MODULAR DEHUMIDIFICATION SYSTEM

FIELD OF THE INVENTION

The invention relates to industrial and commercial air dehumidification systems, equipment, and methods, particularly desiccant dehumidifiers.

BACKGROUND OF THE INVENTION

Commercial and industrial scale dehumidification systems are used in a wide variety of applications. Such dehumidification systems may be used, for example, to control the environment in which a product, such as a pharmaceutical or a food product, is produced to maintain the quality of the product during the manufacturing process. Other industrial dehumidification systems are used directly as part of a manufacturing process, where, for example, the product being produced undergoes a drying or dehumidification step. In some manufacturing processes, the product needs to be produced in an environment that is separated from ambient conditions, creating large transient heat and moisture loads. In other processes, the process may produce moisture that needs to be evacuated in order to maintain product production safety under steady low moisture load. Other examples of applications for such dehumidification systems include industrial, commercial, residential, retail and institutional buildings such as supermarkets, hotels, research laboratories, and hospitals. Further examples include maintaining the air in warehouses storing various goods. Some such warehouse applications may be relatively “passive” storage applications where individuals are not typically working in the warehouse, but others may be “active” where, for example, forklifts move product in and out all day long, creating large transient heat and moisture loads. This wide variety of applications also results in a wide variety of heat loads, moisture loads, and required air handling capacity. Existing dehumidification systems are customized for each of these industrial/commercial applications resulting in different sizes and shapes of components and a wide variety of customized dehumidification systems.

U.S. Patent Publication No. 2022/0178559 to Schaefer et al. (“Schaefer”) discloses a modular dehumidification system for plant matter, such as a dehumidification system used in greenhouses to grow and store various agricultural products. This modular dehumidification system is a cooling-based dehumidification system, where the air is dehumidified by the process of cooling and condensation. The dehumidification system disclosed in Schaefer is a specific implementation of cooling-based dehumidification and includes a head unit and one or more modular dehumidifier units. Each modular dehumidifier unit includes a coil set with a cooling coil and a heating coil. The head unit includes a cooling refrigerant subcircuit that cools refrigerant and circulates the cooled refrigerant through the cooling coils of the modular dehumidifier units and a heating refrigerant subcircuit that heats refrigerant and circulates heated refrigerant through the heating coils of the modular dehumidifier units.

SUMMARY OF THE INVENTION

In one aspect, the invention relates to modular air conditioning systems that include a plurality of air conditioning modules. More specifically, the air conditioning system may be a dehumidification system including a plurality dehumidification modules.

In another aspect, the invention relates to a dehumidification system for dehumidifying process air. The dehumidification system includes a process blower configured produce a process airflow of the process air and a plurality of dehumidification modules. Each dehumidification module includes a sorption section, a desorption section, and a desiccant moveable between the sorption section and the desorption section. The plurality of dehumidification modules is arranged in parallel with each other relative to the process airflow for a portion of the process air to flow over the desiccant in the sorption section of at least one of the dehumidification modules.

In a further aspect, the invention relates to a dehumidification system for dehumidifying process air. The dehumidification system includes a process blower configured produce a process airflow of the process air, a plurality of dehumidification modules, and a plurality of isolation dampers located in the process airflow. Each dehumidification module includes a sorption section, a desorption section, and a desiccant moveable between the sorption section and the desorption section. The plurality of isolation dampers is selectively operated to direct the process air through the plurality of dehumidification modules in a plurality of different configurations.

In still another aspect, the invention relates to a dehumidification system for dehumidifying process air. The dehumidification system includes a process blower configured produce a process airflow of the process air, a plurality of base dehumidification modules, and a plurality of variation dehumidification modules. Each base dehumidification module includes at least one interface. Each variation dehumidification modules includes at least one interface. Each variation dehumidification module has at least one of an additional system not present in the base dehumidification modules or an alternative system from the base dehumidification modules. The least one interface of the variation dehumidification module shares a common feature with at least one interface of the base dehumidification module to allow the variation dehumidification module to be interchanged with the base dehumidification module.

These and other aspects of the invention will become apparent from the following disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a dehumidification module that may be used in the dehumidification systems discussed herein.

FIGS. 2A and 2B are perspective views of the dehumidification module shown in FIG. 1. FIG. 2A is a front view of the dehumidification module showing an inlet and an outlet for process air, and FIG. 2B is a rear view of the dehumidification module showing an inlet and an outlet for reactivation air.

FIG. 3 is a schematic view of another dehumidification module that may be used in the dehumidification systems discussed herein.

FIG. 4 is a schematic view of a dehumidification system including a plurality of the dehumidification modules shown in FIGS. 1 to 2B. FIG. 3 shows the process airflow within the dehumidification system.

FIG. 5 is a schematic view of a dehumidification system including a plurality of the dehumidification modules shown in FIGS. 1 to 2B. FIG. 5 shows the reactivation airflow within the dehumidification system.

FIG. 6 is a schematic view of a variation of a dehumidification module that may be used in the dehumidification systems shown in FIGS. 4 and 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used herein, the terms “upstream” and “downstream” are taken with respect to the flow of a fluid in a fluid pathway, such as, for example, the flow of process air through ducts of the dehumidification system.

