Benefits & Technology for Decentralizing a -40 F Dew Point

Transcription

1 Benefits & Technology for Decentralizing a -40 F Dew Point Sponsored by Hank van Ormer, Air Power USA Featured Speaker For your free subscription, please visit

2 Handouts

3 All rights are reserved. The contents of this publication may not be reproduced in whole or in part without consent of Smith Onandia Communications LLC. Smith Onandia Communications LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. All materials presented are educational. Each system is unique and must be evaluated on its own merits.

4 Benefits & Technology for Decentralizing a -40 F Dew Point Introduction by Rod Smith, Publisher Compressed Air Best Practices Magazine For your free subscription, please visit

5 About the Speaker Founder of Air Power USA Over 50 years of experience in the compressed air and gas industry Sponsored by Hank van Ormer Air Power USA For your free subscription, please visit

6 Does Decentralizing Compressed Air Dryers Make Sense? Perhaps More Often Than You Think! Air Power USA April 20, 2017

7 Introduction The main focus of this webinar is to explain accurately the benefits of delivering a -40 F / -40 C pressure dewpoint ONLY where required and with optimal energy efficiency NOT ALWAYS OVERDRYING ALL THE PLANT COMPRESSED AIR! LOWER PRESSURE DEWPOINT COSTS MORE THERE ARE MANY WAYS TO REACH THE GOAL!

8 What is a Centralized -40 F Pressure Dewpoint System? A very common application in practice today is drying all the compressed air going to production to -40 F / -40 C then delivering the dry air to all the production processes regardless of actual need. 1.Do you know how much this common application costs in operating energy annually? 2.Lost pressure annually? 3.Lost compressed air annually (purge air)? LETS FIND OUT!

9 Establishing the Energy Cost Establishing the energy cost of producing compressed air used for purge and pressure produced but LOST. Purge Compressed Air: 1 cfm = $100 year in power cost (100 psig cfm/hp - $.06 kwh - 8,000 hours year) Pressure Loss: 1 psig = ½% or.005 power 1 psig of 100-hp compressor = $179 year in power cost ($.06 kwh 8,000 hours year -.9 ME) $179 year 400 scfm = $0.45 psig / scfm / year All calculations are based on 8,000 hours year, and $.06 kwh

10 Refrigerated Dryers: +40 F / 4.4 C Pressure Dewpoint Refrigerated Dryers deliver a nominal +40 F / 4.4 C pressure dewpoint at 100 psig with 100 F saturated inlet air temperature Removes about 86% of the moisture from 100 F inlet saturated air.

11 Refrigerated Dryers: Annual Energy Operating Costs per SCFM Annual Energy Cost Non-cycling Refrigerated Dryer 250 cfm 1.5-hp $814 year 500 cfm 3-hp $1,747 year 1,000 cfm 5-hp $2,750 year 2,000 cfm 10-hp $4,875 year

12 Desiccant Dryers Operating Costs Higher initial cost and maintenance costs Heatless = 15-20% purge air Heated purge = 7-8% / kw heater Blower purge = 0-3% purge Total estimated average annual pressure loss (dryer and filters) = 13 psid year $5.85 scfm year

13 Another Drying Technology: Sometimes Ignored - Membrane Dryers Selective membrane compressed air dryer can be a very effective pointof-use when properly applied. Water vapor goes through membrane and is swept away by dry air sweep air always proportion to actual flow lower or no flow lower or no lost sweep air. Centralized System: 50 scfm flow / 100 F / 100 psig PDP SaturatedAir Picture courtesy of Beko Technologies SCFM Flow IN SCFM Flow OUT Sweep Air Lost Delivered PDP 59.8 scfm scfm 5.98 scfm 10% +65 F Pressure loss (8 psid x.45 psig x 60 scfm) (Dryer negligible pressure loss) Estimated cost of sweep air = $216 year Decentralized System: Taking the same air from a refrigerated dryer delivering a +40 F PDP Saturatedair SCFM Flow IN SCFM Flow OUT Sweep Air Lost Delivered PDP 59.8 scfm scfm 5.98 scfm 10% +22 F Significant improvement performance at the same operating costs lower PDP improves the transfer of the water vapor though the membrane while reducing the moisture load to the dryer.

14 What is the True Cost of Over Drying the Air? If you have a centralized -40 F pressure dewpoint compressed air system - ask yourself these questions: 1. Do you know the percentage of air being used that REQUIRES a -40 F? Is it 10%, 25%, 50% etc.? 2. Have you ever performed an audit identifying this percentage requirement? 3. Do you know what to do to get the answer?

