Hybrid Dryer

1105a-09.11

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt ‚ Tel.: +49-(0)4625-189042 ‚ Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
Hybrid Dryer

Synergy results in economic

Compressed air for The principle of the desiccant dryer

Desiccant dryers are being
highest requirements used, when the com-
pressed air system is
exposed to temperatures
Certain production processes such as instrument air, air for pneu-
below the freezing point or
matic control systems and process engineering solutions, feed air
when a particularly low
for the transport of powdery materials in the chemical, pharma-
dew point is required for a
ceutical and food processing industries etc. require dependably
specific applications.
treated, high-quality compressed air – technically oil-free and
very dry – with pressure dew points of under 0°C down to -40°C. The air is channeled
through a vessel filled with
If the compressed air is channeled through extensive pipe net-
an adsorption media (activated Alumina), where the water vapor
works or in areas exposed to ambient weather conditions, distur-
is being captured at the surface of the adsorbent.
bances due to frozen condensate are – especially in winter time
– the order of the day. These drying agents can be regenerated and used again and
again. The dryers have two desiccant vessels.
Until now the economical treatment of a dew point under 0°C
was only achievable by using desiccant dryers. For capacities The compressed air supply is being controlled, so that only one
over 1000m3/h mostly heated regenerative desiccant dryers vessel dries, whereas the other vessel is being regenerated.
(blower purge dryers) were used, which, in comparison to heat- Heated regenerative desiccant dryers (blower purge dryers) are
less regenerative desiccant dryers, are more cost-effective. being regenerated using a blower and mostly an electric operat-
ed heater.

compressed air inlet compressed air outlet

regeneration

Ways to compressed
air inlet

fan heater dustfilter

air/air heat
exchanger
air treatment
dessicant adsobers
(A)
Air-to-air (B) Air-to- (E) Optional fine oil
heat exchanger
air/refdrigerant

heat Refrigerant heat filter

exchanger exchanger
bypass

(C)
separator/filter
regeneration
air outlet

water separator condensate drain

and oil finefilter
(D) Automatic
condensate drain

The HybriDryer unites all advantages

The DELTECH Hybridryer is a combination of a refrigeration
dryer and a heated regenerative desiccant dryer. The saturated
compressed air first enters the refrigeration dryer, it is cooled
The principle of the refrigerated down to +3°C and the water vapor is condensed. The conden-
compressed air dryer sate is then separated from the compressed air flow in the sepa-
rator filter.
They are used in areas, where the compressed air network is
After that the air leaves the refrigeration dryer circulation. The
exposed only to temperatures above the freezing point.
absolute temperature and the dew point are still at +3°C and the
Warm, saturated compressed air is firstly being cooled down via relative humidity is 100%! - the ideal condition of the adsorbent
an Air-to-Air heatexchanger (A) and than further cooled down in is achieved!
an Air-to Refrigerant heatexchanger (B), which is being con-
The compressed air is then introduced into the desiccant dryer,
trolled by a expansion valve. The water vapor condenses into liq-
where it is dried to dew points of -25°C to - 40°C.
uid and is than separated from the compressed air stream in the
cyclone/demister separator/filter (C) and discharged by the fully The still cold compressed air is then supplied to the integrated
automatic condensate drain (D). air-to-air heat exchanger and thus cools the inflowing com-
pressed air.
The cool, dry air is now being used to cool the warm incoming
compressed air by means of the Air-to-Air heat exchanger (A). An ambient air temperature controlled bypass in the combination
makes it possible to bypass the desiccant dryer during the sum-
mer period and only use it in the winter time, as required. Thus
the slightly higher investment costs justify themselves even more
clearly by the considerably lower operating expenses.

