CAGI Article Types of Compressed Air Dryers

Types of Compressed Air Dryers: Regenerative
Desiccant and Refrigerant

By the Compressed Air & Gas Institute
Introduction
The Compressed Air and Gas Institute is the united voice of the compressed air industry, serving as the unbiased
authority on technical, educational, promotional, and other matters that affect the industry. Mention utilities and
energy in a discussion about manufacturing and the Big Three - water, electricity and natural gas - immediately come
to mind. But compressed air is commonly accepted as a manufacturing facility's fourth utility. A careful examination
of a facility's compressed air system will likely reveal several opportunities to improve the performance of the
compressed air system by effectively and efficiently removing moisture from the compressed air system. The
Compressed Air and Gas Institute (CAGI) committed to issuing a series of articles discussing moisture in the
compressed air system. The first article covered “Why Do Compressed Air Systems Need Drying?” This article will
provide a brief overview of the two most popular compressed air drying technologies available – Refrigerant Type and
Regenerative Desiccant Type.
Compressed Air Dryer Selection

Different methods can be used to remove the moisture content of compressed air. Current compressed air dryer types
include the following products:
• Regenerative desiccant type:

o Heatless (no internal or external heaters)
o Heated (internal or external heaters)
o Heat of Compression
• Refrigerant type:
o Cycling
o Non-cycling
Because of such a wide breadth of product offering, we will cover each of these dryer types in some detail. It is always
recommended that the compressed air treatment products be discussed in concert with the entire compressed air
system and the application of the products. You should consult a compressed air expert to assure that the compressed
air dryer selected is correct for your application.
Regenerative Desiccant Type Dryers

These dryers use a desiccant, which adsorbs the water vapor in the air stream. A distinction needs to be made between
adsorb and absorb. Adsorb means that the moisture adheres to the desiccant, collecting in the thousands of small
pores within each desiccant bead. The composition of the desiccant is not changed, and the moisture can be driven off
in a regeneration process by applying dry purge air, by the application of heat, or a combination of both. Absorb
means the material that attracts the moisture is dissolved in and used up by the moisture. Absorption takes place in a
deliquescent desiccant type dryer.
Regenerative desiccant dryers normally are of twin tower construction. One tower dries the air from the compressor
while the desiccant in the other tower is being regenerated after the pressure in the tower has been reduced to
atmospheric pressure. Regeneration can be accomplished using a time cycle or on demand by measuring the
temperature or humidity in the desiccant towers or by measuring the dew point of the air leaving the on-line tower.
In the heatless regenerative desiccant type, no internal or external heaters are used. Purge air requirement can range
up to 18% of the total air-flow. The typical regenerative desiccant dryer at 100 psig has a pressure dew point rating of -
40°F but dew points down to -100°F can be obtained.
Heat reactivated regenerative desiccant dryers may have internal or external heat applied by heaters. In the internal
type, steam or electricity may be used in heaters embedded in the desiccant bed. This reduces the amount of purge air
required for regeneration to less than 10%. The purge air plus normal radiation is used to cool the desiccant bed after
regeneration to prevent elevated air temperatures going downstream.
In externally heated regenerative desiccant dryers, the purge air is heated to an elevated temperature and then passes
through the desiccant bed. The amount of purge air is approximately 5-10% of the air flow through the dryer. The
purge air from the compressed air system can be eliminated if a blower is used for the circulation of heated
atmospheric air through the desiccant bed. To protect the desiccant bed from oil contamination from the air
compressor, a coalescing filter is required upstream of the dryer. To protect downstream equipment from desiccant
dust or “fines”, a particulate filter downstream of the dryer also is also recommended.
Advantages of Regenerative Desiccant Type Dryers include:
• Very low dew points can be achieved without potential freeze-up.

