Compressed air

dryer

Compressed air dryers are special types

of filter systems that are specifically
designed to remove the water that is
inherent in compressed air. The
compression of air raises its temperature
and concentrates atmospheric
contaminants, primarily water vapor, as
resulting in air with elevated temperature
and 100% relative humidity. As the
compressed air cools down, water vapor
condenses into the tank(s), pipes, hoses
and tools connected downstream from the
compressor which may be damaging.
Therefore water vapor is removed from
compressed air to prevent condensation
from occurring and to prevent moisture
from interfering in sensitive industrial
processes.

Excessive liquid and condensing water in

the air stream can be extremely damaging
to equipment, tools and processes that
rely on compressed air. For example, water
can
 cause corrosion in the tank(s) and
piping made out of steel that may
compromise its integrity
wash out lubricating oils from
pneumatic tools
emulsify with the grease used in
cylinders
clump blasting media and fog painted
surfaces.

Therefore, it is desirable to remove

condensing moisture from the air stream
to prevent damage to equipment, air tools
and processes.
Next to these damage mechanisms, in
outdoor situations, water can accumulate
and then freeze, leading to failure of
components, e.g. braking systems.

There are various types of compressed air

dryers. These dryers generally fall into two
different categories: primary, which
includes coalescing, refrigerated, and
deliquescent; and secondary, which
includes desiccant, absorption, and
membrane. Their performance
characteristics are typically defined by
flow rate in standard cubic feet per minute
(SCFM) and dew point expressed as a
temperature.
Applications
Water contamination is an inherent
byproduct of compressing atmospheric air
since the atmospheric air contains a large
amount of water existing in the gaseous
form.[1][2] Because of this phenomenon,
compressed air systems usually benefit
from the addition of a compressed air
dryer located on the output of the air
compressor and/or at various locations
throughout the distribution system. In
most cases, the output of the compressor
is processed through a primary dryer or
system dryer. In cases where higher
quality air is required the output of the
primary dryer is further processed through
a secondary dryer or polishing dryer.

Characteristics
A regenerative desiccant dryer typically
delivers a dew point of between −40 °C
(−40 °F) and −73 °C (−100 °F)
A refrigerated dryer delivers a dew point
not lower than approximately 2 °C
(35 °F)
A deliquescent dryer delivers a dew
point suppression that fluctuates with
air temperature. Typically this
suppression is 11 °C (20 °F) below the
compressed air temperature.
Coalescing filters

Schematic representation of a two-stage coalescing filter set.

Coalescing filters aren’t actually filters,

rather they operate more as a
consolidation element. The idea behind
these devices is that the compressed air is
forced through gaps or porosity within an
otherwise solid element. These gaps
and/or porosity are microscopic and small
enough that water vapor wets to the
internal surfaces. The liquid water that
forms during the wetting process is forced
through the media and drips down into a
trap. The dry air travels up to and out of
the discharge port.

There are two basic types of coalescing

elements. The first type utilizes a cast
material that is dominated with an internal
microscopic lattice. The air is forced to
flow through the lattice which, in turn,
allows the water vapor to wet to the
internal surfaces. The second type is
generally referred to as a stacked plate
element. In this case, fine discs are
stacked with microscopic gaps between
them. The air is forced to flow through the
gaps which, in turn, allows the water vapor
to wet to the internal surfaces.

In principle, a coalescing filter is an ideal

way to separate water from the
compressed air stream. Practically
speaking, this is not the case. Coalescing
elements are extremely sensitive to oil and
particulate contamination and therefore
would be better placed as a second stage
dryer. However, the dew point performance
of a coalescing filter places it in the
primary category of compressed air
dryers. In order to use coalescing filters as
primary dryers, they are typically set-up in
pairs. The first filter has an element with
larger gaps that are designed to remove oil
from the stream. The second filter uses a
finer element that is intended to remove
water vapor. Because of the sensitivity of
the elements, coalescing filters are not
particularly common. One area where
these filters have found acceptance is with
dental compressors. The way that dental
compressors are designed and used
makes a two-stage coalescing filter an
almost ideal solution for water
contamination in these systems.
Refrigerated dryers

Basic schematic of a Freon-based refrigerated compressed air dryer

Illustration of a typical commercial Freon-based refrigerated compressed air dryer

Rotary-screw air compressor equipped with a Freon-based refrigerated compressed air dryer

Sectional illustration showing the internals of a JT type compressed air dryer.

Two-stage air compressor equipped with a JT type refrigerated compressed air dryer.