The solid and liquid dehumidification systems discussed herein are applicable to industrial and commercial air dehumidification systems, as opposed to smaller scale dehumidifiers, such as dehumidifiers sold as consumer products used, for example, by individuals or households for personal use.

As discussed above, existing dehumidification systems are customized for existing industrial/commercial applications, resulting in different sizes and shapes of components. The dehumidification systems discussed herein are modular dehumidification systems. Each modular dehumidification system discussed herein includes a plurality of dehumidification base modules, each with a dehumidification medium such as desiccant. Different dehumidification systems can be built by arranging the dehumidification base modules differently within the system. In some embodiments, this arrangement (or re-arrangement) can be implemented by using system interfaces, such as isolating dampers and a microprocessor-based controller, to change the airflow pattern between the dehumidification base modules, thus providing dynamic or on demand dehumidification services. In some embodiments, variations of the base modules (base variations) can be used, replacing at least some of the base modules. These base variations further increase the versatility of the dehumidification system. The use of a modular dehumidification system retains the ability to customize the dehumidification system to the consumer/application but recognizes volume-based manufacturing savings and standardizes the shipping assemblies.

Further, the modular dehumidification systems discussed herein provide for additional operational savings and efficiency. Existing dehumidification designs typically only operate at part of the design capacity and will infrequently operate at full design capacity. Various methods, systems, and components may be used to increase the efficiency of existing dehumidification systems when such systems are not operating at design capacity. But such systems and methods may also increase the customization of the offered dehumidifiers. The modular dehumidification systems discussed herein can readily and more effectively adapt to these non-design and also unknown design operational conditions without the added complexity and cost of the additional customized systems. Furthermore, the system modularity will allow the dehumidification system to change functionality as the customer change its process and conditioning needs creating a dehumidification on demand capability. In some embodiments, because of the modularity of the system initially built into the dehumidification system, such changes can be implemented via a software change allowing the customer to choose variability in the unit operation without any hardware shipment. For example, if a customer process changes from moderate dehumidification to deep dehumidification, by changing the software programing, the utilization of the base modules will allow for this operational change. Setting the program to an adaptive mode will also allow for this variation.

As noted above, the dehumidification systems discussed herein include a plurality of dehumidification modules. FIG. 1 is a schematic of a dehumidification module 100 that may be used in the dehumidification systems discussed herein. FIG. 2A is a front view of the dehumidification module 100 showing an inlet and an outlet for process air (a process air inlet 112 and a process air outlet 114), and FIG. 2B is a rear view of the dehumidification module 100 showing an inlet and an outlet for reactivation air (a reactivation air inlet 132 and a reactivation air outlet 134).

As will be discussed further below, the dehumidification system may be used to condition air and, more specifically, dehumidify air. The air being dehumidified (conditioned) is referred to herein as process air 12, and the dehumidification system includes a process airflow. The dehumidification system then provides the conditioned (dehumidified) air, as supply air, to a space, such as a room. The air being conditioned (process air 12) may be drawn from various suitable sources including ambient air outside of the room or recirculated air (return air) from within the room. The dehumidification module 100 includes a process air plenum 110. The process air 12 enters the process air plenum 110 via a process air inlet 112, flows through the process air plenum 110 where it is dehumidified, and then flows out of the process air plenum 110 via a process air outlet 114.

The dehumidification module 100 includes a desiccant rotor 120 containing a desiccant located therein. Suitable desiccants include, for example, titanium silicagel and lithium chloride. Such desiccants may be arranged in a porous structure through which air can flow. As shown in FIG. 1, the desiccant rotor 120 is a rotating Honeycombe® wheel, such as the desiccant wheel produced by Munters Corp. of Amesbury, Massachusetts, USA. In the desiccant wheel, the desiccant may be formed, for example, by being impregnated into a semi-ceramic honeycomb structure or other porous structure. The desiccant rotor 120, however, is not limited to such honeycomb structures, but includes other rotary desiccant systems where the desiccant may have other arrangements. For example, the desiccant may also be formed as granules or particulate and form a porous mass through which air can flow. Such granular desiccant may be formed in beds that are arranged horizontally or in multiple vertical beds. In addition, the desiccant is not limited to solid desiccants, but liquid desiccants may also be used as will be discussed further below with reference to FIG. 3.

A portion of the desiccant rotor 120 is located in the process air plenum 110 and positioned to allow the process air 12 to flow through the desiccant in the desiccant rotor 120 located within the process air plenum 110. The portion of the process air plenum 110 in which the desiccant is located is a sorption section 116 of the dehumidification module 100, and the portion of the desiccant rotor 120 through which the process air 12 flows is referred to as the process segment 122 (or process zone) of the desiccant rotor 120. The process air 12 flows through the process segment 122 and moisture from the process air 12 is absorbed by the desiccant in the process segment 122, dehumidifying the process air 12. In the process segment 122 (the sorption section 116), the surface vapor pressure of the desiccant is lower than the process air 12 allowing the desiccant to absorb moisture from the process air 12.

