Energy Consumption: How it Relates to Performance

In Refrigerated Compressed Air Dryers

Timothy J. Fox, P.E.
New Product Development
Hankison, an SPX Brand

INTRODUCTION
Those in charge of specifying and purchasing equipment for industrial
compressed air systems have many decisions to make. The design of a proper
compressed air system does not end after determining the quantity of air required (i.e.,
the air compressor and receiver tank); the user must also pay particular attention to the
quality of the air that his or her process needs. Today’s optimal air systems demand less
moisture, less particulates, less oil aerosols, and less oil vapor than ever before. For most
users, a refrigerated-type compressed air dryer will satisfy their requirements for moisture
removal. With so many manufacturers offering “equivalent products”, each with
promises of delivered pressure dew point, pressure drop and consumed electrical power,
how does one make an intelligent selection? Whose glossy brochure does one believe?

This paper will address power consumption, and how it relates to a refrigerated
dryer’s ability to remove moisture. It will explain how a potential buyer can determine if
the stated performance is possible with the power consumption that is published in the
manufacturer’s literature. Energy guidelines for the user will be determined by
establishing theoretical minimums and practical expectations. To do this, we will first
describe how refrigerated dryers work, and how they are rated. From there, the subject of
heat loads will be discussed, determining the theoretical minimum quantities of heat that
must be removed from the air stream. Next, a range of pragmatic dryer designs and their
corresponding heat loads will be presented which is representative of what is available in
today’s marketplace. Finally, the refrigeration system capacities and the expected power
consumptions will be calculated.

BACKGROUND – HOW REFRIGERATED DRYERS WORK

Water vapor from the ambient enters the compressed air system at the air
compressor intake. In refrigerated dryer technology, this moisture is removed by
condensing the water vapor into a liquid by cooling the air stream to the desired pressure
dew point temperature in one, or more, heat exchangers. Well-designed refrigerated
dryers achieve outlet pressure dew points of +38°F (+3°C). This means that, as long as
the compressed air piping downstream of the dryer is not exposed to ambient
temperatures below +38°F (+3°C), the user will not experience liquid water in his
compressed air system.

Dryers that do not perform to their publicized claims will deliver pressure dew
points higher than expected by the air system designer. In some cases, this performance
discrepancy, as determined by the amount of water not removed by the dryer, can be
dramatic. Figure 1 presents the detrimental effects that a non-performing dryer can have
on a compressed air system. As shown, the difference between a +38°F(+3°C) pressure
dew point and a +60°F (+16°C) pressure dew point for a 1000 standard cubic foot per
minute system can easily be over 70 gallons per week! This additional moisture is
simply being passed downstream into the user’s air piping. For this reason, it is
imperative that the system designer receives the stated level of moisture removal
specified by the manufacturer.

Water a Non-Performing Air Dryer Fails to Remove

+60F pdp vs +38F pdp

150
Gallons per week per 1000 scfm

125

100

75

50

25

0
25 50 75 100 125 150 175

Inlet Pressure (psig)

Figure 1. The Downstream Effects of a Non-Performing Refrigerated Air Dryer

Refrigerated Dryer Designs

The most common design for a refrigerated dryer is shown in Figure 2. It utilizes
an air-to-air heat exchanger (pre-cooler / re-heater), an air-to-refrigerant heat exchanger
(evaporator), a moisture separator, and a refrigeration unit. These components are
labeled as items A, B, C, and D, respectively.

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 Figure 2. Typical Refrigerated Dryer

The Pre-cooler
The pre-cooler section of the air-to-air heat exchanger allows warm, saturated
incoming air to be partially cooled by the colder air exiting the moisture separator. This
pre-cooling reduces the amount of cooling required in the air-to-refrigerant heat
exchanger. The size of the refrigeration unit and, consequently, the electrical energy
consumption of the dryer are reduced.

The Evaporator
The air-to-refrigerant heat exchanger (evaporator) cools the pre-cooled air exiting
the air-to-air heat exchanger to the lowest temperature in the dryer. At this point in the
system, the maximum amount of water vapor has been condensed into a liquid. If proper
and efficient liquid removal is achieved in the separator, this lowest air temperature
should closely match the outlet pressure dew point temperature.