Refrigerated dryers are the most common

type of compressed air dryer. They remove
water from the air stream by cooling the
air to approximately 3 °C (38 °F) and
effectively condensing out the moisture in
a controlled environment. 3 °C (38 °F) is
the realistic lower limit for a refrigerated
dryer because a lower temperature runs
the risk of freezing the separated water.
They are typically specified as primary
dryers and generally produce air quality
that is appropriate for approximately 95%
of all compressed air applications.

Refrigerated dryers employ two heat

exchangers, one for air-to-air and one for
air-to-refrigeration. However, there is also a
single TRISAB heat exchanger that
combines both functions. The
compressors used in this type of dryer are
usually of the hermetic type and the most
common gas used is R-134a and R-410a
for smaller air dryers up to 100 cfm. Older
and larger dryers still use R-22 and R-404a
refrigerants. The goal of having two heat
exchangers is that the cold outgoing air
cools down the hot incoming air and
reduces the size of compressor required.
At the same time the increase in the
temperature of outgoing air prevents re-
condensation.

Some manufacturers produce "cycling

dryers". These store a cold mass that
cools the air when the compressor is OFF.
When the refrigeration compressor runs,
the large mass takes much longer to cool,
so the compressor runs longer, and stays
OFF longer. These units operate at lower
dew points, typically in the 1.5 °C - 4.5 °C
(35 °F – 40 °F) range. When selected with
the optional "cold coalescing filter", these
units can deliver compressed air with
lower dew points. Non-cycling dryers use a
hot gas by pass valve to prevent the dryer
from icing up.

Some manufacturers produce "cold

coalescing filters" that are positioned
inside of the air dryer at the point of the
lowest air temperature (the point at which
maximum condensation has
occurred).[3][4]

Refrigerated dryers are generally

manufactured in one of two different ways,
Freon based units and Joule-Thomson
based units.

Freon-based refrigerated
compressed-air dryers

These dryers derive their cooling from a

closed cycle refrigeration system based
around one of three commercial
refrigerants, R-22, R-134a or R410a. The
refrigeration system these dryers use is
similar to home and commercial air
conditioning systems. The schematic
shown to the right illustrates a typical
Freon-based refrigerated compressed air
dryer.
Freon-based refrigerated compressed air
dryers generally consist of a heat
exchanger that is similar to a water cooled
after cooler. Instead of using water as the
coolant, liquid CFC fills the shell of the
heat exchanger. The liquid CFC is
maintained at a pressure that allows it to
boil at 3 °C (38 °F). After the CFC boils, the
vapor is drawn through the suction line
into a compressor, which compresses the
CFC to a high pressure and high
temperature. The high
pressure/temperature CFC is cooled in the
condenser and relaxes into its liquid state.
The liquid is reintroduced into the heat
exchanger via the metering device and a
closed refrigeration cycle is formed. When
the compressed air passes through the
heat exchanger, it is cooled to the
temperature of the boiling CFC. As the
compressed air is cooled, it loses its
ability to retain moisture and the water
vapor condenses onto the inside of the
exchanger tube.

Variations on this basic design include

units equipped with reheating exchangers,
which are intended to improve efficiency.
In these cases, the cooled compressed air
is reheated by the incoming air.
Oil and water vapors in compressed air
must have cooled to their dew point
(become aerosols) before the coalescing
filter can operate effectively.[5]
Refrigerated compressed air dryers
typically have a Remaining Oil Content of
6 mg/m3.[6] Refrigerated compressed air
dryers with internal cold coalescing filters
are rated to leave the remaining oil content
as low as 0.008 mg/m3, which is far less
than coalescing filters that are
downstream of air dryers, because the
cooled compressed air is reheated by the
incoming air. Larger refrigerant dryers
have air-to-air heat exchanger between
warm incoming air and chilled outgoing
air. Cooled oil and water fogs coalesce
much better in a coalescing filter at the
cold temperatures than one in the warmer
oil and water vapors located downstream
of the air dryer air-to-air heat exchanger.[7]

Compressed Air Coalescing Filter

Performance

Temperature, Solid Particles of this Size and Larger

Type LOCATION PPM mg/m3
typical (in microns) are Captured

Cold Inside 0.006 <0.01[8] 36 to 42 deg F 0.01

General
After 0.4 0.5[9] 75 to 100 deg F 1.0
Purpose

Standard After 3.6 4.0[10] 75 to 100 deg F 3.0

Coalescing Filters collect liquids and

aerosols, not vapors, see the Mechanical
Coalescers section at Coalescer. In the
table above, the LOCATION means where
the Coalescing Filter is relative to
Refrigerated Air Dryer. 1 mg/m3 is a
weight of oil in a volume of air and is
approximately equal to 0.83 ppm by
weight.[11]

High temperature dryers are equipped with

an additional pre-cooler that removes
excess heat via a forced air system. These
units are designed to allow excessively hot
compressed air to be effectively dried.
Compressed air temperatures in excess of
38 °C (100 °F) are very common in
Southern climates, mining operations,
steel mills, shipboard, etc. In areas and
applications that demand operations in
elevated ambient temperatures, high
temperature dryers are a necessity.

