No matter your operation or field, any system that uses compressed air needs to have condensate treatment in place. You need to implement a system to remove excess moisture from the airlines. Moisture in airline conditions can lead to problems if left untreated. The moisture will slowly deteriorate the inside of the air piping and equipment.
Joints and connection points are highly susceptible to this wear and tear over time. It might not seem like a big issue, but the more wear that occurs, the worse off your system will be. Moisture is the silent killer of compressed air systems, and the best way to counter this is with proper moisture management.
Various methods can be implemented into your compressed air system to manage the moisture content. Variables such as air requirements, desired pressure dew point, inlet air pressure, and inlet air temperature can determine what equipment best fits your needs. Membrane Dryers are one of the top options for systems that require clean, compressed air and operate within a strict range.
Membrane dryers operate differently than Refrigerant and Desiccant dryers because they do not require electricity. Once installed, they only require routine maintenance, unlike other dryers. After installation, compressed air flows through the following processes.
Due to their size and nature, these dryers are excellent solutions to applications with limited power supplies. Their compact design and zero electricity requirements allow them to be used in places other dryers cannot. Not only do they use no additional electricity, but these pieces of equipment are quiet, with few moving parts, making maintenance just routine checks. Even with no additional power and a smaller-sized machine, these dryers can take +40 degrees Fahrenheit to as low as -40 degrees Fahrenheit, a significant reduction in PDP for a wide range of applications.
When deciding if the membrane dryer suits you and your operation, you’ll want to consider the costs and benefits of each type of compressed air dryer. Some factors, like a low price point, maybe enticing compared to other options. They may be enticing, but often, equipment like that will only be what you need when it comes to price, not the variables that truly affect your compressed air system.
When trying to find the best fit for your application, it is essential to compare the individual characteristics of your compressed air dryers. Membrane dryers have notable benefits that may put them above their competitors:
When these machines operate in the right conditions, they are truly remarkable pieces of equipment. With so many upsides, drawbacks are expected, and membrane dryers are no different. The disadvantages of membrane dryers are directly correlated to their benefits. What makes them such exceptional solutions to specific scenarios makes them less than an ideal choice in other operations.
Membrane dryers fall short in two main categories: Air Requirements and Limited capacity.
Clean air might seem obvious, but you would be surprised at how contaminated the air around us is, especially after it has been condensed and its total volume drastically reduced. Dirt, dust, and oil are just hanging out in quantities easily manageable by our natural filtration systems, our lungs. The problems occur after compression. You need a robust filtration system to manage this and not overload your membrane dryer.
Keeping the additional particulate matter out of the airstream will improve your dryer’s capacity. Membrane dryers have limited capacity ranges and are often unsuitable for high-flow applications; consequently, they are likely to fail if they exceed this capacity.
The disadvantages of membrane dryers often overshadow their advantages. Not using any additional electricity and having quiet operational volumes can be enticing, but they might not be enough to validate using a membrane dryer in your compressed air system.
When you are selecting a compressed air dryer, 4 main variables determine whether a dryer will work in your compressed air system:
Maximum air velocity is the maximum speed (CFM) at which air travels through your compressed air system; the speed also relates to the amount of air present in a cubic foot of pipe at a specific time. It may not seem like a lot, but 5 CFM can be the difference between two different machines, and with such a limited range, this information can make or break your system.
Desired PDP and inlet compressed air temperature also go hand in hand. Desired PDP is the temperature at which you drop the compressed air temperature down from the inlet air temperature. The greater the range between these two, the more condensate is removed from the compressed air system. Ensuring air reaches your desired PDP is as crucial as sizing your CFM. If your air is too warm, it will take that extra moisture to the point of use.
You want your equipment to maximize productivity with minimal effort from you; let your equipment handle the work. Stick to the air quality that best suits your operation, no higher or lower; if you have too clean of air, your filtration and dryer systems will be working harder than they need to, and we know about air that is not clean enough. This will allow your equipment to run longer and with fewer problems. Longevity is your key to savings; investing in high-end systems will reduce costs tremendously in the long run, saving time and money.
Membrane dryers rely on physical separation to remove condensation from the compressed air through the fibers and their semipermeable characteristics. The semipermeable membrane pulls the water out of the air stream through physical contact between the molecules and fibers.
Contrasting to the physical separation methods used by membrane dryers, refrigerant air dryers use water precipitation principles. The dryer cools the air stream, condensing the water vapor and causing it to drop into a receptacle.. To maximize the application of the precipitation principles, refrigerant dryers come in both cycling and non-cycling variants, with cycling variants being much more energy efficient.
Shop our Refrigerated Air Dryers here.
Membrane dryers and Desiccant Air Dryers are often compared due to their perceived similarities. They may have similar results with low energy requirements; however, the mechanisms for achieving these results are vastly different. Compared to the membrane dryer’s process, desiccant air dryers use hygroscopic materials nested within the drying towers. Typically, two towers are included in a desiccant dryer setup and the air alternates between towers.
As the air flows into one of these towers, it passes through one of these towers filled with desiccant material. The material pulls the water in from the air and stores it inside the individual pellets. Once they become saturated enough, the towers will swap jobs. The first tower that was drying air before will regenerate the desiccant material using purge air, while the second tower will dry the compressed air. Swapping extends the lifespan of the desiccant and increases the time between scheduled downtimes.
Shop our Desiccant Air Dryers here.
Membrane dryers may seem like the best option for you and your system, just from the savings alone; however, these savings may cost you in the long run. Membrane dryers excel in specific industries that have rigid air requirements, such as:
Industries with rigid air requirements have finely tuned filtration systems in place before their dryer; in instances like this, the membrane dryer excels. High-level filtration filters the air before it reaches the dryer, reducing the chances of the dryer being overwhelmed or excess condensation making it downstream.
Refrigerant air dryers effectively remove condensation without requiring stringent air conditions. They may cost a little more upfront, but they will mesh much better with your system.
Oftentimes, the initial cost of membrane dryers will cost more in the long run, even if they are cheaper upfront. With limited fluctuation in these dryers, any environmental fluctuations can overwhelm your dryer and completely throw off your process. They might seem like the cheapest option, but that’s only when you consider the upfront cost, not the equipment’s lifetime cost.
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