As explained earlier, the lower the outlet pressure dew point temperature, the
more moisture that is removed and discharged from the compressed air stream.
However, in order to avoid condensate from freezing in the dryer, the pressure dew point
temperature should not drop below +32°F (0°C). A second limitation to the amount of
cooling done in the evaporator is that the air can only be cooled to some temperature
above that of the refrigerant. The more heat exchange surface that is available, the closer
the evaporator outlet temperature will be to the refrigerant temperature. This temperature
difference between the air exiting the evaporator and the refrigerant entering the
evaporator is defined as the evaporator approach temperature. The lower the evaporator
approach temperature, the closer the exiting air temperature is to the refrigerant
temperature.

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The Separator
After the air exits the evaporator, it enters the separator where the condensed
liquid water is removed from the air stream. An efficient separator is imperative in
assuring the overall moisture removal performance of the dryer. Any liquid “carry-over”
experienced here will simply be vaporized in the re-heater portion of the air-to-air heat
exchanger, only to condense again in the user’s air piping. This often-underestimated step
is responsible for many elevated pressure dew points in dryers capable of achieving low
evaporator approach temperatures.

The Re-heater
After separation, the cool, liquid-free air then enters the secondary side of the air-
to-air heat exchanger. It is reheated to some temperature below the warmer incoming air.
The temperature difference between the air exiting the dryer and the air entering the dryer
is defined as the dryer approach temperature. The smaller the dryer approach
temperature, the closer the exiting air temperature is to the inlet air temperature. We will
see later how the dryer approach temperature influences the demand placed on the
evaporator and the refrigeration system.

PERFORMANCE STANDARDS
In order to compare one dryer design and manufacturer to another, the industry
has adopted rating standards for refrigerated compressed air dryers. In the United States,
the Compressed Air and Gas Institute (CAGI) uses their standard, ADF-100. This
document defines the dryer rating inlet condition as +100°F (+37.8°C) inlet temperature,
saturated with water vapor, 100 psig (6.9 barg) inlet pressure and +100°F (+37.8°C)
ambient temperature. The pressure drop across the unit must be less than 5 psi (0.34 bar).
The manufacturer then assigns an inlet compressed air flow rate (expressed in standard
cubic feet per minute, or scfm) and an outlet pressure dew point temperature for each
individual model. In the European Community, the adopted criterion is ISO-7183. This
standard sets the dryer inlet condition as +35°C (+95°F) inlet temperature, saturated with
water vapor, 7 barg (101.5 psig) inlet pressure and +25°C (+77°F) ambient temperature.
Again, the manufacturer must state the inlet flow rate (in normal cubic meters per hour,
or Nm3/hr) and the outlet pressure dew point. When comparing equipment, it is
imperative that the potential buyer first confirms that all equipment is being rated to the
same standard, and produces equivalent pressure dew points at the advertised
compressed air flow rates.

THE BUSINESS OF HEAT LOADS

As stated previously, the purpose of a refrigerated compressed air dryer is to
remove moisture from the air stream by cooling the compressed air down to the desired
pressure dew point temperature. When evaluating the energy required to accomplish this,
one must first assess the amount of heat that must be removed from the air. We will now
address this topic.

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 The incoming compressed gas is comprised of two main components: compressed
air (mainly, nitrogen and oxygen) and water vapor. Both of these components must be
cooled simultaneously. As the mixture is cooled, the water vapor component will change
phase, condensing from a vapor to a liquid. The air remains as a gas as it is cooled, and
there is no phase change. The heat removed from the water vapor as it changes phase is
known as the latent heat. The heat removed from the air, without a change in phase, is
termed sensible heat. It is the sum of these heats that determines the total quantity of
cooling required to reduce the compressed air from its incoming temperature to the stated
outlet pressure dew point temperature.

HeatTotal = HeatSensible + HeatLatent

Table 1 compares the latent heat, sensible heat and total heat loads for different
inlet temperatures, inlet pressures and outlet pressure dew points.

