Referring to
Membrane dryer 16 is shown in
Accumulator 21 is shown connected to the first outlet 18 of membrane dryer 16 and functions to receive the primary compressed fluid stream 27a therein after the primary fluid stream has been dried by membrane dryer 16.
Compressed fluid membrane dryer system 10 of
Compressed fluid membrane dryer system 10 also includes a tee 12 located between membrane dryer 16 and accumulator 21. In membrane dryer system 10, tee 12 is connected to the first outlet 18 and second inlet 19 of membrane dryer 16 and a first inlet of accumulator 21 and in fluid communication with the first outlet 18 of membrane dryer 16 and a first inlet of accumulator 21. Tee 12 functions to divert the sweep fluid stream 27b of the original compressed fluid stream 27 through the second fluid pathway 16b of membrane dryer 16 via the second inlet 19 and the second outlet of membrane dryer 16 to remove water vapor from membrane dryer 16.
Located between tee 12 and the second inlet 19 of membrane dryer 16 is a flow control valve 24 for decompressing or expansion of the gas in the compressed sweep fluid stream 27b to further dry the sweep fluid stream 27b before the sweep fluid stream 27b enters the second inlet 19 of membrane dryer 16.
Although it is noted that it would be possible in some situations to operate membrane dryer 16 by using the aforementioned expanded feed gas as a sweep, this has not been considered in the past since the resulting sweep will not be as dry, thus the performance of the membrane dryer 16 in drying the compressed fluid stream 27 flowing through membrane dryer 16 via the first inlet 17 and the first outlet 18 of membrane dryer 16 will suffer, and the membrane dryer 16 will not be capable of drying the compressed fluid stream 27 any further than the dew point of the expanded feed gas.
In further regards to flow control valve 24, in most compressed fluid system that uses membrane dryer device, the flow control valve 24 comprises either a fixed orifice or a controlled leakage through the membrane dryer 16. The aforementioned leakage flow is then controlled by the membrane unit pressure, which leads to membrane dryer 16 generally using gas continuously as sweep whether there is any net gas demand on the dryer or not. This presents a problem for systems in which the source of compressed fluid 11, such as a compressor, is shut off once demand has been met and the accumulator 21 filled. If membrane dryer 16 is installed after the one-way check valve 13 but before the accumulator 21, as shown in
Referring generally to
Although compressed fluid membrane dryer system 25 solves the gas conservation issue, there are two problems associated with compressed fluid membrane dryer system 25. Firstly, as the source of compressed fluid 11 first starts and begins pressurizing the membrane dryer system 25 prior to the one-way check valve 13, gas starts passing through the membrane dryer 16 while at very low pressure and consequently with very little sweep and often at much higher flow rates. This means that the initial fluid flowing through the membrane dryer 16 is not dried as well and as the fluid is subsequently compressed downstream prior to the one-way check valve 13, the fluid could produce condensation and a slug of water.
Secondly, the gas pressure in the membrane dryer 16 cycles as the source of compressed fluid 11 cycles. This can cause wear and fatigue of the membrane dryer 16. Since the total volume of the membrane dryer system 25 prior to the one-way check valve 13 is generally small compared to the output of the source of compressed fluid 11, the rate of pressurization can be quite high. This high rate of pressurization can fatigue the polymeric materials from which the membrane dryer 16 is commonly constructed. One way to deal with the two complications presented by the compressed fluid membrane dryer system 25 of
This control can be done pneumatically, using gas pressure from the source of compressed fluid 11, for instance, to open a solenoid valve. Alternatively, the control can be done electronically, with an electric signal from the source of compressed fluid 11 or a control circuitry. The control can also be done mechanically, using the gas flow through the module, for instance, to control the amount of sweep flow. In this way the membrane dryer 16 is always kept at pressure thereby saving membrane fatigue, and the compressed fluid system only consumes gas as purge when there is a demand on the source of compressed fluid 11 and there is a net product flow.