As the desiccant absorbs moisture from the process air 12, the ability for the desiccant to absorb additional moisture is reduced, as the surface vapor pressure of the desiccant increases because of absorption. The desiccant is thus reactivated (regenerated) to restore its ability to absorb moisture. In this embodiment, the desiccant is reactivated using reactivation air 14 and the dehumidification system includes a reactivation airflow. The reactivation air 14 may be drawn from various suitable sources including ambient air. The dehumidification module 100 includes a reactivation air plenum 130. The reactivation air 14 enters the reactivation air plenum 130 via a reactivation air inlet 132, flows through the reactivation air plenum 130 where the reactivation air 14 is used to reactivate the desiccant, and then flows out of the reactivation air plenum 130 via a reactivation air outlet 134. The portion of the desiccant rotor 120 through which the reactivation air 14 flows is referred to as the reactivation segment 124 (or reactivation zone) of the desiccant rotor 120. The reactivation air 14 flows through the reactivation segment 124 and removes moisture from the desiccant in the reactivation segment 124, reactivating (regenerating) the desiccant. The portion of the reactivation air plenum 130 in which the desiccant is located is a desorption section 136 of the dehumidification module 100. Within the reactivation segment 124 (the desorption section 136), the desiccant has a surface vapor pressure that is significantly higher than the reactivation air 14 so moisture from the desiccant is transferred to the reactivation air 14 to equalize the pressure differential.

In this embodiment, the desiccant rotor 120 is rotatable to move the desiccant between the sorption section 116 and the desorption section 136. Various suitable mechanisms may be used to rotate the desiccant rotor 120. As shown in FIG. 2A, for example, a motor 126 is drivingly coupled to the desiccant rotor 120 to transmit torque to the desiccant rotor 120 and rotate the desiccant rotor 120. The motor 126 may be coupled to the desiccant rotor 120 by various suitable means including, for example, by a belt 128. The motor 126 rotates the belt 128, which in turn rotates the desiccant rotor 120. The desiccant is fixed within the desiccant rotor 120 and rotates with the rotation of the desiccant rotor 120. The desiccant is thus a moveable desiccant that moves between the sorption section 116 and a desorption section 136 of the dehumidification module 100. In embodiments using the desiccant rotor 120, the desiccant is exposed to a continuous repeating cycle of sorption and desorption to continuously dry the process air 12.

Referring back to FIG. 1, the surface vapor pressure of the desiccant in the reactivation segment 124 (desorption section 136) should be higher than the vapor pressure of the reactivation air 14 to reactivate the desiccant. To increase the surface vapor pressure of the desiccant, the desiccant may be heated such as by using hot reactivation air 14. Accordingly, in some embodiments, the reactivation air 14 may be heated. Optionally, the dehumidification module 100 may include a heater 137 located within the reactivation airflow, such as within the reactivation air plenum 130, upstream of the desiccant rotor 120 and, more specifically, upstream of the desorption section 136. Suitable heaters include, for example, a direct electrical heater (e.g., resistive heater), a gas-fired heater, and/or a heat-pump module.

In each of the process air plenum 110 and the reactivation air plenum 130, the various components include a resistance to air flowing from the inlet (process air inlet 112 or reactivation air inlet 132) to the outlet (process air outlet 114 or reactivation air outlet 134). The dehumidification module 100 thus has a process air pressure drop from the process air inlet 112 to the process air outlet 114. Each dehumidification module 100 may optionally include a process booster blower 118 located within the process airflow, such as within the process air plenum 110. The process booster blower 118 is sized to overcome the process air pressure drop of the dehumidification module 100 and maintain the process airflow through the process air plenum 110 of each dehumidification module 100. Similarly, the dehumidification module 100 also has a reactivation air pressure drop from the reactivation air inlet 132 to the reactivation air outlet 134. Each dehumidification module 100 may optionally include a reactivation booster blower 138 located within the reactivation airstream, such as within the reactivation air plenum 130. The reactivation booster blower 138 is sized to overcome the reactivation air pressure drop of the dehumidification module 100 and maintain the reactivation airflow through the reactivation air plenum 130 of each dehumidification module 100.

As will be discussed in more detail below, the dehumidification systems discussed herein may use a plurality of dampers and, more specifically, a plurality of isolation dampers to direct the various airflows within the dehumidification system. Each damper may include, for example, one or more moveable louvers (blades) that can be positioned in an open position to allow air to pass through the isolation damper and a closed position to prevent air from passing through the isolation damper. Although these isolation dampers may be provided in other parts of the system, at least some of the isolation dampers may, optionally, be included in each dehumidification module 100.

As shown in FIG. 1, for example, the dehumidification module 100 includes a process air module inlet damper 142 located within the process airflow, such as within the process air plenum 110, upstream of the desiccant rotor 120 and, more specifically, upstream of the sorption section 116. For example, the process air module inlet damper 142 may be located at or within the process air inlet 112. When the process air module inlet damper 142 is in the open position, the process air module inlet damper 142 allows the process air 12 to enter the dehumidification module 100 and, more specifically, the process air plenum 110. When the process air module inlet damper 142 is in the closed position, the process air module inlet damper 142 isolates the dehumidification module 100 from the rest of the system by preventing the process air 12 from entering the dehumidification module 100 and, more specifically, the process air plenum 110. The dehumidification module 100 may also include a process air module outlet damper 144 located within the process airflow, such as within the process air plenum 110, downstream of the desiccant rotor 120 and, more specifically, downstream of the sorption section 116. For example, the process air module outlet damper 144 may be located at or within the process air outlet 114. The process air module outlet damper 144 may be open when it is desired to have the process air 12 flowing through the dehumidification module 100 and closed to prevent backflow into the dehumidification module 100 under certain conditions and arrangements.