+38ºF +50ºF +70ºF

Pressure Dew Point Pressure Dew Point Pressure Dew Point
Inlet Inlet
Sensible Latent Total Sensible Latent Total Sensible Latent Total
Temperature Pressure
Heat Heat Heat Heat Heat Heat Heat Heat Heat
(BTU/hr per 100 scfm) (BTU/hr per 100 scfm) (BTU/hr per 100 scfm)
+80 ºF 4536 1359 5895 3240 1122 4362 1080 483 1563
+100 ºF 75 psig 6696 2906 9602 5400 2653 8053 3240 1986 5226
+120 ºF 8856 5567 14423 7560 5284 12844 5400 4570 9970
+80 ºF 4536 1061 5597 3240 876 4116 1080 377 1457
+100 ºF 100 psig 6696 2267 8963 5400 2069 7469 3240 1548 4788
+120 ºF 8856 4334 13190 7560 4114 11674 5400 3556 8956
+80 ºF 4536 870 5406 3240 719 3959 1080 309 1389
+100 ºF 125 psig 6696 1858 8554 5400 1696 7096 3240 1269 4509
+120 ºF 8856 3548 12404 7560 3368 10928 5400 2910 8310

Table 1. Heat Loads in a Refrigerated Dryer

From this table, one can see that the sensible heat is a function of inlet
temperature and outlet dew point temperature. Higher inlet temperatures will increase
the sensible heat load; higher outlet dew point temperatures will lower it. The latent heat
is a function of inlet temperature, inlet pressure and outlet dew point. Higher inlet
temperatures, lower inlet pressures and lower outlet dew points will all work to increase
the amount of latent heat. The values presented in this table substantiate the argument
that, for comparability, all equipment must be rated at equivalent inlet conditions and
outlet pressure dew points. For example, a dryer designed for the CAGI ADF-100 inlet
criteria (+100°F, 100 psig) and an outlet pressure dew point of 38°F is expected to handle
a total heat load of 8963 BTU/hr for every 100 scfm of inlet flow. A different dryer,
rated for the same flow rate, but delivering an outlet pressure dew point of 50°F, will
only handle 7469 BTU/hr for every 100 scfm, a reduction of 17%.

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THEORETICAL LIMITS
We have discussed how the use of an air-to-air heat exchanger reduces the
amount of refrigeration (and associated energy consumption) required to dry compressed
air. A more efficient air-to-air heat exchanger will result in a smaller refrigeration
system. How efficient can this air-to-air heat exchanger be? Is it possible that the
exchanger is so large that virtually no refrigeration is required? The answer is, of course,
no. In a heat exchanger of infinite size and length, the air exiting the separator can only
be reheated up to the point where it equals the temperature of the incoming air (a 0°F
dryer approach temperature). Since there is no liquid water present after the separator,
the heat added to the exiting air results only in an increase in the air temperature and no
change of phase (i.e., sensible heat). It turns out that the sensible heat added to reheat the
air stream from the separator temperature to the inlet temperature is equal to the sensible
heat removed from the air stream as it is cooled from the inlet temperature down to the
outlet pressure dew point temperature. From examining Table 1, subtracting the sensible
heat load from the total heat load results in a difference equivalent to the latent heat load.
Therefore, the latent heat load is the theoretical minimum heat load that must be removed
by the refrigeration system in a compressed air dryer while still providing the stated level
of moisture removal. Without the refrigeration capacity to remove the latent heat, the
dryer can simply not perform as advertised. Table 2 presents the theoretical minimum
heat load distribution for a +38°F (+3°C) refrigerated air dryer at different inlet
temperatures and pressures.

PRACTICAL EXPECTATIONS
While an air-to-air heat exchanger producing a dryer approach temperature of 0°F
(0°C) sounds interesting as a discussion point (i.e., the outlet temperature equals the inlet
temperature), it is not realistic from a design and manufacturing point. Even “extremely
large” heat exchangers are not practical in a competitively designed unit. Limitations
quickly become evident in the areas of packaging and the control of airside pressure drop.
Most notably, the manufacturing costs of such a device makes the extremely large heat
exchanger impractical. So what then, is the dryer approach temperature of a practical
air-to-air heat exchanger? An examination of today’s compressed air dryer designs
suggests that practical air-to-air heat exchangers have dryer approach temperatures in the
range of 10°F to 20°F (5°C to 11°C).

For a given dryer approach temperature and outlet pressure dew point, the heat
loads on the air-to-air and air-to-refrigerant heat exchanger can be calculated. As the
dryer approach temperature increases, a larger percentage of the total heat load is shifted
to the air-to-refrigerant heat exchanger. These results are also shown in Table 2.

