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Refrigerated air dryers

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Refrigerated air dryers

OC Industrial Group AG designs heat exchangers and impurities filtration systems for the refrigeration industry. These exchangers are the heart of refrigerated air dryers and it was only a short step to designing the whole package. Heat exchangers are produced from stainless steel and or aluminum.

After the compression process the air is saturated with moisture including dust particles and oil. These particles represent a serious danger for the end device where it could cause dysfunction, damage or influence proper operation.

Zephyr dryer has specifically designed compact exchanger modules with a cross flow system of the air and refrigerant. Hot and saturated air enters the unit for precooling. The air is cooled down by outgoing dried compressed air and this process decreases the heat load on the exchanger. It has a positive influence on the operating cost by about 30%. The cooled saturated air enters the exchanger where it reaches the required pressure dew point (PDP). The air is cooled in the exchanger and subsequently the condensed moisture is collected and drained out. The dried and cooled air then flows through the cross flow exchanger where it is heated by the incoming compressed air.

OC Industrial Group AG uses only environmentally friendly coolant.

Standard refrigerated air dryers are constructed to withhold 15barg and on demand it is possible to increase the pressure to 50barg. Zephyr refrigerated dryers are designed for the inlet air temperature of 38°C and the maximum allowed inlet temperature is 60°C. The capacity of the refrigerated dryers are in the range of 0,6 to 300m3/min.

Zephyr refrigerated air dryers are available in air or water cooled versions.

Refrigerated air dryer

Bypass valve

It can ensure the temperature of refrigerant into evaporator at the range of 0-1 °C, which not only can stabilize the PDP at 3 °C, but also can avoid the ice block in the heat exchanger.

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Compressor

In the gas circuit is working reliable compressor from established producers as are Copeland, Sanyo or Maneurop. Compressors have high performance, low noise level and build-in overheat protection.

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Compact Heat Exchanger

The unique design of the precooler makes efficient heat transfer, reduces the evaporator load and the power consumption of the dryer is lower about 30%. Moisture flows directly to the timer controlled drain. The dried and cool air then flows through the cross flow exchanger where it’s heated by the incoming compressed air.

Technical specification of the Zephyr refrigerated dryers:

Model Capacity Power Connection Dimensions, mm Weight
m3/min kW l w h kg
ZD-24 2.4 0.47 G 3/4 750 360 550 50
ZD-30 3.0 0.49 G 3/4 750 360 550 50
ZD-40 4.0 0.65 G 3/4 750 360 550 55
ZD-80 8.0 1.4 G1 1/2 750 550 880 80
ZD-100 10.0 1.85 G1 1/2 750 550 880 85
ZD-120 12.0 2.3 G2 1000 670 1030 130
ZD-150 15.0 3.03 G2 1000 670 1030 140
ZD-200 20.0 3.1 G2 1000 670 1030 150
ZD-250 25.0 3.63 G2 1/2 1000 820 1600 250
ZD-300 30.0 4.4 G2 1/2 1000 820 1600 260
ZD-350 35.0 5.1 G2 1/2 1000 820 1600 270
ZD-400 40.0 6.13 DN 100 1150 1120 1750 500
ZD-500 50.0 6.9 DN 100 1150 1120 1750 510
ZD-600 60.0 8.34 DN 100 1150 1120 1750 550
ZD-700 70.0 9.81 DN 125 1150 1120 1750 580
ZD-800 80.0 11.9 DN 150 1850 1200 2350 800
ZD-900 90.0 13.1 DN 150 1850 1200 2350 810
ZD-1000 100.0 16.7 DN 150 1850 1200 2350 850
Limited working conditions
Min/Max parameters
Working pressure 3/20 barg
Inlet temperature 5/60 °C
Ambient temperature 5/60 °C
Correction factors of the Zephyr dryers
To ensure real capacity according to operation conditions multiply nominal capacity of dryer by correction factors x KA x KB x KC
Working pressure factors
Inlet pressure barg 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Correction factor KA 0.76 0.86 0.92 0.96 1 1.04 1.08 1.11 1.15 1.18 1.22 1.25 1.28 1.30 1.31 1.32 1.32 1.33
Inlet temperature factors
Inlet temperature °C 27 30 35 38 40 43 46 49 54 60
Correction factor KB 1.5 1.36 1.11 1 0.92 0.83 0.76 0.69 0.56 0.46
Ambient temperature factors
Ambient temperature °C 20 25 30 35 38 40 45 50
Correction factor KC 1.21 1.15 1.1 1.02 1 0.89 0.79 0.69
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