Similarly, the dehumidification module 100 may include a reactivation air module inlet damper 146 located within the reactivation airflow, such as within the reactivation air plenum 130, upstream of the desiccant rotor 120 and, more specifically, upstream of the desorption section 136. For example, the reactivation air module inlet damper 146 may be located at or within the reactivation air inlet 132. When the reactivation air module inlet damper 146 is in the open position, the reactivation air module inlet damper 146 allows the reactivation air 14 to enter the dehumidification module 100 and, more specifically, the reactivation air plenum 130. When the reactivation air module inlet damper 146 is in the closed position, the reactivation air module inlet damper 146 isolates the dehumidification module 100 from the rest of the system by preventing the reactivation air 14 from entering the dehumidification module 100 and, more specifically, the reactivation air plenum 130.

The dehumidification module 100 includes various interfaces 150 that allow it to interface with the dehumidification system. Such interfaces may include, for example, the shape, the size, and the configuration (e.g., engagement features) of the process air inlet 112, the process air outlet 114, the reactivation air inlet 132, and the reactivation air outlet 134. Other interfaces may include electrical interfaces 152 to receive electricity to operate the various electrical components of the dehumidification modules 100 and communication interfaces 154 that communicatively couple a controller 240 (FIG. 4) to the dehumidification module 100.

FIG. 3 is a schematic of another dehumidification module 102 that may be used in the dehumidification systems discussed herein. The dehumidification module 102 shown in FIG. 3 is similar to the dehumidification module 100 shown in FIG. 1 and the same reference numerals will be used for components of this dehumidification module 102 that are the same or similar to the dehumidification module 100 discussed above. The discussion of these components above also applies to this dehumidification module 102 and a detailed discussion of these components is omitted here. The dehumidification module 102 shown in FIG. 3 can be used in the same manner as the dehumidification module 100, discussed below.

As noted above, the dehumidification module is not limited to rotary desiccant systems discussed above, and the dehumidification module and other dehumidification processes and, in particular, other desiccant systems may be used, such as liquid desiccant systems. FIG. 3 shows a dehumidification module 102 utilizing a dual sump assembly 180 for a liquid desiccant system, instead of the desiccant rotor 120. The dual sump assembly 180 includes a process sump 182 containing a liquid desiccant such as lithium chloride, for example. A process pump 184 draws the liquid desiccant from the process sump 182 and at least a portion of the liquid desiccant flows from the process sump 182 to a process header 186 that is fluidly connected to the process sump 182. The process header 186 contains a plurality of nozzles and the liquid desiccant is discharged from the process header 186 and, more specifically in this embodiment, the plurality of nozzles to create a process waterfall or other appropriate flow of the liquid desiccant. The process air 12 flows through the process waterfall and moisture is absorbed from the process air 12 into the liquid desiccant. To reduce the vapor pressure of the liquid desiccant and increase the liquid desiccant's ability to absorb moisture, the liquid desiccant may be cooled by a cooler 188 before as it is circulated from the process sump 182 to the process header 186.

Over time, the concentration of the desiccant in the process sump 182 will reduce unless it is regenerated. Accordingly, the process sump 182 is also fluidly connected to a regenerator sump 192, and a portion of the liquid desiccant may flow from the process sump 182 to the regenerator sump 192. A regenerator pump 194 draws the liquid desiccant from the regenerator sump 192 and at least a portion of the liquid desiccant flows from the regenerator sump 192 to a regenerator header 196 that is fluidly connected to the regenerator sump 192. The regenerator header 196 contains a plurality of nozzles and the liquid desiccant is discharged from the regenerator header 196 and, more specifically in this embodiment, the plurality of nozzles to create a regenerator waterfall or other appropriate flow of the liquid desiccant. The reactivation air 14 flows through the regenerator waterfall to remove water from the regenerator waterfall and concentrate the liquid desiccant. To increase the vapor pressure of the liquid desiccant, the liquid desiccant may be heated by a heater 198 before it is circulated from the regenerator sump 192 to the regenerator header 196. A portion of the strong desiccant from the regenerator sump 192 may also flow from the regenerator sump 192 to the process sump 182 to replenish the liquid desiccant in the process sump 182.

FIG. 4 is a schematic of a dehumidification system 200 including a plurality of the dehumidification modules 100 discussed above. FIG. 4 shows the process airflow within the dehumidification system 200. The reactivation airflow in the dehumidification system 200 may be discrete or separate airflows for each dehumidification module 100, discrete or separate airflows for groups (sets) of dehumidification modules 100, or a common airflow as described below with reference to FIG. 5. Each of the components discussed below are fluidly connected to each other by suitable fluid connections for the process air 12 to flow between them such as air ducts or other suitable fluid conduits. In general, the following discussion will discuss the flow of the process air 12 through the dehumidification system 200 from an inlet (a return air inlet 212 and a makeup air inlet 214) to an outlet of the dehumidification system 200 (a process outlet 238).