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt ‚ Tel.: +49-(0)4625-189042 ‚ Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
 Hybrid Dryer

cal advantage: the DELTECH HybriDryer Series

All the advantages of the HybriDryer at a glance
Flexible
Environmentally
friendly
Economical
䡲 Low operating expenses in com-
parison with heated regenerative
desiccant dryers
䡲 Selectable summer/winter
operation (+3°C / -25°C / -
40°C)
䡲 Constant pressure dew point
䡲 No temperature or dew point
peaks during switch over
䡲 No loss of compressed air
䡲 Efficient finest oil filtration at the
coolest point
䡲 Extended lifetime of the
absorbent through extremely low
regeneration temperatures
䡲 Optimal outlet temperatures
䡲 Volume flows of 1200
to 9000 m3/h
(higher capacities upon request)
䡲 Lowest operating expenses
energy consumption W/m3

40 20
adsorption = g H2O / 100g adsorbent

silicia gel
hea m
t em
les br
15 s re
gen
an
ed
= e rye
he rativ r
a te *
30 dr
eg e
ed
esic
activated ner can
alumina 10 a tive
t dr
yer
des
ic c an t
molecular sieve dryer
20 5
H yb refrigera
ridry tion drye
er
r

10 dew 1 2 3 4 5 6
point (-70 ∞C) (-40 ∞C) (-20 ∞C) (+3 ∞C) (+7 ∞C) (+10 ∞C)
class HybriDryer
regenerative desiccant dryer refrigeration dryer
0 20 40 60 50 100 membrane dryer*
* only for small volume flows
relative huminity %
ideal condition for the adsorbent activated alumina dew point classes and their energy requirements

200 t
desiccant dryer* C02 reduction r*
ye
49% t dr
an
CO2 emissions in 12 months

c
sic
dew point -40∞C de

100 t
savings
investment

HybriDryer
dew point -40∞C HybriDryer

1 2 3 4 5

– flow 5000 m3/h in 12 months *market

standard years *market standard

CO2 reductions with the HybriDryer cost savings with the HybriDryer

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt ‚ Tel.: +49-(0)4625-189042 ‚ Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
Hybrid Dryer

The desiccant dryer section displaying the bypass for The refrigeration dryer section of
“summer/winter” operation the HybriDryer with the refrigera-
tion specifics

Technical Data

operation +3°C operation -40°C

DHD 400 1200 4300 2250 1550 3,1 5,7
DHD 500 1500 4300 2250 1550 4,3 7,5
DHD 670 2000 4600 2250 1900 6,7 10,8
DHD 835 2500 4600 2250 1900 7,5 12,4
DHD 1000 3000 4600 2250 1900 9,4 15,7
DHD 1335 4000 4600 2250 1900 11,5 19,4
DHD 1670 5000 5150 2600 3250 11,5 21,2
DHD 2000 6000 5150 2600 3200 13,8 25,4
DHD 2335 7000 5500 2600 3600 15,3 28,6
DHD 2670 8000 5500 2600 3600 17,7 32,7
DHD 3000 9000 5550 2600 3700 20,0 35,7

Volume flow acc. to VDI 2045 for suction conditions +20°C and 1 bar absolute, operating pressure 7 bar, compressed air inflow temperature
+35°C, ambient temperature +25°C, power connection 400/3/50

Subject to technical alterations

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt ‚ Tel.: +49-(0)4625-189042 ‚ Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
 Hybrid Dryer

Deltech Hybridryer
Deltech introduces an innovative compressed air filter- and dryer system, which will reduce energy
consumption by more than 50%. A perfect combination and integration of refrigerant- and adsorption-
technologies offers highest efficiency. This unique system adapts automatically to changing demands in both
compressed air and pressure dew point. The enormous potential in energy savings allows the replacement of
existing adsorption dryers (both heatless- or heat- reactivated) with very short pay-back time.

Energy saving-CO2 reduction!

Modern technology!
Reliable Quality and Performance!

These are the key issues to which new industrial developments are measured. In compressed air systems
where the quality demands of the application (ref. to ISO 8573-1class 1 to 7) often requires high investments
and implementation of the wrong technologies will result in excessive operational- and service- costs. In order
to meet required quality standards drying and filtration of compressed air are unavoidable. Only the right
choice of equipment to this purpose will increase the efficiency and economical use of the compressed air
installation.