• Moderate cost of operation for the dew points achieved.
• Heatless type can be designed to operate pneumatically for remote, mobile or hazardous locations.
Disadvantages of Regenerative Desiccant Type Dryers include:
• Relatively high initial capital cost

• Periodic replacement of the desiccant bed (typically 3-5 years)
• Oil aerosols can coat the desiccant material, rendering it useless if adequate pre-filtering is not maintained.
• Purge air usually is required.
Refrigerant Type Dryers
Although it does not offer as low a dew point as can be obtained with other types, the refrigerant type dryer has been
the most popular, as the dew point obtained is acceptable in many general industrial plant air applications. The
principle of operation is similar to a domestic refrigerator or home air conditioning system. The compressed air is
cooled in an air-to-refrigerant heat exchanger to about 35°F, at which point the condensed moisture is separated and
drained off. The air is then reheated in an air-to-air heat exchanger by means of the incoming air, which also is pre-
cooled before entering the air-to-refrigerant heat exchanger. This means that the compressed air leaving the dryer has
a pressure dew point of 35 to 40°F. A lower dew point is not feasible in this type of dryer as the condensate would
freeze at 32°F or lower.
In a non-cycling refrigerant dryer (see below), the refrigerant circulates continuously through the system. This design
provides rapid response to changes in operating loads. Since the flow of compressed air will vary and ambient
temperatures also vary, a hot gas bypass valve or unloader valve often is used to regulate the flow of the refrigerant
and maintain stable operating conditions within the refrigerant system. In most designs, the refrigerant evaporates
within the air-to-refrigerant heat exchanger (evaporator) and is condensed after compression by an air-or water-to-
refrigerant heat exchanger (condenser).
Non-cycling Refrigerant Dryer Diagram

While older refrigerant type air dryers have used CFC refrigerants such as R12 and R22, newer designs are in
compliance with the Montreal Protocol and use chlorine free refrigerants such as R134A and R407C or other
environmentally friendly refrigerant blends. The properties of these newer refrigerants require careful attention to the
refrigeration system design, due to differences in operating pressures and temperatures. Refrigerant type dryers
should only be serviced by a licensed and trained technician to assure that the refrigerant material is properly
handled.
Cycling type refrigerant dryers use refrigerant to chill a mass surrounding the air passage in the heat exchanger. This
mass may be a liquid such as glycol or a metal such as aluminum block, beads or related substance, which act as a
heat sink. The compressed air is cooled by the heat sink which has its temperature controlled by a thermostat and
shuts off the refrigerant compressor during reduced loads, providing savings in operating costs but at higher initial
capital cost.
Refrigerant Cycling Dryer Schematic
Advantages of Refrigerant Type Air Dryers include:
• Low, initial capital cost.

• Relatively low operating cost.
• Low maintenance costs.
• Not damaged by oil in the air stream (although, filtration normally is sometimes recommended).
Disadvantages of Refrigerant Type Air Dryers include:
• Limited dew point capability.
Advantages of non-cycling designs include:
• Minimal dew point swings

• Refrigerant compressor operates continuously
Disadvantages of non-cycling designs include:
• No energy savings at partial and zero air flow
Advantages of cycling designs include:
• Energy savings at partial and zero air flow.

Disadvantages of cycling designs include:
• Dew point swings

• Increased size and weight to accommodate the heat sink mass
• Increased capital cost
The CAGI website is an excellent source for more information on the application of compressed air dryers,
compressed air dryer and filtration selection, and information on the Air Dryer & Filtration Section.
For more detailed information about CAGI, its members, compressed air applications or answers to any of your
compressed air questions, please contact the Compressed Air and Gas Institute. CAGI educational resources include
e-learning coursework on the SmartSite, selection guides, videos and as well as mentioned Compressed Air & Gas
Handbook.

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Types of Compressed Air Dryers: Regenerative

Desiccant and Refrigerant

Compressed Air Dryer Selection

• Regenerative desiccant type:

Regenerative Desiccant Type Dryers

Advantages of Regenerative Desiccant Type Dryers include:

• Very low dew points can be achieved without potential freeze-up.

Disadvantages of Regenerative Desiccant Type Dryers include:

• Relatively high initial capital cost

Non-cycling Refrigerant Dryer Diagram

Refrigerant Cycling Dryer Schematic

Advantages of Refrigerant Type Air Dryers include:

• Low, initial capital cost.

Disadvantages of Refrigerant Type Air Dryers include:

• Limited dew point capability.

Advantages of non-cycling designs include:

• Minimal dew point swings

Disadvantages of non-cycling designs include:

• No energy savings at partial and zero air flow

Advantages of cycling designs include:

• Energy savings at partial and zero air flow.

• Dew point swings

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