15 How is the Air System Effected When You Decentralize? What tools do you have to evaluate? Potential procedures Identify -40 F / -40 C processes as a percent of the total air supply Measure flow Talk to the operator Talk to the machine manufacturer Experiment Consider the economics of removing 86% of moisture with refrigerated dryers at less cost per scfm ($8.83 scfm/year vs. average desiccant cost of $20.71 scfm/year) What are the economics of downstream / decentralized, point-of-use dryers with +40 F pressure dewpoint inlet air instead of 100 F pressure dewpoint inlet air Lets look at typical scenarios at 10%, 25%, and 50% required air at - 40 F / -40 C.

16 Desiccant Dryers: Annual Energy Operating Costs per SCFM Desiccant Dryer energy profile with a fixed cycle dewpoint demand control (100 F / 100 psig saturated inlet air). Dryer Type Heatless External Heat Blower Purge Rated Flow (scfm) 2,000 2,000 2,000 Heater Power (kw) FL N/A 40 kw 72 kw Blower Power ( FL kw) N/A N/A 8 kw Amount of Purge Air (scfm) Heater kw Percentage Average (FL kw x.75) N/A 30 kw 54 kw Utilization (%) Dewpoint Control N/A N/A N/A Purge and Prospective Energy Costs Average Annual Energy Cost ($/yr.) - $14,400 $29,760 (62 kw) Average Annual Purge Air ($100 per scfm/yr.) $30,000 $15,000 $0 Total Average Annual Cost ($/yr.) $30,000 $29,400 $29,760 Average Annual Cost per ($ scfm/yr.) $15.00 $14.70 $14.88 Estimated Annual Pressure Loss (dryers and filters) $ scfm/yr. 13 psid / $ psid / $ psid / $5.85 Total Annual Operating Cost ($ scfm/yr.) $20.85 $20.55 $20.73

17 Total Annual Average Operating Cost Summary TOTAL ANNUAL AVERAGE OPERATING COST SUMMARY Purge Air Cost (Desiccant / Membrane Dryers) Pressure Loss Cost (All dryers) Refrigerated Dryer Heatless Desiccant Dryer External Heat Dryer Blower Purge Dryer $100 scfm / year $.45 scfm / year $2.98 scfm / year $15.00 scfm / year $11.82 scfm / year $14.88 scfm / year Annual Operating Cost of Centralized Drying Systems at 500, 1,000 and 2,000 scfm. Drying to -40 F / -40 C with NO purge control. Dryer and 500 SCFM 1,000 SCFM 2,000 SCFM Measurement Heatless Dryer Purge Air Pressure Loss $7,500 year $2,929 year $15,000 year $5,858 year $30,000 year $11,716 year Total $10,429 year $20,858 year $41,716 year External Heat Dryer Purge Air & Heater Pressure Loss $5,910 year $2,929 year $11,820 year $5,858 year $23,640 year $11,716 year Total $8,839 year $17,678 year $35,356 year Blower Purge Dryer Purge Air & Blower Pressure Loss $7,440 year $2,929 year $14,880 year $5,858 year $29,760 year $11,716 year Total $10,369 year $20,738 year $41,479 year

18 500 SCFM System: 10% at -40 F / -40 C Demand Membrane Dryers Centralized System - Desiccant Dryer System Cost: (-40 F PDP / $20.71 cfm x 500 scfm) $10,355 year Decentralized System - Refrigerated Dryer (+40 F / 4.4 C) Operating with (2) Point-of-use Membrane Dryers at (-40 F / -40 C) Refrigerated dryer operating cost : (+40 F / 4.4 C) (500 cfm x $8.83 per cfm) Membrane dryer operating cost: (sweep air loss): (10 cfm x $100 per cfm = $1,000 x 2 dryers) System pressure loss: (filters only) (dryer negligible) (8 psid x 25 cfm x $.45 x 2 dryers) Total system operating cost: (refrigerated dryer and (2) point-of-use dryers) $4,415 year $2,000 year $ 180 year $6,595 year Total decentralized system savings: $3,760 year or 36%

19 500 SCFM System: 25% at -40 F / -40 C Demand - Desiccant Dryer Centralized System Desiccant Dryer System Cost (no purge control) ($20.71 scfm x 500 scfm) $10,355 year Decentralized System Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 25% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (500 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 125 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings: (All ($scfm/yr.) include operating cost and pressure loss) $4,415 year $2,588 year $7,003 year $3,351 year or 32%