The dehumidification system 200 includes an inlet for the process air 12. As noted above, the process air 12 may be drawn from various suitable sources including ambient air or recirculated air (return air) from a space such as a room. In this embodiment, the dehumidification system 200 includes both a return air inlet 212 drawing air from a space and a makeup air inlet 214 drawing makeup air from a source such as ambient air. A return air inlet damper 216 and a makeup air inlet damper 218 may be used to control the flow of the return air and makeup air, respectively. The return air and makeup air may be mixed in desired proportions in a mixing box 222 to form the process air 12.

The dehumidification system 200 also includes a process blower 224. The process blower 224 is configured to produce a process airflow of the process air 12 within the dehumidification system 200. As noted above, the process booster blower 118 is optional and in systems where the process booster blower 118 is omitted, the process blower 224 is sized to produce the desired flowrate within the dehumidification system 200. The dehumidification system 200 may have a process air pressure drop from the return air inlet 212 and the makeup air inlet 214 to the process outlet 238, and the process blower 224 may be sized to overcome the entire process air pressure drop of the dehumidification system 200, including the pressure drop of all of the dehumidification modules 100, and maintain the process airflow through the dehumidification system 200. In embodiments where the dehumidification modules 100 each include a process booster blower 118, the size of the process blower 224 can be reduced such that the process blower 224 overcomes the pressure drop of the components other than the dehumidification modules 100 within the system. As will be discussed below, each of the dehumidification modules 100 can be selectively operated for different desired operating conditions and thus when each dehumidification module 100 includes a process booster blower 118, the process blower 224 can be operated independently of the number of dehumidification modules 100 being operated. The process blower 224 may have a capacity greater than each of the process booster blowers 118.

The dehumidification system 200 may include various filters to filter the process air 12 as it flows through the system. In FIG. 4, a first filter 226 is positioned upstream of the plurality of dehumidification modules 100 and downstream of the process blower 224 to filter the process air 12 before it is dehumidified.

As noted above, the desiccant absorbs moisture from the process air 12 when the surface vapor pressure of the desiccant is lower than the vapor pressure of the process air 12. The dehumidification system 200 may include a cooler 228, such as a cooling coil or other suitable cooling module positioned upstream of the plurality of dehumidification modules 100 to cool the process air 12 before it is dehumidified. The cooling coil (cooler 228) may be part of a suitable cooling system such as a heat pump, direct expansion cooling system (refrigeration system), or chilled water system.

The process air then flows through the plurality of dehumidification modules 100 to dehumidify the air as will be discussed further below.

The dehumidification system 200 may be used to further condition the air to desirable temperatures before exiting the dehumidification system 200. The dehumidification system 200 may, optionally, include one or both of a cooler 232 or a heater 234. The cooler 232 may be a cooling coil or other suitable cooling module positioned downstream of the plurality of dehumidification modules 100 to cool the process air 12 after it is dehumidified. The cooling coil (cooler 232) may be part of a suitable cooling system such as a heat pump, direct expansion cooling system (refrigeration system), or chilled water system. Similarly, the heater 234 may be a direct electrical heater (e.g., resistive heater), a gas-fired heater, and/or a heat-pump module.

As noted above, various filters may be used and the dehumidification system 200 shown in FIG. 4 includes a second filter 236 positioned downstream of the plurality of dehumidification modules 100 to filter the air before it exits the system at the process outlet 238 and into a space, such as a room.

The dehumidification system 200 may also include a controller 240. The controller 240 is configured to operate various aspects of the dehumidification system 200, including, in some embodiments, each dehumidification module 100, including the process booster blower 118 and the motor 126, and the various dampers discussed herein. The controller 240 is thus communicatively and operatively coupled to such components of the dehumidification system 200. In this embodiment, the controller 240 is a computing device having one or more processors 242 and one or more memories 244. The processor 242 can be any suitable processing device, including, but not limited to, a microprocessor, a microcontroller, an integrated circuit, a logic device, a programmable logic controller (PLC), an application-specific integrated circuit (ASIC), and/or a Field Programmable Gate Array (FPGA). The memory 244 can include one or more computer-readable media, including, but not limited to, non-transitory computer-readable media, a computer-readable non-volatile medium (e.g., a flash memory), a RAM, a ROM, hard drives, flash drives, and/or other memory devices.

The memory 244 can store information accessible by the processor 242, including computer-readable instructions that can be executed by the processor 242. The instructions can be any set of instructions or a sequence of instructions that, when executed by the processor 242, causes the processor 242 and the controller 240 to perform operations. In some embodiments, the instructions can be executed by the processor 242 to cause the processor 242 to complete any of the operations and functions for which the controller 240 is configured, as will be described further below. The instructions can be software written in any suitable programming language, or can be implemented in hardware. Additionally, and/or alternatively, the instructions can be executed in logically and/or virtually separate threads on the processor 242. The memory 244 can further store data that can be accessed by the processor 242.

The technology discussed herein makes reference to computer-based systems and actions taken by, and information sent to and from, computer-based systems. One of ordinary skill in the art will recognize that the inherent flexibility of computer-based systems allows for a great variety of possible configurations, combinations, and divisions of tasks and functionality between components and among components. For instance, processes discussed herein can be implemented using a single computing device or multiple computing devices working in combination. Databases, memory, instructions, and applications can be implemented on a single system or distributed across multiple systems. Distributed components can operate sequentially or in parallel.