Quality Dust filtration Oil filtration Pressure dew Water content

Class µm mg/m³ point °C gr/m³
1 0,1 0,01 -70 0,003
2 1 0,1 -40 0,12
3 5 1 -20 0,88
4 15 5 3 6
5 40 25 7 7,8
6 - - 10 9,4
7 - -
Not specified 35 39

Compressed air quality according to ISO 8573-1

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt  Tel.: +49-(0)4625-189042  Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
Hybrid Dryer

In many cases the selection of the right compressor from the right manufacturer is given much more attention
than the selection of the required air treatment equipment. Unfortunately for many compressor vendors, the
prime consideration is selling the compressor. The level of knowledge of filtration and drying often does not
match the priority which should be given to this subject.

The energy consumption of the air treatment package can vary from 5% (Class 4 air quality) to 30% (Class 1
air quality), depending on the technology used. In view of the fact that compressor manufacturers compete
with energy-saving arguments of far below 5% over their competitors, it is obvious that the “real” savings are
to be made with the right selection of the air-treatment equipment.

Deltech has over 60 years of experience in developing filtration- and drying- systems for compressed air.
With the newly developed Hybrid system, Deltech offers a package which suits most industrial applications,
offering the highest possible economical use. Hybrid technology will offer an important contribution to today’s
desire and obligation for energy savings and CO2 reduction.

Basic requirement

Many industrial processes ( e.g. instrument air, pneumatic cylinders and valves, conveying of powder or
granular matter, or other chemical, pharmaceutical and food production processes) demand a relatively high
compressed air quality, which means free from oil and particles and with a pressure dew point as low as -
40°C.

In all compressed air installations condensation of remaining water vapour must be avoided. While under
“summer conditions” a pressure dew point of +3°C can be sufficient, remaining water vapour might condense
and freeze under “winter conditions”. Freezing condensate will cause costly problems to products, processes
and equipment. Hybrid technology adapts to these requirements by offering the required pressure dew point
(as low as -40°C) matching most process- and ambient- conditions.

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt  Tel.: +49-(0)4625-189042  Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
 Hybrid Dryer

Refrigeration dryers

provide 3°C pressure dew point and use about 2% of the compressor power consumption. It is however not
possible to use this pressure dew point under “winter conditions”.

Schema: Refrigeration dryer.

Adsorption dryers

So far pressure dew points below 0 °C could only be achieved by using standard adsorption technology,
whereby the regeneration of the saturated adsorbents require about 15% of the compressor capacity (for
heatless systems) or about 8% of the compressor power consumption (for heated systems). The energy
saved by means of heated regeneration justifies the somewhat higher investment with a short pay-back time.

Schema: Adsorption dryer.

Combining technologies

A simple calculation shows the basic logic of combining a refrigerant system with an adsorbent system:

 Compressed air at 35°C (standard to ISO 7183) contains 39 gr. of water vapour.
 Compressed air at 3°C (standard to ISO 7183) contains 6 gr. of water vapour.
 Compressed air at -40°C (standard to ISO 7183) contains 0,12 gr. of water vapour.

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt  Tel.: +49-(0)4625-189042  Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
Hybrid Dryer

Below an example for drying 2,500 m3/h of compressed air at 7 bar (g) and 35˚C.

1. Drying to a pressure dew point of +3°C using a refrigeration dryer.

The energy consumption of the dryer is approx. 5 kW.
The reduction of water vapour content is 39 – 6 = 33 gr.
The energy consumption per gram of water reduction is 5 : 33 = 0,15 kW/gr.

2. Drying to a pressure dew point of -40°C using a heat regenerated adsorption dryer.
The energy consumption is approx. 20,6 kW.
The reduction of water vapour content is 39 – 0,12 = 38,88 gr. Energy consumption per gram of water
is 20,6 : 38,88 = 0,53 kW/gr., which is 3,5 times higher compared to refrigeration systems.

3. Using the combination of refrigeration dryer and an adsorption dryer will result in following energy
consumption:
Refrigeration dryer uses 5 kW. Remaining water vapour content is 6 grams.
The adsorption dryer removes 5,88 grams and uses 5,88 x 0,53 kW = 3,1 kW.
Total energy consumption of the combination is 5 kW + 3,1 kW = 8,1 kW.