20 500 SCFM System: 50% and 75% at -40 F / -40 C Demand - Desiccant Dryer Centralized System Desiccant Dryer System Cost (no purge control) ($20.71 scfm x 500 scfm) $10,355 year Decentralized System Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 50% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (500 scfm x $8.83 per scfm) $4,415 year Desiccant dryer operating cost: ($20.71 scfm x 250 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings at 50%: (All ($scfm/yr.) include operating cost and pressure loss) $5,177 year $9,592 year $762 year or 7% Decentralized System Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 75% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (500 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 375 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings at 75%: (All ($scfm/yr.) include operating cost and pressure loss) $4,415 year $7,766 year $12,181 year N/A Use of a modern, effective dewpoint demand control particularly in this scenario will shift the decentralized system more positively.

21 1,000 SCFM System: 25% at -40 F / -40 C Demand - Desiccant Dryer Centralized System: Desiccant Dryer System Cost including filter (no purge air) (-40 F / -40 C PDP / $20.71 scfm x 1,000 scfm) $20,710 year Decentralized System: Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 25% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (1,000 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 250 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings at 25%: (All ($scfm/yr.) include operating cost and pressure loss) $8,830 year $5,177 year $14,007 year $6,703 year or 32%

22 1,000 SCFM System: 50% and 75% Demand at -40 F / -40 C - Desiccant Dryer Centralized System: Desiccant Dryer System Cost including filter (no purge air) (-40 F / -40 C PDP / $20.71 scfm x 1,000 scfm) $20,700 year Decentralized System: Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 50% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (1,000 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 500scfm) Total system operating cost: (refrigerated dryer and (1) desiccantdryer Total decentralized system savings at 50%: (All ($scfm/yr.) include operating cost and pressureloss) $8,830 year $10,355 year $19,185 year $1,515 year or 7% Decentralized System: Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 75% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (1,000 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 750scfm) Total system operating cost: (refrigerated dryer and (1) desiccantdryer Total decentralized system savings at 75%: (All ($scfm/yr.) include operating cost and pressureloss) $8,830 year $15,532 year $24,362 year N/A Use of a modern, effective dewpoint demand control particularly in this scenario will shift the decentralized system more positively.

23 2,000 SCFM System: 25% Demand at 40 F /-40 C - Desiccant Dryers - Centralized System: Desiccant Dryer System Cost including filter (no purge air) (-40 F / -40 C PDP / $20.71 scfm x 2,000 scfm) $41,420 year Decentralized System: Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 25% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (2,000 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 500 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings at 25%: (All ($scfm/yr.) include operating cost and pressure loss) $17,660 year $10,355 year $28,015 year $13,405 year or 32% Use of a modern, effective dewpoint demand control particularly in this scenario will shift the decentralized system more positively.

24 2,000 SCFM System: 50% and 75% -40 F / -40 C Demand - Desiccant Dryers Centralized System: Desiccant Dryer System Cost including filter (no purge air) (-40 F / -40 C PDP / $20.71 scfm x 2,000 scfm) $41,420 year Decentralized System: Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 50% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (2,000 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 1,000 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings at 50%: (All ($scfm/yr.) include operating cost and pressure loss) $17,660 year $20,710 year $38,370 year $3,050 year or 7% Decentralized System: Refrigerated Dryer (+40 F / 4.4 C) Operating with (1) Point-of-use Desiccant Dryer at 75% (-40 F / -40 C) Refrigerated dryer operating cost: (+40 F / 4.4 C) (2,000 scfm x $8.83 per scfm) Desiccant dryer operating cost: ($20.71 scfm x 1,500 scfm) Total system operating cost: (refrigerated dryer and (1) desiccant dryer Total decentralized system savings at 75%: (All ($scfm/yr.) include operating cost and pressure loss) $17,660 year $31,065 year $48,725 year N/A Use of a modern, effective dewpoint demand control particularly in this scenario will shift the decentralized system more positively.

25 Summary: Important Take Aways Know what your -40 F / -40 C PDP demand requirement is 10-25% at -40 F PDP demand for a decentralized system strong consideration 50-75% at -40 F PDP demand for a decentralized system should still be evaluated with the following considerations: The point-of-use dryers will see a 20% or lower moisture load (80+% reduction) Under sizing basic desiccant dryers that much will cause pressure loss problems and should be avoided Your evaluation should ALWAYS include a modern, effective dewpoint demand controller for these point-of-use desiccant dryers An effective pressure dewpoint controller will reduce desiccant dryer operating costs by about: Heatless dryer type at 10-15% Heated dryer type at 30-35% The values used in this presentation are fixed examples -- use the methodology and generate your own site specific answers! Thank You For The Opportunity To Present!