While using solenoid valves or some sort of control circuit to adjust the purge flow solves the problems outlined, one of the disadvantages of their use is that it can be fairly costly, especially for smaller systems. In addition these moving pieces of equipment are also susceptible to fatigue and failure in their own rights.
The present invention provides a compressed fluid membrane dryer system 26 that corrects the problems outlined in the compressed fluid membrane dryer systems 10 and 25 of
With the configuration of the compressed fluid membrane dryer system 26 of
Lastly, since the membrane dryer 16 is constantly at pressure, there is no point at which fluid flows through the membrane dryer 16 without being dried. Purge gas begins flowing as soon as the compressed gas source 11 starts, and will reach full flow when the compressed fluid membrane dryer system 26 reaches the pressure of the accumulator prior to the one-way check valve 13 and the one-way check valve 13 opens allowing gas to begin flowing through the membrane dryer 16. This avoids the possibility of a slug of water being created during start up of the compressed gas source 11 as in the membrane dryer system 25 described in
In further regards to the compressed fluid membrane dryer system 26 of
Referring back to
For instance, for a system operating at 100 psig using a portion the feed gas or original compressed fluid stream 27 as sweep, the system would be unable to reduce the humidity of the high pressure gas below 12.8% of the inlet humidity (usually 100%), since this is the reduction in humidity that would result from expanding a portion of the feed gas from 100 psig to 0 psig. Thus if the inlet gas were saturated at 100° F., the membrane dryer would not be able to reduce the gas dew point below about 40° F. (RH=12.8%) no matter how high a sweep fraction is used. Consequently the maximum dew point suppression for such a system would be about 60° F., where achieving anything close to that would require a very high sweep ratio and a very large amount of membrane. Many compressed gas systems, however, only need moderate dew point suppression, of 20° F. or so, where we have found that using the feed gas as the source of sweep provides acceptable performance.
By comparison a system as shown in
We conducted experiments to determine the difference in drying performance of a membrane dryer 16 when operated under steady state conditions (compressed gas source 11 continuously on, a constant system pressure, and a constant system demand at 23). Under these conditions, the check valve 13 is continuously open, and
For membrane dryers, the difference in RH between the two streams 27a and 27b in
Note that when the compressed gas source 11 shuts off in a system arranged according to
The membrane dryer 16 will thus stop consuming gas as sweep until the compressed gas source 11 restarts, and the pressure at compressed gas source 11 increases again. At this point flow will resume through the valve 24, creating a sweep flow through the membrane dryer 16 from the second inlet 19 to the second outlet 20 of the membrane dryer 16. Once the pressure at compressed gas source 11, which is in communication with the inlet 14 of one-way check valve 13, surpasses the pressure at the outlet 15 of one-way check valve 13, flow will once again resume through one-way check valve 13 and consequently through the primary compressed fluid stream 27a from the first inlet 17 to the first outlet 18 of the membrane dryer 16 supplying the system connected to an outlet 23 of the accumulator 21 and recharging the accumulator 21 with any excess. The primary compressed fluid stream 27a, which has had the water vapor reduced by the membrane dryer 16 exits at the first outlet 18 of membrane dryer 16, which is in fluid communication with an inlet 22 of the receiver/accumulator 21. The outlet 23 of receiver/accumulator 21 then supplies the dried primary compressed fluid stream 27a to the desired system.
With the present system the pressure on the high pressure side of the membrane dryer 16, from the first inlet 17 to the first outlet 18 of membrane dryer 16, is not allowed to decompress, so the membrane is not subjected to as much stress as systems in which the high pressure side is allowed to decompress. With the present system, the sweep flow from second inlet 19 to the second outlet 20 of membrane dryer 16 is shut off when the compressed gas source 11 shuts off. This minimizes gas waste. Finally, since the pressure supplied to valve 24 shuts off when the compressed gas source 11 shuts off, a simple flow control can be used for valve 24, reducing cost over a complicated flow control valve system.