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 0ºF
Dryer Approach 10ºF 15ºF 20ºF
(Theoretical Dryer Approach Dryer Approach Dryer Approach
Inlet Inlet Minimum)
Temperature Pressure Air to Air to Air to Air to Air to Air to Air to Air to
Air Refrig Total Air Refrig Total Air Refrig Total Air Refrig Total
(BTU/hr per 100 scfm) (BTU/hr per 100 scfm) (BTU/hr per 100 scfm) (BTU/hr per 100 scfm)
+80 ºF 4536 1359 5895 3456 2439 5895 2916 2979 5895 2376 3519 5895
+100 ºF 75 psig 6696 2906 9602 5616 3986 9602 5076 4526 9602 4536 5066 9602
+120 ºF 8856 5567 14423 7776 6647 14423 7236 7187 14423 6696 7727 14423
+80 ºF 4536 1061 5597 3456 2141 5597 2916 2681 5597 2376 3221 5597
+100 ºF 100 psig 6696 2267 8963 5616 3347 8963 5076 3887 8963 4536 4427 8963
+120 ºF 8856 4334 13190 7776 5414 13190 7236 5954 13190 6696 6494 13190
+80 ºF 4536 870 5406 3456 1950 5406 2916 2490 5406 2376 3030 5406
+100 ºF 125 psig 6696 1858 8554 5616 2938 8554 5076 3478 8554 4536 4018 8554
+120 ºF 8856 3548 12404 7776 4628 12404 7236 5168 12404 6696 5708 12404

Table 2. Heat Load Comparisons for a +38°F Pressure Dew Point

ENERGY CONSUMPTION
Once the heat demand on the evaporator has been established, the size of the
refrigeration unit can be determined, and the power consumption of the entire dryer can
be calculated. To do this, one must first recognize that there are three (3) main
components in a refrigerated dryer that consume electrical power:
• The refrigeration compressor,
• The refrigerant condenser cooling fan motors (assuming air-cooled
units),
• And the electrical control system.
For this analysis, we will assume that the units are air-cooled, and the electrical power
consumed by the control system (indicator lights, electronic control boards, electronic
condensate drain valves, etcetera) is negligible. We will now assess the power
consumption of the refrigeration compressor and the cooling air fan motors.

Refrigeration Compressor
The refrigeration industry has experienced a dramatic change over the past fifteen
years. New environmental laws have resulted in a large selection of new CFC-free
refrigerants. Traditional reciprocating compression technologies (piston-type machines)
are being replaced with more efficient rotary technologies (scroll and screw
compressors). This vast product mix has complicated the issue of energy efficiency in
refrigeration units.

The simplest way to assess the amount of electrical power required to produce a
desired amount of refrigeration is to use the Energy Efficiency Rating (EER) of the
compressor. This value is simply the quotient of the amount of refrigeration produced
(expressed in BTUs per hour, or Watts), divided by the amount of energy consumed by

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the refrigeration compressor (expressed in Watts). These figures, for a given compressor,
will vary as the compressor suction and discharge conditions change. Therefore, it is
important that compressors are competitively analyzed at equivalent inlet and outlet
conditions. When used in a refrigerated dryer, it is proper to use the suction and
discharge values that occur as the dryer is operating at its rated condition (either CAGI
ADF-100 or ISO-7183). For most dryers running at the CAGI ADF-100 rating point,
these approximate values are +35°F (+1.7°C) saturated suction temperature and a +130°F
(+54°C) saturated discharge temperature. For ISO-7183 conditions, the saturated suction
temperature is also +35°F (+1.7°C), but the saturated discharge temperature drops to
+105°F (+41°C) due to the lower ambient temperature. Typical refrigeration
compressors at the CAGI operating points will generate EERs in the range of 8.0 to 10.0
BTU/hr-Watt (2.3 to 2.9 Watts/Watt).

Table 3 shows the expected compressor power consumption for both the
theoretical (infinite air-to-air) and the practical cases (dryer approach temperature of
15°F) discussed earlier in Table 2. This table assumes a dryer inlet condition of +100°F,
saturated with water vapor, 100 psig and a +38°F outlet pressure dew point. An average
refrigeration compressor EER value of 9.0 BTU/hr-Watt (2.6 Watts/Watt) is used. The
user should be cautioned that, in most cases, dryer designers would not utilize
compressors with the exact refrigeration capacity necessary for the evaporator heat load.
Compressors are only available in incremental sizes, and the dryer designer will likely be
forced to use a compressor with more capacity than actually required. In these cases, the
air-to-air heat exchanger may be reduced in size so as to optimize the design and reduce
manufacturing costs and pressure drop.

