it reduces the space for the water molecules to remain as a vapor; which causes condensation.  For this, compressed air dryers are an important part of a compressed air system.  They are designed to remove moisture to prevent condensation further downstream in the system.  The three main types of dryers are refrigerated, desiccant, and membrane. For this blog, I will cover the refrigerant-type compressed air dryers.

Compressed air dryers are rated with a dew point rating.  A dew point is the temperature at which the air has a relative humidity of 100%.  Since the air cannot become more saturated with water than 100%RH, water will condense and fall out like “rain”.  You can see this effect during the cool mornings when dew forms on the grass.  Compressed air dryers are designed to reduce the dew point temperature of your compressed air.  For a refrigerant type, they are near the dew point temperature of 38oF (3oC).  Like a refrigerator, they use refrigerant to cool the compressed air.  We cannot go below this temperature as it could form ice inside the dryer.  But, as long as the ambient temperature does not go below 38oF (3oC), liquid water will not be present in the pneumatic system. 

There are two main types of refrigerated air dryers; cycling and non-cycling.  Cycling type refrigerant air dryers will cool a liquid mass, generally a glycol-water mixture, to a set-point and turn off.  The liquid will go through an air-to-liquid heat exchanger to remove the heat from the compressed air.  Referring to the cycling action, when the liquid mass goes above the set point, the refrigeration system will restart and cool the liquid mass again.  The cycling refrigerant air dryers are more expensive, but they are more efficient. 

Non-cycling refrigerant air dryers are more common.  The refrigeration system continues to run through an air-to-air heat exchanger to cool the compressed air.  It is similar to your AC system in your car.  With this type of system, they are more susceptible to the environment, i.e., temperature, elevation, and humidity.  So, adjustments are required for proper installation. 

With both types of refrigerant dryers, the internal compressed air section is very similar.  They will have a filter separator to remove the liquid that is created from the condensation from the cold temperatures.  They also have an additional air-to-air heat exchanger.  This will provide two important features for the refrigerated air dryers.  As the cold air leaves the refrigerant section, it helps to cool the incoming compressed air.  This will make the system more efficient.  And as the hot incoming compressed air helps to warm the cold air leaving the dryer, it will stop the condensation of liquid water on the outside of the pipes.  Like the dew forming on the grass during cool mornings, the same will occur with the compressed air piping system. 

Moisture-laden compressed air can cause issues such as increased wear on the pneumatic tools, the formation of rust in piping and equipment, quality defects in painting processes, and frozen pipes in colder climates.  Regardless of what products you’re using at the point-of-use, a compressed air dryer is undoubtedly a critical component of the compressed air system.  Delivering clean, dry air to your EXAIR Products or other pneumatic devices will help to ensure a long life out of your equipment.  If you wish to discuss more about your compressed air system or how EXAIR can provide a more efficient way to use that compressed air, an Application Engineer will be happy to assist you. 

John Ball, CCASS


Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Photo: Grass morning dew by RuslanSikunov.  Pixabay License

Intelligent Compressed Air: Refrigerant Dryers

Published on by Tyler DanielLeave a comment

When we talk with customers about their EXAIR Products, we also discuss the quality of their compressed air. Many of our products have no moving parts and are considered maintenance-free when supplied with clean, moisture free compressed air. One of the most critical aspects of a compressed air distribution system is the dryer.

No matter where you are in the world, the atmospheric air will contain water vapor. Even in the driest place in the world, McMurdo Dry Valley in Antarctica, there is some moisture in the air. As this air cools to the saturation point, also known as dew point, the vapor will condense into liquid water. The amount of this moisture will vary depending on both the ambient temperature and the relative humidity. According to the Compressed Air Challenge, a general rule of thumb is that the amount of moisture air can hold at a saturated condition will double for every increase of 20°F. In regions or periods of warmer temperatures, this poses an even greater problem. Some problems that can be associated with moisture-laden compressed air include:

  • Increased wear of moving parts due to removal of lubrication
  • Formation of rust in piping and equipment
  • Can affect the color, adherence, and finish of paint that is applied using compressed air
  • Jeopardizes processes that are dependent upon pneumatic controls. A malfunction due to rust, scale, or clogged orifices can damage product or cause costly shutdowns
  • In colder temperatures, the moisture can freeze in the control lines

In order to remove moisture from the air after compression, a dryer must be installed at the outlet of the compressor. It is recommended to dry the compressed air to a dew point at least 18°F below the lowest ambient temperature to which the distribution system or end use is exposed. A dew point of 35-38°F is often sufficient and can be achieved by a refrigerated dryer (Best Practices for Compressed Air Systems). This makes the refrigerant dryer the most commonly used type in the industry.

A refrigerant dryer works by cooling the warm air that comes out of the compressor to 35-40°F. As the temperature decreases, moisture condenses and is removed from the compressed air supply. It’s then reheated to around ambient air temperatures (this helps to prevent condensation on the outside of distribution piping) and sent out to the distribution system.

With your air clean and dry at the point of use, you’re making sure you get the most out of EXAIR’s Intelligent Compressed Air Products without adhering to pesky maintenance procedures.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Compressor image courtesy of Tampere Hacklab via Flickr Creative Commons License