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PCM COMBINATION
Phase change type air dryer, it only runs when it's needed, so the cost of electricity is 1/10
Optimum dew point with lowest energy cost!
Energy savings are now a necessity, not an option.
This world’s first patented technology developed by SPX FLOW produces super-dried air (up to – 100℃ dew point) and yet is able to maintain lowest energy cost.
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Optimum discharge air temperature without the use of after cooler.
Achieves a super dry dew point, as low as – 100℃.
Minimizes dew point spike during tower switch over.
Energy saving steps:
-
Drastically reduces energy consumption by pre-removing up to 75% of moisture by using the PCM dryer.
- PCM dryer, cycles (on/off) are controlled automatically according to inlet load: e.g. lunch time, season change.
- Reduces total energy consumption by operating PCM dryer alone if necessary. (except winter)
- Reduces energy consumption by controlling the desiccant dryer cycle time according to outlet dew point, which corresponds to inlet moisture load.
- Integrated high efficiency blower, which regenerates with ambient air. No purge loss.
Phase change in PCM dryer
Desiccant Dryer VS PCM COMBINATION
- When a refrigeration compressor and condenser fan are running, the cold refrigerant in the chiller (evaporator) cools the liquid Phase Change Material(PCM) and it gradually freezes.
- When a PCM is sufficiently cooled and frozen, the refrigeration compressor and condenser fan stop.
- The compressed air is continuously cooled by the PCM while the refrigeration compressor is inactive. No power is consumed during this period.
- The PCM gradually melts as it adsorbs heat from the compressed air, and when fully melted, the refrigeration compressor and condenser fan resume to cool down the PCM.
- Compressed air saturated with water vapor enters reheater, and is pre-cooled by the outgoing chilled air.
- It is then directed to chiller where it is further cooled by the Phase Change Material (PCM).
- As the air is cooled, water vapor condenses into liquid droplets, which are then removed by high efficiency integral moisture separator with a NO Loss Drain.
- Chilled air enters the heated desiccant tower to dry and supply lower than guaranteed dew point of -40℃ or -70℃.
- Dried air returns to the PCM dryer’s reheater, where it is reheated with very low dew point. This in turn, supplies clean and dry compressed air to point of use.
| Dryer Type | Flow Capacity [Nm3/hr] | Power Consumption [kW] | Purge Air [%] | Regeneration Time [hr] | Daily Power Consumption [kW] | Daily Energy for Purging [kW] | Annual Power Consumption [USD] | Energy Saving [%] |
|---|---|---|---|---|---|---|---|---|
| Heated Purge | 14,000 | 120 (Heater 120) | 15 | 4 (Drying 3 + Cooling 1) | 2,160 | 5,880 | 352,152 | 68% |
| Combination Heated Purge | 96 (Heater 42 + PCM Dryer 54) | 5 | 16 (Drying 10 + Cooling 3 + Stand by 3) | 1,019 | 1,593 | 114,375 |
| Blower Purge | 14,000 | 197 (Heater 179 + Blower 18) | 15 | 4 (Drying 3 + Cooling 1) | 3,546 | 1,470 | 219,700.80 | 68% |
| Combination blower Purge | 111 (Heater 46 + Blower 11 + PCM Dryer 54) | 5 | 16 (Drying 10 + Cooling 3 +Stand by 3) | 1,244 | 368 | 70,575 |
| Blower Non-Purge | 14,000 | 250 (Heater 230 + Blower 20) | 0 | 6 (Drying 4.25 + Cooling 1.25 + Parallel 0.5) | 4,350 | 0 | 190,530 | 59% |
| Combination Blower Non-Purge | 135.5 (Heater 74 + Blower 7.5 + PCM Dryer 54) | 0 | 16 (Drying 11 + Cooling 4 + Stand by 1) | 1,779 | 0 | 77,900 |
※ Purge cost USD 0.01 per 1 Nm3/hr ※ Power cost USD 0.12 per kW/hr ※ PCM dryer energy saving of 70% ※ Daily energy for purge air [kW] : (purge flow rate x purge cost) ÷ power cost ※ Following figures varies on customer’s environment
- Above table shows an energy savings comparison rate between a desiccant and a PCM COMBINATION without changing the dryer type.
- The below example shows the detailed energy cost, when a heater purge dryer is converted into a PCM COMBINATION- blower non-purge.
- AS a result, energy saving are maximized when a desiccant dryer is converted to a PCM COMBINATION along with their types.
| Heated Purge Energy Cost (Annual) |
|---|
| Total
124,173 + 343,392
USD 467,565
|
| Electric HeaterUSD 124,173
189kW x (2.5hr ÷ 4hr) x 24hr x 365day x 0.12$/kW)
|
| Purge AirUSD 343,392
(14,000Nm3/hr x 20%) x (24day x 0.014$ ÷ 0.12$/kW) x 365day x 0.12$/kW)
. |
| PCM COMBINATION Blower Non-Purge Energy Cost (Annual) |
|---|
| Total
53,480 + 7,391 + 17,029
USD 77,900
|
| PCM COMBINATION Blower Non-Purge Energy Cost (Annual) |
|---|
| Total
53,480 + 7,391 + 17,029
USD 77,900
|
| Electric HeaterUSD 53,480
(74kW x (11hr ÷ 16hr) x 24hr x 365day x 0.12$/kW)
|
| BlowerUSD 7,391
(7.5kW x (11+4)hr ÷ 16hr) x 24hr x 365day x 0.12$/kW)
|
| PCM DryerUSD 17,029
(54kW x Average utilization rate 30% x 24day x 365day x 0.12$/kW)
|
Product Features
Optimum discharge air temperature without the use of after cooler.
