What Are Air Compressor Dryers?
If your compressed air solution is integral to your business’s daily operations, you simply cannot afford to overlook maintenance. Like all industrial equipment, air compressors are subject to wear and tear, and moisture is among the main culprits behind corrosion, rust, and toxins. Fortunately, an expertly installed Atlas Copco compressed air dryer can eliminate virtually all moisture from your compressed air.
An air dryer is a piece of air equipment designed to separate water vapour from industrial process air. Some compressor models come equipped with aftercoolers capable of removing up to 70% of the moisture from compressed air. However, you may require an additional air dryer in a sensitive or humid environment or an industry such as pharmaceutical, oil and gas, chemical engineering, or food.
At Search Air, we have set the bar high for the compressed air industry for over 78 years. That is why we were named Atlas Copco’s Compressor Distributor of the Year as recently as 2022. With a professionally fitted air dryer, you could extend the lifespan of your valuable equipment, guarantee high-quality and precise end products, eliminate environmental hazards, and much more.
Below, we will explain the benefits and inner workings of compressor dryers in detail but do not hesitate to give us a call for specific advice based on your unique needs.
Why Are Air Compressor Dryers Necessary?
The air around us naturally contains water vapour in the air. This moisture becomes highly concentrated when compressed, leading to condensation within your air compressor system. Essentially, the process leaves compressed air saturated with water. Without an effective method to remove moisture from compressed air, your system can suffer from corrosion, efficiency losses, and contamination, especially in applications requiring dry compressed air.
Factors like air temperature and pressure significantly impact how much moisture builds up. For example, a 7-bar system operating at 20 degrees Celsius can release over ten litres of water from the compressed air every hour. This moisture, if not treated, can compromise compressed air quality across all industrial air applications.
If left unchecked, water from the compressed air can:
- Corrode internal components and reduce equipment life.
- Contaminate products, putting compliance with standards such as ISO 8573-1 at risk.
- Freeze in pipelines, blocking air passes and damaging tools.
- Increase energy usage by forcing compressors to work harder.
This is why an air dryer for your compressor is essential. Whether using a refrigerated dryer, desiccant air dryers, or other dryer types, the goal is the same: to absorb moisture from the air stream and protect your compressed air drying system.
Choosing the right air dryer for your needs ensures high-quality air delivery, safeguards your equipment, and maintains operational efficiency. At Search Air, we specialise in air dryers for air compressors, providing solutions that match your air demand, environment, and compliance requirements.
Compressed air dryers are essential to remove moisture from compressed air to prevent corrosion contamination and system damage.
Air compressor dryers remove moisture from compressed air to prevent corrosion contamination and system damage
How Do Air Dryers Work?
If you need an air dryer for your compressor, it helps to understand the different types of air dryers available and how they work. An air dryer is a device that reduces the dew point of the compressed air to precipitate water. Air dryers are essential for removing moisture from compressed air to protect your system and maintain high-quality air across all applications.
The basic air dryer working principle depends on the specific technology, but generally, as air enters the dryer, the moisture is either cooled, absorbed, or diffused. The goal is always to treat compressed air and deliver the right air quality for your processes.
Here are the four main dryer types used in industrial compressed air systems and how compressed air dryers work:
What Are Air Compressor Dryers
Refrigerant Air Dryers
Refrigerant dryers are the most common type in industrial settings and are suitable for general manufacturing. These solutions remove moisture from the air using heat exchangers, which cool the compressed air to approximately +3°C. This causes the air to condense moisture into liquid water, which is separated from the air and drained away. The dry air is then reheated before leaving the dryer system to prevent pipe sweating.
Refrigerant air dryers can be cycling or non-cycling. Cycling dryers (like the Atlas Copco FD VSD series) adjust cooling based on demand, being the eco-friendliest solution, while non-cycling dryers run continuously but have lower installation costs.
These dryers work particularly well with rotary screw compressors and are an economical option ideal for a variety of industrial settings where extremely low dew points are not critical.
Desiccant Dryers
Desiccant dryers are preferred in environments where moisture-free air is necessary, with no margin for error. These advanced solutions can achieve a pressure dew point as low as -70 degrees Celsius by adsorbing water from the air using an adsorbent material such as activated alumina or silica gel.
In this type of dryer, air flows over a desiccant bed which strips the moisture out of the air. Much more effective than refrigerant alternatives, desiccant dryers are suitable for industries such as medical and dental, electronics, food and drinks, pharmaceuticals, and painting.
While they are more expensive to purchase and install than their refrigerant counterparts, their higher energy efficiency could reduce operating costs. Modern units reduce energy waste by optimising purge air—the dry air used to regenerate the desiccant towers. Options include heatless, blower purge, and heat of compression models (like the Atlas Copco XD series) which use waste heat for regeneration.