Dehumidification of the process air 12 is accomplished by passing the process air through one or more dehumidification modules 100 of the plurality of dehumidification modules 100. The plurality of dehumidification modules 100 are arranged in a plurality of sets of dehumidification modules. In the embodiment shown in FIG. 4, for example, the dehumidification system 200 has four sets, a first set of dehumidification modules 252, a second set of dehumidification modules 254, a third set of dehumidification modules 256, and a fourth set of dehumidification modules 258, but any suitable number of sets may be used. Each set of dehumidification modules 252, 254, 256, 258 includes a plurality of the dehumidification modules 100. For example, four dehumidification modules 100 are included in each set of dehumidification modules 252, 254, 256, 258 in FIG. 4, but other suitable numbers of dehumidification modules 100 may be used in each set.

The first set of dehumidification modules 252 includes an inlet plenum 262 fluidly connected to the process air inlet 112 of each of the dehumidification modules 100 in the first set of dehumidification modules 252. The first set of dehumidification modules 252 also includes an outlet plenum 264 fluidly connected to the process air outlet 114 of each of the dehumidification modules 100 in the first set of dehumidification modules 252. The dehumidification modules 100 of the first set of dehumidification modules 252 are thus arranged in parallel with each other relative to the flow of the process air 12. Although shown in parallel, the dehumidification modules 100 of the first set of dehumidification modules 252 may have other arrangements such as being arranged in series with each other relative to the flow of the process air 12 or even a reconfigurable arrangement (e.g., between series and parallel) using isolation dampers and other fluid connections for the process air 12.

The first set of dehumidification modules 252 also includes a bypass plenum 266 fluidly connected to each of the inlet plenum 262 and the outlet plenum 264 to allow at least a portion of the process air 12 to bypass the dehumidification modules 100 in the first set of dehumidification modules 252. A bypass damper 268 may be positioned in the bypass plenum 266 to close the bypass plenum 266 and thus prevent air from bypassing the dehumidification modules 100 in the first set of dehumidification modules 252.

The controller 240 is communicatively and operatively coupled to each of the dehumidification modules 100 of the first set of dehumidification modules 252, and more specifically to the process booster blower 118, the motor 126, the heater 137, the reactivation booster blower 138, the process air module inlet damper 142, process air module outlet damper 144, and the reactivation air module inlet damper 146 of each of the dehumidification modules 100 of the first set of dehumidification modules 252. The controller can thus selectively operate each dehumidification modules 100 by opening or closing the appropriate dampers on the dehumidification modules 100 (e.g., process air module inlet damper 142, process air module outlet damper 144), turning on and off the process booster blower 118, the heater 137, and the reactivation booster blower 138 as needed, and operating the motor 126 to rotate the desiccant rotor 120. The controller 240 can thus selectively operate the dehumidification modules 100 of the first set to increase the dehumidification capacity of the dehumidification system 200. For example, if the dehumidification system 200 is operating with one dehumidification module 100 of the first set of dehumidification modules 252 operating, the controller 240 can turn on a second dehumidification module 100 of the first set of dehumidification modules 252 to increase the dehumidification capacity of the dehumidification system 200. The controller 240 can likewise stage on additional dehumidification modules 100, as needed, to further increase the dehumidification capacity. Similarly, the controller 240 can turn off dehumidification modules 100 of the first set of dehumidification modules 252 to reduce the dehumidification capacity. That is, the controller 240 can stage off dehumidification modules 100, as needed, to decrease the dehumidification capacity.

The second set of dehumidification modules 254, the third set of dehumidification modules 256, and the fourth set of dehumidification modules 258 are similarly configured and this discussion of the first set of dehumidification modules 252 applies equally to the second set of dehumidification modules 254, the third set of dehumidification modules 256, and the fourth set of dehumidification modules 258.

In the configuration shown in FIG. 4, the dehumidification modules 100 of each set of dehumidification modules 252, 254, 256, 258 can be operated in parallel with the dehumidification modules 100 of the other sets of dehumidification modules 252, 254, 256, 258. For example, with the bypass dampers 268 of the first set of dehumidification modules 252 and the second set of dehumidification modules 254 open, the dehumidification modules 100 of the first set of dehumidification modules 252 and dehumidification modules 100 of the second set of dehumidification modules 254 can be operated in parallel with each other. Such a configuration allows for a further increase in the dehumidification capacity beyond just the first set of dehumidification modules 252. If the dehumidification capacity of the first set of dehumidification modules 252 is sufficient for the operation, the dehumidification modules 100 of the second set of dehumidification modules 254, the third set of dehumidification modules 256, and the fourth set of dehumidification modules 258 can be turned off. If further dehumidification capacity is required, dehumidification modules 100 of these other sets can be staged on as needed to increase the dehumidification capacity of the dehumidification system 200 with the bypass damper 268 of the first set of dehumidification modules 252 open.

The bypass damper 268 in each set of dehumidification modules 252, 254, 256, 258 also allows the sets of dehumidification modules 252, 254, 256, 258 to be operated in series (so-called deep dehumidification). For example, the bypass damper 268 of the first set of dehumidification modules 252 can be closed and at least one dehumidification module 100 in the first set of dehumidification modules 252 operated. All of the process air 12 thus flows first through the operating dehumidification modules 100 of the first set of dehumidification modules 252 to be dehumidified to a first moisture content. Then, with the bypass damper 268 of the second set of dehumidification modules 254 closed and at least one dehumidification module 100 of the second set of dehumidification modules 254 operating, the process air 12 flows through the operating dehumidification modules 100 of the second set of dehumidification modules 254 to be dehumidified to a second moisture content, the second moisture content being less than the first moisture content.