Conclusion

Providing a pressure dewpoint of -40°C using only an adsorption dryer costs 20,6 kW.
Providing a pressure dewpoint of -40°C using the combination costs 8,1 kW.

The logic consequence would be a combination of the two drying systems, where pre-drying is done with a
refrigeration dryer and the final pressure dew point of -40°C is reached with an adsorption dryer. This principle
is not new and already in use in many applications.

The Hybrid technology is a further development of this principle, where both systems are integrated. As shown
in the schema below, the refrigeration system supplies cold (+3°C) compressed air to the adsorption dryer. The
adsorption process shows its highest efficiency when the compressed air is cold (+3°C) and fully saturated (R.H.
is 100%). Since 85% of the water content has been removed by the refrigerant dryer, the adsorption dryer only
needs to remove the remaining 15%, under ideal process conditions. This allows long adsorption times using an
adsorption dryer of reduced size. After the adsorption process the cold dry air (-40°C pressure dew point) is led
back to the air/air heat exchanger of the refrigerant dryer, where it is reheated to 27°C.

Schematic Hybridryer.

Before entering the adsorption dryer, the cold air flows through a high-efficiency demister/water separator and
through a 0,01 micron oil fine-filter. At this low filtration temperature the efficiency of the oil fine-filter is about
10 times higher than at a filtration temperature of 20°C. Before entering back into the refrigeration dryer the
air is cleaned from desiccant dust particles in a 1 micron dust filter.

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt  Tel.: +49-(0)4625-189042  Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de
 Hybrid Dryer

Energy Management

Further savings are automatically achieved whenever the operating conditions become more favourable. In
case the air capacity or the inlet temperature is reduced, the energy management systems on both the
refrigerant dryer and the adsorption dryer adapt their drying capacity immediately. For this purpose the
refrigerant dryer is equipped with digital scroll technology, which controls the cooling capacity of the
refrigerant system. The adsorption dryer is equipped with a dew point controller, which measures the
saturation degree of the adsorbing material and starts the regeneration cycle as required.

Dew point Selection

Hybridryers offer the user the possibility of selecting his required pressure dew point. Under “winter
conditions” the pressure dew point of the adsorption dryer can be selected from between -25 and -40°C.
A real Highlight of the Hybridryer is the selection of the “summer” mode.
The adsorption dryer can be bypassed so that the refrigeration dryer provides +3°C pressure dew point
without using energy for the adsorption dryer. Operation of the bypass can also be done automatically by
using an ambient temperature sensor (optional).

The following summary shows the extraordinary advantage of the Hybrid technology and the savings which
can be achieved by the synergy of this combination:

• Lowest operating cost compared to standard adsorption dryers (heatless and heat regenerated)
• Winter/Summer selection mode offers significant saving potential.
• Constant and selectable pressure dew point.
• Efficient cooling of the regenerated adsorber by means of 1% cold compressed air, thus avoiding
temperature- and dew point spikes at cycle changeover.
• Most efficient oil fine filtration by „Cold Coalescing“ filter.
• Extended desiccant life time due to low regeneration temperature (only 130°C) and very long adsorption
time (min. 8 hours).
• Automatic energy reduction using Digital Scroll Technology and dew point-controlled adsorption time
under low-load conditions.
• Compact skid-mounted design, saving floor space and allowing container packaging.
• The important savings in energy consumption measured against the relatively low investment cost enable
a very short pay-back time for this state-of-the-art air treatment package.

Schema: Energy savings versus investment cost.

Deltech designs and produces Hybrid packages in their production facilities in Moers/Germany. Hybrid dryers
contribute to energy and CO2 reducing programs and are subsidized in many European countries. Please
check your local authorities for support programs.

- Technical details to change without not ce -

Filter- und Trocknertechnik GmbH

Mühlenstraße 21, D-24855 Bollingstedt  Tel.: +49-(0)4625-189042  Fax: +49-(0)4625-189048
Internet: www.fut-gmbh.de ▪ e-mail: info@fut-gmbh.de