Cycling dryers (also known as thermal

mass dryers) utilize a thermal mass,
usually a tank of water, to store the energy
produced by the refrigeration system. The
temperature of the water controls the
refrigeration system through a thermostat.
The compressed air passes through the
thermal mass via a water cooled heat
exchanger. The value of this type of
configuration is that they normally produce
more consistent cooling results.
Joule–Thompson (JT) based
refrigerated compressed air dryers

JT type dryers are units that utilize the

compressed air stream as their
refrigeration element. High pressure
compressed air (150~175 PSI) is fed into
a pressure reducing valve on top of the
dryer. The output of this valve (90–120
PSI) is directed into an expansion chamber
which is surrounded with porous walls. As
the air expands to a lower pressure, it
becomes cold (based on the Joule-
Thomson Effect) and its ability to retain
moisture is reduced. The moisture is
released from the air in the form of fog.
The fog laden air then passes through the
porous walls of the chamber. The micro-
droplets of water that make up the fog wet
to the porous material and collect until
they form droplets that can be affected by
gravity. The water then drops into a trap
and the dried air travels up to and out of
the discharge port. The drawback of the
JT Dryer is that it can only be used with
two-stage compressors. This is because a
two-stage compressor derives its
efficiency by pumping to a high pressure
(150–175 PSI.) This pressure is
inappropriate for the shop floor and must
be dropped to (90–120 PSI.) The JT Dryer
takes advantage of this pressure drop to
remove moisture from the compressed air
stream through the inherent refrigeration
based on the Joule-Thompson effect of
the expanding air. Leveraging this pressure
drop allows a JT dryer to produce the
same relative dew points that Freon-based
dryers produce.

Deliquescent dryer
Deliquescent dryers typically consist of a
pressure vessel filled with a hygroscopic
medium that has a high affinity for water
vapor. Practically speaking, these dryers
are typically a large pressure vessel that is
filled with salt crystals.
Schematic representation of a deliquescent compressed air dryer.

When water vapor comes in contact with

the salt, it attaches and dissolves the
media, or deliquesces. As liquid water
builds on the salt crystals, brine is formed,
which drains down and collects in the
bottom of the vessel. Periodically, the
brine must be drained and similarly, the
media must be refilled. Typically,
deliquescent dryers will produce a dew
point suppression of 10 °C to 14 °C (18 °F
to 25 °F).

On the plus side, these dryers are very

simple, have no moving parts and do not
require electrical power. However, they do
not perform well with high temperature air
streams and/or in high ambient
temperatures. They are disproportionately
large units which are filled with a corrosive
substance. Their size and corrosive nature
can present problems with any system
that uses them. Because of this, these
dryers are typically used only in specialty
applications. Common applications often
involve remote, hazardous, or mobile work
sites. Deliquescent dryers are used for
removing water vapor from compressed
air, natural gas, and waste gases such as
landfill gas and digester gas.

The performance of a deliquescent dryer,

as measured by outlet dew point, is highly
dependent on the temperature of the air or
gas being processed, with cooler
temperatures resulting in better
performance
Desiccant dryers

Schematic representation of a twin tower desiccant compressed air dryer.

Desiccant dryers, sometimes referred to

as absorption dryers, operate by absorbing
water vapor into a porous media with a
high affinity for water.[12][13] These types of
dryers are also referred to as absorption
systems or getters. Because these dryers
get and hold the water, they are minimally
effective as a first stage dryer. If a
desiccant is used in this role, the media
quickly becomes saturated and the
effectiveness of the dryer is negated.
Desiccant dryers are best applied in a
second stage or polishing role. They are
usually used down-stream from a
refrigerated dryer or some other primary
dryer. When applied as a second stage
dryer, they can easily and reliably produce
dew points in the sub zero range.

Desiccant dryers are typically supplied in

two patterns, “Single Canister” and “Twin
Tower” units. Single canister units have
the outward appearance of a filter
housing. However, they are filled with a
granular media that must be periodically
replaced. The media can be regenerated
by baking it at a high temperature in
accordance with the manufacturers’
recommendations. Single canister
desiccant dryers are typically installed in
point-of-use applications. When applied as
a second stage dryer, they can easily and
reliably produce dew points in the sub-zero
range.