Cooling Air Fan Motors

Evaluating the power consumed by the cooling fan motors is more difficult than
assessing the refrigeration compressor. These motors are smaller, less efficient electrical
components. Variations affecting air-cooled condenser designs include the fan blade
pitch, the condenser face area, static pressure drop and the desired cooling air velocities.
These design variables can result in fan motors of drastically different sizes and energy
requirements. Fortunately, the power consumed by the cooling air fan motors is much
less that the refrigeration compressor. A study of current manufacturers’ data provides
the necessary information to develop an industry average. A good approximation of the
fan power required for air-cooled refrigeration units is expressed by the equation:

P = (1.5 x 10-5) Q + 0.3,

Where,
P = fan power, in kW
Q = refrigeration capacity, in BTU/hr

The results are shown in Table 3.

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 0ºF 15ºF
Dryer Approach Dryer Approach
(Theoretical Minimum) (Expected Practical)
Inlet Flow Rate
Air to Compressor Estimated Air to Compressor Estimated
Total Power Total Power
Refrigerant Power @ Fan Refrigerant Power @ Fan
Consumption Consumption
Heat Load EER=9.0 Power Heat Load EER=9.0 Power
(scfm) (BTU/hr) (kW) (kW) (kW) (BTU/hr) (kW) (kW) (kW)
500 11,335 1.26 0.47 1.73 19,435 2.16 0.59 2.75
750 17,003 1.89 0.56 2.44 29,153 3.24 0.74 3.98
1000 22,670 2.52 0.64 3.16 38,870 4.32 0.88 5.20
1250 28,338 3.15 0.73 3.87 48,588 5.40 1.03 6.43
1500 34,005 3.78 0.81 4.59 58,305 6.48 1.17 7.65
2000 45,340 5.04 0.98 6.02 77,740 8.64 1.47 10.10
2500 56,675 6.30 1.15 7.45 97,175 10.80 1.76 12.55
3000 68,010 7.56 1.32 8.88 116,610 12.96 2.05 15.01

Table 3. Power Consumption in a Refrigerated Dryer

Total Power
The total power consumed by the refrigerated dryer is simply the sum of the
compressor power and the cooling fan power:

PowerTotal = PowerCompressor + PowerFan

The results are given in Table 3.

RESULTS
Table 3 displays the total theoretical minimum power consumption for air-cooled
refrigerated compressed air dryers at different compressed air flow rates. Also shown are
the expected practical values. This information can be used when evaluating air-cooled
equipment. (When evaluating water-cooled designs, the user should subtract the power
consumed by the fan motors.) For example, in a 1000 scfm refrigerated dryer, power
consumption less than 3.16 kW is simply not possible; whereas a value closer to the
expected number of 5.20 kW is acceptable.

In anther example, Manufacturer A advertises a 2000 scfm refrigerated air dryer

to deliver a +38°F (+3°C) outlet pressure dew point at the CAGI ADF-100 rating
conditions. This manufacturer also claims the unit will consume 7.0 kW of electrical
power. Referring to Table 3, this value is only slightly above the theoretical minimum
power consumption of 6.02 kW. It is highly unlikely that all of the performance claims
of this particular dryer manufacturer are going to be met. Either the unit will consume
more power than listed, while providing the promised level of moisture removal, or, the
unit will not remove the stated amount of moisture. In the worst scenario, neither the
power consumption nor the moisture removal performance will be met.

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CONCLUSIONS
Evaluating different brands of refrigerated compressed air dryers can become a
difficult and confusing task. The extensive array of performance criteria (flow rate, inlet
temperature, inlet pressure, outlet pressure dew point, pressure drop, etcetera) permits
manufacturers to publish data at conditions that benefits them favorably. An educated
potential buyer can wade through these issues by first confirming that all equipment
under consideration is rated at the same industry standard, the same inlet flow rate and
the same outlet pressure dew point.

When evaluating energy consumption, the information presented above provides

guidelines for determining the quantity of electrical power that must be consumed if the
unit is to perform to the advertised specifications. Any unit with advertised energy
consumption below the theoretical minimum values in Table 3 is suspect for actual
energy consumption and / or outlet pressure dew point performance. In these cases….
buyers beware- if it appears too good to be true, it most likely is! Advertised energy
consumption values should be centered on the practical expected values listed above. By
confirming that a reasonable amount of energy is being consumed, the user has additional
assurance that the expected quality of the compressed air system will be realized.

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