PCM COMBINATION SYSTEM
PCM COMBINATION SYSTEM
Phase changing complex type air dryer system
It is the air dryer system, which has been developed for the first time by SPX FLOW, supplying ultra-dry air (maximum 100℃ dew point) with the lowest energy cost.
Product configuration
– Complex type air dryer uses refrigerated dryer for removing 75% of moisture contained in compressed air and uses absorptive dryer for removing remaining 25%. By doing this, it can supply ultra-dry air at a much economical cost compared to using single absorptive type dryers.
– Phase changing complex type dryer has combined phase changing type and non-purge absorptive type. With phase changing dryer, it is automatically linked to change in dehumidification load depending on the air flow and temperature change for each day and season. By automatically operating and stopping, unnecessary energy has been reduced. By using absorptive type dryer, it can achieve ‘zero’ consumption for compressed air.
– Phase changing complex type dryer has combined phase changing type and non-purge absorptive type. With phase changing dryer, it is automatically linked to change in dehumidification load depending on the air flow and temperature change for each day and season. By automatically operating and stopping, unnecessary energy has been reduced. By using absorptive type dryer, it can achieve ‘zero’ consumption for compressed air.
Product characteristics
• Achieve optimal discharge air temperature without using cooler
• Achieve ultra-dry dew point at -100°C
• Minimize the dew point hunting when dehumidification tower is changed
• Achieve ultra-dry dew point at -100°C
• Minimize the dew point hunting when dehumidification tower is changed
Energy reduction sequence
- By removing 75% of moisture in phase changing type, energy consumption can be significantly reduced in absorptive type.
- Reduction by phase changing depending on the operation linked to air flow change and temperature change for each day and season
- Entire energy consumption can be reduced significantly based on single operation of phase changing type (excluding winter season)
- Energy consumption can be reduced by linking with absorptive dew point and cycle time depending on the load.
- Energy consumption in absorptive and phase changing type is ‘zero’ if load does not exist during lunch time.
Operating principle
Dehumidification in compressed air
① When high-temperature compressed air moves into dryer, 1st cooling is carried out by exchanging heat with cool air in the exit.
② Compressed air that has gone through 1st cooling moves through chiller and carries out 2nd heat exchange as PCM is melted.
③ Condensate water that has passed through chiller is separated from compressed air in the separator and discharged to the outside.
④ Compressed air that has been cooled by PCM passes through absorptive tower and generates compressed air below the dew point (-40℃ or -70℃).
⑤ Compressed air that has been dehumidified to dew point passes through phase changing heater for lowering relative humidity and supplying high-quality of compressed air to the outside.
Understanding phase-changing operation system
① If cooling compressor and condenser fan are operated for coolant recirculation, coolant in the chiller freezes PCM.
② If the PCM becomes frozen, coolant compressor and condenser fan stop operation.
③ While the coolant circulation is stopped, compressed air is continuously cooled and dehumidified by frozen PCM and the energy can be reduced with no consumption of electricity.
④ With continuously flowing compressed air, PCM starts melting. When PCM is completely melted, freezing compressor and condenser fan start operation and PCM cooling is carried out.
Absorptive type vs phase changing complex type
| Dryer time | Processing flow rate [Nm³/hr] |
Energy consumption [kW] |
Purge consumption amount [%] |
Regeneration time [hr] |
Daily energy consumption [kW] |
Daily purge consumption [kW] |
Annual energy cost [W] |
Energy reduction rate |
| Heater purge | 14,000 | 120(Heater 120) | 15 | 4(Heating 3+Cooling 1) | 2,160 | 5,880 | 352,152,000 | 68% |
| Complex heater purge | 96(heater 42+phase changing type 54) | 5 | 16(Heating 10+Cooling 3+atmosphere 3) | 1,019 | 1,593 | 114,374,940 | ||
| Blower purge | 14,000 | 197(heater 179+Blower 18) | 15 | 4(Heating 3+Cooling 1) | 3,546 | 1,470 | 219,700,800 | 68% |
| Complex blower purge | 111(heater 46+blower 11+phase changing type 54) | 5 | 16(Heating 10+Cooling 3+atmosphere 3) | 1,244 | 368 | 70,574,940 | ||
| Blower non-purge | 14,000 | 250(Heater 230+Blower 20) | 0 | 6(Heating 4.25+Cooling 1.25+equilibrium 0.5) | 4,350 | 0 | 190,530,000 | 59% |
| Complex blower non-purge | 135.5(Heater 74+phase changing type 54) | 0 | 16(Heating 1+Cooling 4+atmosphere 1) | 1,779 | 0 | 77,900,490 |
※ Purge cost of KRW 14 per m3/hr
※ Energy cost of KRW 120 per kW/hr
※ Energy saving for phase changing dryer is applied as 70%
※ Daily purge consumption [kW] : (purge flow rate x purge cost) / electricity cost
※ Corresponding item can be different depending on the usage environment.
• Example above is comparison table for energy reduction rate for when it is remodeled to phase changing complex type without changing absorptive type.
• Example below is the details for energy cost for when heater purge dryer is remodeled to complex type blower non-purge. If absorptive type is changed,
energy reduction rate can be maximized.
Heater purge energy cost (annual)
| Electric heater energy cost 124,173,000￦/years 189kW x (2.5hr ÷ 4hr) x 24hr x 365day x 120￦/kW) |
| Purge air cost 343,392,000￦/years (14000m3/hr x 20%) x (24day x 14￦ ÷ 120￦/kW) x 365day x 120￦/kW) |
| Total energy cost 124,173,000 + 343,392,000 467,565,000￦/years |
Purge air
Electric heater
83% (389,664,510￦/years) Reduction of energy cost
Electric heater/Air blower/phase changing dryer
Investment collection period is less than 1 year for new investment
Complex blower non-purge energy cost (annual) air blower energy cost average operation rate
Electric heater energy cost 53,479,800￦/years
(74kW x (11hr ÷ 16hr) x 24hr x 365day x 120￦/kW)Air blower energy cost 7,391,250￦/years
(7.5kW x (11+4)hr ÷ 16hr) x 24hr x 365day x 120￦/kW)Phase changing dryer 17,029,440￦/years
(54kW x operation rate 30% x 24day x 365day x 120￦/kW)Total energy cost
53,479,800 + 7,391,250 + 17,029,440
77,900,490￦/years