A variation on the single canister

desiccant dryer is the Toilet Paper filter.
These types of filters provide the same
basic function as a desiccant dryer except
they use an ordinary roll of toilet paper as
their absorption media. When the toilet
paper becomes saturated, it is removed
and replaced with a fresh roll. The
popularity of these filters is primarily
based around their low cost, convenience
and effectiveness. Surprisingly enough,
these types of filters are very effective in
point-of-use roles.

Twin Tower, or regenerative desiccant

dryers, have two vertical tanks filled with
media. The compressed air is passed
through a pressure vessel with two
"towers" filled with a media such as
activated alumina, silica gel, molecular
sieve or other desiccant material. This
desiccant material attracts the water from
the compressed air via adsorption. As the
water clings to the desiccant, the
desiccant "bed" becomes saturated. When
the media in the first tank becomes
saturated, the air stream is automatically
redirected through the second tank. The
first tank is then heated while a portion of
the dried air, referred to as the purge air, is
back flowed through the tank and vented
to atmosphere. This process dries, or
regenerates, the media in the first tank and
makes it ready for the next redirect. One of
the most significant drawbacks of twin
tower desiccant dryers is their use of the
purge air. Typically, a twin tower desiccant
dryer uses some 15 to 20% of its capacity
to regenerate the opposite tank, making
these dryers inefficient and costly to
operate.

The task of the desiccant is to bring the

pressure dew point of the compressed air
to a level in which the water will no longer
condense, or to remove as much water
from the compressed air as possible. A
standard dew point that is expected by a
regenerative dryer is −40 °C (−40 °F); this
means that when the air leaves the dryer
there is as much water in the air as if the
air had been "cooled" to −40 °C (−40 °F).
Required dew point is dependent on
application and −70 °C (-94 °F) is required
in some applications. Many newer dryers
come equipped with a dew dependent
switching (DDS) which allows for the dryer
to detect dew point and shorten or
lengthen the drying cycle to fulfill the
required dew point. Oftentimes this will
save significant amounts of energy which
is one of the largest factors when
determining the proper compressed air
system.

The regeneration of the desiccant vessel

can be during three different methods:
 Heatless "pressure-swing" drying, which
uses part of the dry compressed air
coming from the other vessel to dry the
desiccant in the vessel being
regenerated at lower pressure. 17-20%
purge rate
Heated dryer, which uses a hot air
blower, so there is no loss of
compressed air. >7% Purge Rate.
Heat of compression, which can only be
used with an oil-free compressor.

Membrane dryer
Schematic representation of a membrane type compressed air dryer.

Membrane dryer refers to a

dehumidification membrane that removes
water vapor from compressed air.
Membrane dryers operate on the principle
of migration. The compressed air to be
dried is passed over a membrane that has
a high affinity for water vapor. The water
vapor builds on the membrane and
migrates through to the opposite or low
pressure, side. A dry cover gas is flowed
across the low pressure side and absorbs
the water on the membrane. After
absorbing the water, the cover gas is
discharged to the atmosphere. The cover
gas is generally taken from the output of
the dryer. The membrane is typically a
series of small tubes collected in a bundle
within an outer housing.

Some dryers are non-porous, which means

they only permeate water vapor. Non-
porous membranes' drying power is only a
function of flow rate, pressure. The sweep
flow is strictly controlled by an orifice and
is not a function of temperature. Porous
membranes are modified nitrogen
membranes and pass air as well, usually
changing the composition of the
compressed air by reducing the oxygen
content. The only maintenance required is
changing the prefilter cartridge twice a
year. The performance of porous
membranes are dependent on temperature
as well as operating pressure and flow.