The controller 240 may be used to operate the sets of dehumidification modules 252, 254, 256, 258 in the manner discussed above. More specifically, the controller 240 may be configured to position the plurality of isolation dampers (e.g., the process air module inlet dampers 142, the process air module outlet dampers 144, and/or the bypass dampers 268) to direct the process air 12 through the plurality of the dehumidification modules 100 in the manner discussed above. Although shown and described above with the process air module inlet dampers 142, the process air module outlet dampers 144, and/or the reactivation air module inlet damper 146 as being located within the dehumidification module 100, these dampers maybe be positioned outside of the dehumidification module 100 at the fluid connection between the inlet plenum 262 and the outlet plenum 264.

In the preceding discussion, the controller 240 and the plurality of isolation dampers are arranged to provide a variety of different configurations of a single dehumidification system 200. However, the isolation dampers may be omitted (or reduced) such that the dehumidification system 200 has a static configuration and arrangement of the dehumidification modules 100 relative to each other.

FIG. 5 is a schematic of a dehumidification system 300 including a plurality of the dehumidification modules 100 discussed above. FIG. 5 shows the reactivation airflow within the dehumidification system 300. The process airflow in the dehumidification system 300 may be discrete or separate airflows for each dehumidification module 100, discrete or separate airflows for groups (sets) of dehumidification modules 100, or a common airflow as described above with reference to FIG. 4. The process airflow may be configured as shown and described above in FIG. 4. Each of the components discussed below are fluidly connected to each other by suitable fluid connections for the reactivation air 14 to flow between them such as air ducts or other suitable fluid conduits. In general, the following discussion will discuss the flow of the reactivation air 14 through the dehumidification system 300 from a reactivation air inlet 312 to a reactivation air outlet 314.

As discussed above, each dehumidification module 100 includes a heater 137 and a reactivation booster blower 138 in some embodiments. In other embodiments, however, one or both of the heater 137 and the reactivation booster blower 138 may be omitted from each dehumidification module 100, such as in the embodiment shown in FIG. 5.

The reactivation air 14 may be drawn from various suitable sources, including ambient air, and is drawn into the dehumidification system 300 via a reactivation air inlet 312. The dehumidification system 300 may include a filter 316 positioned downstream of the reactivation air inlet 312 to filter the reactivation air 14. When the heater 137 is omitted, the dehumidification system 300 may include a heater 322 positioned upstream of the plurality of dehumidification modules 100 to heat the reactivation air, as discussed above. Suitable heaters include, for example, a direct electrical heater (e.g., resistive heater), a gas-fired heater, and/or a heat-pump module. Each reactivation air plenum 130 of each of the dehumidification modules 100 is fluidly connected to the heater 322 to receive the reactivation air 14. In the embodiment shown in FIG. 5, the plurality of dehumidification modules 100 are arranged in sets in a manner similar to that shown and described above with reference to FIG. 5. For consistency, the same reference numerals are used for the sets in FIG. 5 as in FIG. 4.

In FIG. 5, the plurality of dehumidification modules 100 are arranged in parallel with each other relative to the flow of the reactivation air 14, but other arrangements many be used. More specifically in this embodiment, the first set of dehumidification modules 252 includes an inlet plenum 332 fluidly connected to the reactivation air inlet 132 of each of the dehumidification modules 100 in the first set of dehumidification modules 252. The first set of dehumidification modules 252 also includes an outlet plenum 334 fluidly connected to the reactivation air outlet 134 of each of the dehumidification modules 100 in the first set of dehumidification modules 252. The dehumidification modules 100 of the first set of dehumidification modules 252 are thus arranged in parallel with each other relative to the reactivation airflow. The first set of dehumidification modules 252 also includes a bypass plenum 336 fluidly connected to each of the inlet plenum 332 and the outlet plenum 334 to allow at least a portion of the reactivation air 14 to bypass the dehumidification modules 100 in the first set of dehumidification modules 252. A bypass damper 338 may be positioned in the bypass plenum 336 to close the bypass plenum 336 and thus prevent air from bypassing the dehumidification modules 100 in the first set of dehumidification modules 252. The second set of dehumidification modules 254, the third set of dehumidification modules 256, and the fourth set of dehumidification modules 258 are similarly configured and this discussion of the first set of dehumidification modules 252 applies equally to the second set of dehumidification modules 254, the third set of dehumidification modules 256, and the fourth set of dehumidification modules 258. The controller 240 is communicatively and operatively coupled to each of the dehumidification modules 100 and the bypass damper 338 to control the reactivation airflow as needed.

When the reactivation booster blower 138 is omitted, the dehumidification system 300 may include a reactivation blower 324 to generate the reactivation airflow and overcome any pressure drops within the system. The reactivation blower 324 positioned downstream of the plurality of dehumidification modules 100.