Achieves a super dry dew point, as low as – 100℃.
Minimizes dew point spike during tower switch over.
Energy saving steps:
-
Drastically reduces energy consumption by pre-removing up to 75% of moisture by using the PCM dryer.
- PCM dryer, cycles (on/off) are controlled automatically according to inlet load: e.g. lunch time, season change.
- Reduces total energy consumption by operating PCM dryer alone if necessary. (except winter)
- Reduces energy consumption by controlling the desiccant dryer cycle time according to outlet dew point, which corresponds to inlet moisture load.
- Integrated high efficiency blower, which regenerates with ambient air. No purge loss.
Operating Fundamental
Phase change in PCM dryer
Desiccant Dryer VS PCM COMBINATION
- When a refrigeration compressor and condenser fan are running, the cold refrigerant in the chiller (evaporator) cools the liquid Phase Change Material(PCM) and it gradually freezes.
- When a PCM is sufficiently cooled and frozen, the refrigeration compressor and condenser fan stop.
- The compressed air is continuously cooled by the PCM while the refrigeration compressor is inactive. No power is consumed during this period.
- The PCM gradually melts as it adsorbs heat from the compressed air, and when fully melted, the refrigeration compressor and condenser fan resume to cool down the PCM.
- Compressed air saturated with water vapor enters reheater, and is pre-cooled by the outgoing chilled air.
- It is then directed to chiller where it is further cooled by the Phase Change Material (PCM).
- As the air is cooled, water vapor condenses into liquid droplets, which are then removed by high efficiency integral moisture separator with a NO Loss Drain.
- Chilled air enters the heated desiccant tower to dry and supply lower than guaranteed dew point of -40℃ or -70℃.
- Dried air returns to the PCM dryer’s reheater, where it is reheated with very low dew point. This in turn, supplies clean and dry compressed air to point of use.
| Dryer Type | Flow Capacity [Nm3/hr] | Power Consumption [kW] | Purge Air [%] | Regeneration Time [hr] | Daily Power Consumption [kW] | Daily Energy for Purging [kW] | Annual Power Consumption [USD] | Energy Saving [%] |
|---|---|---|---|---|---|---|---|---|
| Heated Purge | 14,000 | 120 (Heater 120) | 15 | 4 (Drying 3 + Cooling 1) | 2,160 | 5,880 | 352,152 | 68% |
| Combination Heated Purge | 96 (Heater 42 + PCM Dryer 54) | 5 | 16 (Drying 10 + Cooling 3 + Stand by 3) | 1,019 | 1,593 | 114,375 |
| Blower Purge | 14,000 | 197 (Heater 179 + Blower 18) | 15 | 4 (Drying 3 + Cooling 1) | 3,546 | 1,470 | 219,700.80 | 68% |
| Combination blower Purge | 111 (Heater 46 + Blower 11 + PCM Dryer 54) | 5 | 16 (Drying 10 + Cooling 3 +Stand by 3) | 1,244 | 368 | 70,575 |
| Blower Non-Purge | 14,000 | 250 (Heater 230 + Blower 20) | 0 | 6 (Drying 4.25 + Cooling 1.25 + Parallel 0.5) | 4,350 | 0 | 190,530 | 59% |
| Combination Blower Non-Purge | 135.5 (Heater 74 + Blower 7.5 + PCM Dryer 54) | 0 | 16 (Drying 11 + Cooling 4 + Stand by 1) | 1,779 | 0 | 77,900 |
※ Purge cost USD 0.01 per 1 Nm3/hr ※ Power cost USD 0.12 per kW/hr ※ PCM dryer energy saving of 70% ※ Daily energy for purge air [kW] : (purge flow rate x purge cost) ÷ power cost ※ Following figures varies on customer’s environment
- Above table shows an energy savings comparison rate between a desiccant and a PCM COMBINATION without changing the dryer type.
- The below example shows the detailed energy cost, when a heater purge dryer is converted into a PCM COMBINATION- blower non-purge.
- AS a result, energy saving are maximized when a desiccant dryer is converted to a PCM COMBINATION along with their types.
| Heated Purge Energy Cost (Annual) |
|---|
| Total
124,173 + 343,392
USD 467,565
|
| Electric HeaterUSD 124,173
189kW x (2.5hr ÷ 4hr) x 24hr x 365day x 0.12$/kW)
|
| Purge AirUSD 343,392
(14,000Nm3/hr x 20%) x (24day x 0.014$ ÷ 0.12$/kW) x 365day x 0.12$/kW)
. |
| PCM COMBINATION Blower Non-Purge Energy Cost (Annual) |
|---|
| Total
53,480 + 7,391 + 17,029
USD 77,900
|
| PCM COMBINATION Blower Non-Purge Energy Cost (Annual) |
|---|
| Total
53,480 + 7,391 + 17,029
USD 77,900
|
| Electric HeaterUSD 53,480
(74kW x (11hr ÷ 16hr) x 24hr x 365day x 0.12$/kW)
|
| BlowerUSD 7,391
(7.5kW x (11+4)hr ÷ 16hr) x 24hr x 365day x 0.12$/kW)
|
| PCM DryerUSD 17,029
(54kW x Average utilization rate 30% x 24day x 365day x 0.12$/kW)
|