26 About the Speaker President of BEKO Technologies Tilo Fruth, BEKO Technologies For your free subscription, please visit

27 Smart Technology / Artificial Intelligence / Industry 4.0

28 2 Smart Technology / Artificial Intelligence / Industry 4.0 Foundation Key sensors & microprocessors, and the awareness of the environment programming software enables an autonomous control of the machine

29 DRYPOINT M space saving compressed air membrane dryers ecointelligent membrane dryer Drying Truth In Compressed Air

30 4

31 ecointelligent membrane dryer The Challenge 5 ecointelligent reaction to changing TEMPERATURE

32 ecointelligent membrane dryer The Challenge 6 Temperature 6 a.m. 8 a.m. 10 a.m. 12 a.m. 2 p.m. 4 p.m. 6 p.m.

33 ecointelligent membrane dryer The Challenge ecointelligent reaction to changing PRESSURE 7

34 ecointelligent membrane dryer The Challenge 8 Temperature Pressure 6 a.m. 8 a.m. 10 a.m. 12 a.m. 2 p.m. 4 p.m. 6 p.m.

35 ecointelligent membrane dryer The Challenge 9 ecointelligent reaction to changing FLOW

36 ecointelligent membrane dryer The Challenge 10 Temperature Pressure Consumption 6 a.m. 8 a.m. 10 a.m. 12 a.m. 2 p.m. 4 p.m. 6 p.m.

37 ecointelligent membrane dryer The Solution DRYPOINT MDi ecointelligent World Unique & Patented ecointelligent Membrane Dryer

38 ecointelligent membrane dryer The Solution The DRYPOINT MDi membrane dryer is ecointelligent because it autonomously adjusts to changing operating conditions 12

39 ecointelligent membrane dryer The Solution The ecointelligent membrane dryer is WORLD UNIQUE because you can pre-select a stable Pressure Dew Point 13

40 ecointelligent membrane dryer The Solution 14 Temperature Pressure Consumption Pressure Dew Point 6 a.m. 8 a.m. 10 a.m. 12 a.m. 2 p.m. 4 p.m. 6 p.m.

41 ecointelligent membrane dryer The Solution The ecointelligent membrane dryer is WORLD UNIQUE because you can pre-select a stable Pressure Dew Point save energy through the autonomous adjustment of the purge air consumption 15

42 ecointelligent membrane dryer The Solution 16 Temperature Pressure Consumption Pressure Dew Point 6 a.m. 8 a.m. 10 a.m. 12 a.m. 2 p.m. 4 p.m. 6 p.m. Purge Air

43 Smart Technology / Artificial Intelligence / Industry 4.0 Foundation Key sensors & microprocessors, and the awareness of the environment programming software enables an autonomous control of the machine 17

44 ecointelligent membrane dryer How does it work

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48 ecointelligent membrane dryer The Result Energy Saving through autonomous adjusted purge air consumption up to 90% Pre-selected stable Pressure Dew Point Laser Cutting

49 About the Speaker President of Kahn Instruments David Kahn, Kahn Instruments For your free subscription, please visit

50 Measuring Moisture on the Factory Floor Presented by: David A. Kahn Kahn Instruments, Inc. Wethersfield, CT April 20, 2017 Kahn Instruments, Inc. 50

51 How can you improve compressed air system performance in decentralized environments? Measure the dewpoint of your air dryers! Use the measured dewpoint to control the dryer s tower switching cycle Verify whether the dryer is working at peak efficiency Determine the temperature at which condensation will form in the process gas or piping Kahn Instruments, Inc. 2

52 Measuring Dewpoint To Improve Air System Performance Kahn can provide three different methods to measure dewpoint A dewpoint transmitter Lowest cost, easiest to implement A dewpoint hygrometer with a display Gives you a local readout of measurements A portable hygrometer Allows monitoring of the air dryer, as well as the air system throughout the plant 3

53 Useful Results of Measuring Dewpoint You can observe -- not guess -- the improvement in air system performance When you change the desiccant in the dryer Better dewpoints When you perform maintenance or make repairs Better dewpoints Better Dewpoints = Improved System Efficiency, Less Dryer Usage and Lower Energy Costs 4

54 What instrument do you require to improve air system performance? For continuous on-line measurement, install the instrument on the air dryer Dewpoint Transmitter 4-20 ma output and no display Output signal wired to DCS or dryer control system Easidew Dewpoint Transmitter On-Line Dewpoint Hygrometer Dewpoint sensor, display, sensor cable, power cord Cermet II Hygrometer Kahn Instruments, Inc. 5