Other Types of Air Dryers
Other popular dryers include membrane air dryers, which depress the dew point and dehumidify the air as it enters the compressor system via hollow fibre membranes. These are often used for point-of-use applications. Another type is deliquescent dryers, which use a pressure chamber containing salt tablets to absorb vapour. While these electric-free methods are eco-friendly, they are not as effective as desiccant or refrigerant dryers in terms of dew point performance and moisture removal.
In most industrial settings, where extremely low dew points are not required, refrigerant dryers are often the most cost-effective and practical option. However, every business’s needs differ. We are only a phone call away if you want to discuss your unique needs and future practicalities with an expert.
Benefits of Using Air Compressor Dryers
Moisture is inevitable when it comes to compressed air systems. It can, however, cause serious harm to your system and equipment if left unchecked. Fortunately, different types of compressed air dryers can effectively eliminate moisture from your compressed air, delivering benefits such as:
Prevent Freezing
In some industrial settings, vapour contained within compressed air can condense and freeze, jamming and wearing your solution’s internal moving components in the process. Dry air is essential in outdoor lines to prevent these blockages.
Eliminate Contamination
Contaminated compressed air poses a serious risk to product quality if you operate in an industry such as food and drink or pharmaceuticals. Similarly, high moisture levels in compressed air can cause damage when sanding and blasting. A dryer can virtually eliminate these risks.
Minimise Bacterial Growth
Bacteria and other harmful microorganisms are often found in the water vapour contained in air, which can build up in your system as it compresses. A dryer ensures that your compressed air remains toxin-free by lowering the dew point of the air to levels where microbes cannot survive.
Prevents Corrosion
An air dryer can prevent moisture in compressed air from corroding internal components such as drums, pipes, vessels, and tanks, often made from steel. Using a compressed air dryer protects your investment.
Enhance Operational Efficiency
Even low moisture levels in compressed air can reduce the efficiency of your compressed air system and all the equipment it powers. This loss in efficiency is compounded by damage to your compressor’s internal components. Dryers play an important role in protecting your equipment while enhancing operational efficiency and minimising downtime.
Choosing the Right Dryer for Your Air Needs
When choosing the right air compressor dryer, you must consider your specific air quality requirements.
- ISO 8573-1 Standards: If your application requires Class 4 air (general manufacturing), a refrigerant dryer is sufficient. For Class 1 or 2 (food/pharma), you will need a desiccant dryer.
- Temperature: Consider the temperature of the compressed air and the ambient environment. High inlet temperatures can significantly reduce dryer capacity.
- Air Demand: Ensure the dryer is sized for your maximum air flow to prevent moisture carryover during peak usage.
Air Dryer Support in Wakefield, South Yorkshire & Barnsley
At Search Air, we provide expert advice, installation, and servicing of compressed air dryers for businesses across Wakefield, South Yorkshire, and Barnsley. Whether you need a new drying solution or regular maintenance to protect your system from moisture damage, our team is here to help. Get in touch to keep your compressed air clean, dry, and efficient.
Discuss Your Dryer Needs with Our Experts
The best dryer for your compressor depends on your industry, environment, needs, and goals. If you want to discuss those with a seasoned expert, you have come to the right place. We can help you know about compressed air dryers and select the perfect unit. At Search Air, we have remained at the top of our game for the better part of eight decades, as you can see by perusing our reviews and industry accolades. Contact us today for more information on the latest range of dryers and how they can elevate your business.
FAQ
What is the purpose of an air dryer for your air compressor?
The purpose of an air dryer is to remove moisture from the compressed air after it has been compressed, preventing corrosion, contamination, and damage to downstream equipment. By drying the air, air dryers help deliver consistent quality air, protect your system, and improve the efficiency of your industrial process air applications. Dryers are critical for maintaining system health.
What types of air dryers are available for compressed air systems?
Main types of air dryers include refrigerated dryers, which work by cooling the air to condense and remove water vapour, and desiccant air dryers, which use adsorption to achieve extremely low dew points. Some options, such as cycling dryers and heated desiccant air dryers, are designed to optimise energy use while maintaining high compressed air quality. Other types of air compressor dryers include membrane and deliquescent models.
How do desiccant air dryers use adsorption to achieve extremely dry air?
Desiccant air dryers use specially designed materials like activated alumina to absorb water vapour from compressed air. As the compressed air passes through the desiccant bed, moisture is drawn out, allowing the system to reach a very low dew point, which is critical for applications needing extremely dry air. Dryers reduce moisture significantly more than standard aftercoolers.