One advantage of the dehumidification system 200 described in FIG. 4 and the dehumidification system 300 described in FIG. 5 is that a standard size dehumidification module 100 can be designed and mass produced and the number and arrangement of dehumidification modules 100 may be adjusted to provide a wide variety of different dehumidification systems. In some embodiments, variations of the dehumidification modules 100 (base variations) can be used, replacing at least some of the base modules within a dehumidification system. These base variations further increase the versatility of the dehumidification system. FIG. 6 is a schematic of a variation dehumidification module 104 that may be used as a base variation. The variation dehumidification module 104 is similar to the dehumidification module 100 and the same reference numerals will be used for components of the variation dehumidification module 104 that are the same or similar to the dehumidification module 100 discussed above. The discussion of these components above applies to the variation dehumidification module 104 and a detailed discussion of these components is omitted here. For the purposes of the following discussion, the dehumidification module 100 will also be referred to as a base dehumidification module 100.

The variation dehumidification module 104 includes a bypass regeneration system 160. The desiccant rotor 120 includes a bypass segment 162 (or process zone). A portion of the process air 12 (referred to herein as bypass air 16) flows through the bypass segment 162 and moisture from the bypass air 16 is absorbed by the desiccant in the bypass segment 162 in a manner similar to the process segment 122 discussed above. The bypass air 16 may be used as at least a portion of the reactivation air 14. Thus, instead of being directed to the process air outlet 114, the bypass air 16 flows through a bypass plenum 164 fluidly connecting the process air plenum 110 with the reactivation air plenum 130. A bypass damper 166 may be used to control the flow of bypass air 16 used as the reactivation air 14.

The variation dehumidification module 104 also includes a purge system 170. The desiccant rotor 120 of the variation dehumidification module 104 shown in FIG. 6 also includes a first isolation segment 172 (first isolation zone) and a second isolation segment 174 (second isolation zone). Isolation air 18 is circulated in a closed loop, independent of the process air 12, the reactivation air 14, and the bypass air 16, between the desiccant in the first isolation segment 172 and in the isolation segment 174. The isolation air 18 is circulated by an isolation blower 176. As discussed above, the reactivation air 14 heats the desiccant in the reactivation segment 124. An isolation air damper 178 may be used to control the flow of the isolation air 18. The first isolation segment 172 is positioned downstream of the reactivation segment 124 in the direction of rotation of the desiccant rotor 120, and, in this embodiment, adjacent to each of the reactivation segment 124 and the bypass segment 162. As the isolation air 18 passes through the desiccant in the first isolation segment 172, the isolation air 18 absorbs heat from the desiccant, cooling the desiccant before it enters the process segment 122 and heating the isolation air 18. The now heated isolation air 18 is then circulated through the second isolation segment 174 to preheat the desiccant in the second isolation segment 174. The second isolation segment 174 is positioned upstream of the reactivation segment 124 in the direction of rotation of the desiccant rotor 120, and, in this embodiment, adjacent to each of the reactivation segment 124 and the process segment 122.

The variation dehumidification module 104 thus includes additional systems that are not present in the base dehumidification module 100 and/or alterative systems that operate differently than the base dehumidification module 100. The bypass regeneration system 160 and the purge system 170 are examples of such additional or alternative systems, but other suitable variations may be used in the variation dehumidification module 104.

Although the internal components and systems of the variation dehumidification module 104 differ from the base dehumidification module 100, the interfaces 150 of the variation dehumidification module 104 preferably share common features that allow the variation dehumidification module 104 to be interchanged with the base dehumidification module 100. Such common features include, for example, the position of the process air inlet 112, the process air outlet 114, the reactivation air inlet 132, and the reactivation air outlet 134. For example, the relative position of the process air inlet 112 to the process air outlet 114 may be the same between the variation dehumidification module 104 and the base dehumidification module 100, and the relative position of the reactivation air inlet 132 to the reactivation air outlet 134 may be the same between the variation dehumidification module 104 and the base dehumidification module 100. In addition, the shape, the size, and the configuration (e.g., engagement features) of the process air inlet 112, the process air outlet 114, the reactivation air inlet 132, and the reactivation air outlet 134 may be the same between the variation dehumidification module 104 and the base dehumidification module 100, allowing the variation dehumidification module 104 to be interchanged with the base dehumidification module 100 in the dehumidification system 200, discussed above. Similarly, the same type of electrical interfaces 152 and communication interfaces 154 may be used.

The variation dehumidification module 104 can be used to increase the versatility of a dehumidification system, such as the dehumidification system 200 shown in FIG. 4 and the dehumidification system 300 shown in FIG. 5. As shown in FIG. 4, for example, each base dehumidification module 100 of the fourth set of dehumidification modules 258 may be replaced by a variation dehumidification module 104. The controller 240 thus activates the variation dehumidification modules 104 in the fourth set of dehumidification modules 258 in a manner similar to that discussed above when the capabilities of the variation dehumidification module 104 are desired.

Although this invention has been described with respect to certain specific exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art in light of this disclosure. It is, therefore, to be understood that this invention may be practiced otherwise than as specifically described. Thus, the exemplary embodiments of the invention should be considered in all respects to be illustrative and not restrictive, and the scope of the invention to be determined by any claims supportable by this application and the equivalents thereof, rather than by the foregoing description.

MODULAR DEHUMIDIFICATION SYSTEM

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