Membrane air dryers depress the incoming

dew point. Most dryers have a challenge
air dew point and pressure specification.
So if the inlet dew point is lower than the
specified challenge air then the outlet dew
point is even lower than specified. For
example, a dryer could be rated at a -40 °C
(−40 °F) dew point with a challenge of
21 °C (70 °F) dew point and 100 psig. If the
incoming air has an inlet dew point of only
0 °C (32 °F), the outlet dew point will be
somewhat less. Pressure also plays a role.
If the pressure is higher than the rated
specification then the outlet dew point will
be lowered. This lowering of the outlet
dew point is due to the longer residence
time that the air has inside the membrane.
Using the spec above, an operating
pressure of 120 psig will yield a lower
outlet dew point than specified. The extent
of the improvement is dependent on the
nature of the membrane and could vary
among manufacturers. Several
manufacturers have commercially
available membrane driers.[14]
Membrane air dryers are designed to
operate continuously, 24 hours per day, 7
days per week. Membrane air dryers are
quiet, reliable and require no electricity to
operate. If set up and operated properly,
membrane dryers can produce extremely
low dew points. For this reason they are
very common in laboratories, medical
facilities and specialty manufacturing
environments where limited amounts of
high quality compressed air is required.
They are usually set up as a point-of-use
dryer and provide the best service when
used in a second or third stage role. The
delicate nature of the equipment and how
it is used makes them generally unsuitable
for more mainstream or industrial
applications. Membrane air dryers are
used in pneumatic components, spray
painting, laser plenum purge, air bearings,
air spindles, medical equipment, air guns
and pneumatic brakes for vehicles and
trains.

References
1. Sandle, T. (2018). Biocontamination Control
for Pharmaceuticals and Healthcare (http
s://books.google.com/books?id=vOR8DwA
AQBAJ&pg=PA187) . Elsevier Science.
p. 187. ISBN 978-0-12-814912-6. Retrieved
2021-11-11.
2. Roesti, D.; Goverde, M. (2019).
Pharmaceutical Microbiological Quality
Assurance and Control: Practical Guide for
Non-Sterile Manufacturing (https://books.g
oogle.com/books?id=ffa9DwAAQBAJ&pg=
PA198) . Wiley. p. 198. ISBN 978-1-119-
35611-0. Retrieved 2021-11-11.

3. "SPX Hankinson | Page 3 of 12, Intergal 3

micron cold coalsecing filter, optional cold
coalescing oil removal filter" (https://www.s
pxflow.com/en/assets/pdf/BC-100-2013_w
eb_tcm11-8920.pdf) (PDF). Retrieved
2018-10-03.

4. "Newgate Technologies | Air Dryer with Cold

Coalescing Filter" (http://www.newgatetech
nologies.com/brochurepdfs/RefBrch.pdf)
(PDF). Retrieved 2018-10-03.
5. http://filtrationtechnologies.com/gas-
coalescing-filter-failure/ Gas Coalescing
Filter Failure | Filtration Technologies

6. KONAN | Air Cleaning System (https://www.

konan-em.com/sanki_data/products/8505
e.pdf)

7. SPX | HES Series (https://www.spxflow.co

m/cn/assets/pdf/HES_Series_3750-12500_
web.pdf)

8. SPX HES_Series Page 5, Column 2,

Paragraph 3, last sentence (https://www.sp
xflow.com/assets/pdf/hankison-hprp-serie
s-web.pdf)

9. BCAS | The Filtration and Drying of

Compressed Air, Best Practices | Page 19
(26 of 67) (https://www.bcas.org.uk/media/
Download.aspx?MediaId=923)
10. SPX | HES_Series Page 5, Column 2,
Paragraph 3 (https://www.spxflow.com/cn/
assets/pdf/HES_Series_3750-12500_web.p
df)

11. CAGI | Compressed Air Treatment (https://

www.cagi.org/pdfs/cagi_electhb_ch3.pdf)

12. US 5522150 (https://worldwide.espacenet.

com/textdoc?DB=EPODOC&IDX=US552215
0) , Schultz, Paul A., "Modular air dryer for
compressed air with desiccant", published
1996-06-04, assigned to Allied Signal Truck
Brake Systems
13. US 5286283 (https://worldwide.espacenet.
com/textdoc?DB=EPODOC&IDX=US528628
3) , Goodell, David J., "Air dryer for
compressed air system having a
serviceable oil filter", published 1994-02-15,
assigned to AlliedSignal Inc.

14. "Dehumidification | FOR BLUE sunsep |

Products | AGC Engineering" (https://www.a
gec.co.jp/eng/product/sunsep/unwater.ht
ml) .

Books

Elliott, Brian S. Compressed Air

Operations Manual, McGraw-Hill Books,
2006 ISBN 0-07-147526-5
 Barber, Antony, Pneumatic Handbook-
Eighth Edition, Elsevier Science, 1998
ISBN 978-1856172493
Compressed Air Handbook-Sixth Edition,
Compressed Air and Gas Institute, 2003
ISBN 0974040002
Improving Compressed System
Performance-Third Edition, U.S.
Department of Energy, 2017
Best Practices for Compressed Air
Systems Manual-Second Edition,
Compressed Air Challenge, 2007
ISBN 978-0615386829

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