55 What instrument do you require to improve air system performance? For spot-check measurement Hand-held, battery operated portable Easidew Plus Portable Hygrometer HygroPort Portable Hygrometer Kahn Instruments, Inc. 6

56 Technology Used in Kahn Transmitters, Sensor/Display Models and Portables Ceramic Dewpoint Sensor Sensing element produces a capacitance value that s related to the amount of water vapor it measures Wide measurement range: -148 to +68 Fdp -100 to +20 Cdp One instrument covers entire range Use on -40 Fdp or -100 Fdp air dryers Excellent measurement accuracy: ±1 to ±2 Cdp Special units measure to: -184 Fdp/-120 Cdp Kahn Instruments, Inc. 7

57 Capacitive Kahn Ceramic Dewpoint Sensor Porous Conductive Layer Hygroscopic Active Layer Conductive Layer Ceramic Substrate Ceramic sensor is used in transmitters, sensor/display models and portables 8

58 Instrument Installed on Air Dryer Easidew Dewpoint Transmitter 4-20 ma analog output -148 to +68 Fdp range -100 to +20 Cdp range 2-Wire loop powered 12 to 28 VDC operating voltage Easidew Transmitter NEMA 4 stainless steel housing 6500 PSIG operating pressure Sample Block Simple and economical NIST traceable calibration Kahn Instruments, Inc. 9

59 Instrument Installed on Air Dryer Cermet II Hygrometer -148 to +68 Fdp range -100 to +20 Cdp range Ceramic dewpoint sensor Digital display 6-ft long sensor cable Power cord for 120 VAC Cermet II Hygrometer 4-20 ma analog output Programmable alarm relays NIST traceable calibration Sample Block Kahn Instruments, Inc. Easidew Transmitter 10

60 What instrument do you require? For spot-check measurements: A hand-held, battery-operated, portable hygrometer Verify air dryer performance Check the accuracy of the dewpoint sensor installed on the dryer Monitor the air system throughout the plant Kahn Instruments, Inc. 11

61 Hand-held, Portable Instruments At or Downstream of the Air Dryer Measure dryer dewpoint, check accuracy of on-board sensor, monitor dewpoint downstream Economical Dewpoint range -58 F to +68 F Accuracy of ±3.6 F Pressures to 4300 PSIG Fast response F or C display NEMA 6 enclosure NIST calibration Easidew Plus Portable Hygrometer Ideal for -40 Fdp air dryers 61

62 Hand-held, Portable Instruments At or Downstream of the Air Dryer Easidew Plus Portable Hygrometer Simple to operate Teflon tubing stored in lid. Built-in sampling system with filter. Ideal for -40 Fdp air dryers Kahn Instruments, Inc. 13

63 Hand-held, Portable Instruments At or Downstream of the Air Dryer HygroPort Portable Hygrometer Use on -40 or -100 Fdp air dryers Measure dryer dewpoint, check accuracy of on-board sensor, monitor dewpoint downstream Internal or external dewpoint sensor -148 to +68 Fdp (-100 to +20 Cdp) Extremely fast measurements Fdp, Cdp, PPMv, PPMw Data log up to 320,000 points BlueTooth wireless data upload Backlit display NimH battery hour usage Pressures to 5000 PSIG Durable NEMA 4 industrial design Easy to handle and operate NIST traceable calibration 14

64 Summary Measuring dewpoint is essential for efficient dewpoint demand systems Dewpoints of decentralized compressed air dryers can be measured using transmitters, display units and portable hygrometers Transmitters and local display hygrometers can output directly to the dryer s control system or a centralized DCS Portable hygrometers allow for monitoring multiple points downstream of air dryers and throughout the compressed air system Kahn offers high accuracy, wide range, NIST traceable dewpoint transmitters and hygrometers Kahn Instruments, Inc. 15

65 Thank You! Contact Information David A. Kahn Kahn Instruments, Inc. 885 Wells Road Wethersfield, CT Phone: (860) Fax: (860) Web site: Kahn Instruments, Inc. 16

66 Benefits & Technology for Decentralizing a -40 F Dew Point Q&A Please submit any questions through the Question Window on your GoToWebinar interface, directing them to Compressed Air Best Practices Magazine. Our panelists will do their best to address your questions, and will follow up with you on anything that goes unanswered during this session. Thank you for attending! For your free subscription, please visit Sponsored by

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