In further regards to membrane dryer system 26, it is noted that one of the limitations of membrane dryer system 26 is that the use of a portion of the original feed gas or original fluid stream 27, which has not been dried by membrane dryer 16 as the sweep for membrane dryer 16 will not allow membrane dryer 16 to produce as dry of a product gas 27a as compared to the use of an equal volume of sweep gas 27b derived from the product gas 27a. That is, the sweep gas 27b derived initially from the compressed gas source 11 will not be as dry as if a portion of the product gas 27a is used, thus the driving force for water vapor to permeate across the membrane dryer 16 is reduced. As the gas on the high-pressure side of the membrane dryer 16 approaches the dew point of the sweep gas 27b on the low-pressure side, water permeation will cease and the membrane dryer 16 will not be able to dry the gas any further.
In view of the above, membrane dryer system 26 will not generally be useful for systems in which extremely dry gas is required. Two exceptions for this are firstly when the high-pressure gas is at very high pressure and secondly when a vacuum source is available to lower the pressure of the sweep gas. In both these cases, the sweep gas 27b can be quite dry, and the membrane system could reach very low dew points. However, since for many systems only a moderate suppression of the dew point is required, using the feed gas as sweep without any added assistance is adequate. This is especially true since in the configuration of the membrane dryer system 26 shown in
As such, for systems, where the compressed gas source cycles and only moderate dew point suppression is required, the configuration of the compressed fluid membrane dryer system 26 of
The present invention also includes a method of sweep control for a membrane dryer in a pressure cycling system comprising the steps of (1) supplying a fluid 27a at a first pressure from a source of compressed fluid 11 to an accumulator 21 located downstream of a check valve 13 and a membrane dryer 16 and (2) reducing the pressure of a sweep fluid 27b extracted from the source of compressed fluid located upstream of the check valve 13 before directing the sweep fluid 27b through the membrane dryer 16 to thereby remove moisture from the compressed fluid 27a in the membrane dryer 16 without creating backflow through the membrane dryer 16.
The above method can also include the step of (3) simultaneously supplying compressed fluid 27a and 27b to the accumulator 21 and the membrane dryer 16 and (4) directing a flow direction of the sweep fluid 27b through the membrane dryer 16 counter-current to a flow direction of the fluid 27a at a first pressure through the membrane dryer 16.
The present invention further includes a method of sweep control for membrane dryers in pressure cycling systems comprising the steps of (1) directing a primary compressed fluid stream 27a of an original compressed fluid stream 27 through a one-way check valve 13 into a first inlet 17 of a membrane dryer 16, through a body of the membrane dryer 16 and out through a first outlet 18 of the membrane dryer 16 to remove water vapor from the primary compressed fluid stream 27a; and (2) directing a sweep fluid stream 27b of the original compressed fluid stream 27 into a second inlet 19 of the membrane dryer 16, through the body of the membrane dryer 16 and out through a second outlet 20 of the membrane dryer 16 to remove water vapor from the body of the membrane dryer 16; and (3) decompressing the sweep fluid stream before the sweep fluid stream is directed through the membrane dryer 16.
The above method can also include (4) the step of directing a flow direction of the sweep fluid stream 27b through the membrane dryer 16 counter-current to a flow direction of the primary compressed fluid stream 27a through the membrane dryer 16; (5) the step of directing a flow direction of the sweep fluid stream 27b through the membrane dryer 16 co-current to a flow direction of the primary compressed fluid stream 27a through the membrane dryer 16; and (6) the step of directing a flow direction of the sweep fluid stream 27b through the membrane dryer 16 cross-current to a flow direction of the primary compressed fluid stream 27a through the membrane dryer 16.
This application claims priority to currently pending U.S. Provisional Application Ser. No. 60/811,332; filed on Jun. 6, 2006; titled METHOD OF SWEEP CONTROL FOR MEMBRANE DRYERS IN PRESSURE CYCLING SYSTEMS.
Number | Date | Country | |
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60811332 | Jun 2006 | US |