Modular construction compressed air/gas dryer system with filtration

Abstract

A modular compressed-gas dryer including in series: an inlet module, a precooler/reheater module, an evaporator module, and a sump module. The modules form columns where at least one column has a filtration chamber. Further provided are a gas outlet and gastight seals between modules. The system creates a first and second set of heat transfer passages where refrigerant passes through the second set in a heat exchange relationship in a direction perpendicular to incoming gas passing in the first set. The filtration chamber conducts chilled gas from the first set to a third set of heat transfer passages. The third set extends through the precooler/reheater in heat exchange relationship with the first set. Chilled gas passes in heat exchange relationship in a direction perpendicular to the incoming gas so that the incoming gas chilled in the evaporator exchanges heat with the incoming gas in the precooler/reheater.

1 ) A modular compressed-gas dryer system comprising:
 a flow through gas system, including in series,   a) an inlet module for introducing incoming gas into said system;   b) a precooler/reheater module for housing a gas-to-gas heat exchanger;   c) an evaporator module for housing a refrigerant-to-gas heat exchanger;   d) a sump module for collecting and draining condensate from said system;   e) wherein said modules together form a plurality of columns for creating gas flow through passages where at least one of said columns has a filtration chamber for housing a filter;   f) a gas outlet for discharging outgoing gas;   g) a sealing means interposed between respective modules to ensure a gastight seal;   h) a first set of heat transfer passages extending through said heat exchangers in which said incoming gas passes serially through said heat exchangers in a first direction;   i) a second set of heat transfer passages extending through said evaporator module in heat exchange relationship with said first set of heat transfer passages through which a charge of refrigerant passes in a heat exchange relationship with said incoming gas and in a direction substantially perpendicular to said first direction of said incoming gas to produce chilled gas;   j) a filtration passage within said filtration chamber for conducting said chilled gas through said filter from said first set of heat transfer passages to a third set of heat transfer passages;   k) said third set of heat transfer passages extending through said precooler/reheater module in heat exchange relationship with said first set of heat transfer passages and through which chilled gas passes in heat exchange relationship with said incoming gas and in a direction substantially perpendicular to said first direction of said incoming gas; and   l) so that said incoming gas is chilled in said evaporator module and chilled gas therefrom exchanges heat with said incoming gas in said precooler/reheater module to precool said incoming gas and to raise the temperature of said chilled gas to a temperature for ultimate use upon discharge.   
     
     
         2 ) The modular compressed-gas dryer system of  claim 1  wherein said series of modules are removably held together by a multiplicity of rods and bolts and wherein said sealing means is a gasket and mating interlocking edges between each module. 
     
     
         3 ) The modular compressed-gas dryer system of  claim 1  wherein said filtration chamber houses a replaceable filter. 
     
     
         4 ) The modular compressed-gas dryer system of  claim 3  wherein said filter is a coalescing filter. 
     
     
         5 ) The modular compressed-gas dryer system of  claim 1  wherein said gas-to-gas heat exchanger is a tube-and-shell heat exchanger. 
     
     
         6 ) The modular compressed-gas dryer system of  claim 5  wherein said tube-and-shell heat exchanger is equipped with a baffle assembly. 
     
     
         7 ) The modular compressed-gas dryer system of  claim 1  wherein said heat exchangers are constructed as corrugated sheet units having vertical channels and horizontal channels. 
     
     
         8 ) The modular compressed-gas dryer system of  claim 1  further comprising a sensor port for insertion of a level sensor and a dew point port for insertion of a dew point sensor. 
     
     
         9 ) A modular compressed-gas dryer system comprising:
 a flow through gas system, including in series,   a) an inlet module for introducing incoming gas into said system;   b) at least one precooler/reheater module for housing a gas-to-gas heat exchanger;   c) at least one evaporator module for housing a refrigerant-to-gas heat exchanger;   d) a sump module for collecting and draining condensate from said system;   e) wherein said modules together form a plurality of columns for creating gas flow through passages where at least two of said columns have a filtration chamber for housing a filter;   f) a gas outlet for discharging outgoing gas;   g) a sealing means interposed between respective modules to ensure a gastight seal;   h) a first set of heat transfer passages extending through said heat exchangers in which said incoming gas passes serially through said heat exchangers in a first direction;   i) a second set of heat transfer passages extending through said evaporator module in heat exchange relationship with said first set of heat transfer passages through which a charge of refrigerant passes in a heat exchange relationship with said incoming gas and in a direction substantially perpendicular to said first direction of said incoming gas to produce chilled gas;   j) a third set of heat transfer passages extending through said precooler/reheater module in heat exchange relationship with said first set of heat transfer passages and through which chilled gas passes in heat exchange relationship with said incoming gas and in a direction substantially perpendicular to said first direction of said incoming gas;   k) at least one filtration passage within said at least two of said columns having a filtration chamber for conducting said gas from any one of said modules to one of said heat transfer passages; and   l) so that said incoming gas is chilled in said evaporator module and chilled gas therefrom exchanges heat with said incoming gas in said precooler/reheater module to precool said incoming gas and to raise the temperature of said chilled gas to a temperature for ultimate use upon discharge.   
     
     
         10 ) The modular compressed-gas dryer system of  claim 9  wherein said series of modules are removably held together by a multiplicity of rods and bolts and wherein said sealing means is a gasket and mating interlocking edges between each module. 
     
     
         11 ) The modular compressed-gas dryer system of  claim 9  wherein said gas-to-gas heat exchanger is constructed as a tube-and-shell heat exchanger. 
     
     
         12 ) The modular compressed-gas dryer system of  claim 11  wherein said tube-and-shell heat exchanger is equipped with a baffle assembly. 
     
     
         13 ) The modular compressed-gas dryer system of  claim 9  wherein said heat exchangers are constructed as corrugated sheet units having vertical channels and horizontal channels for directing gas and refrigerant. 
     
     
         14 ) The modular compressed-gas dryer system of  claim 9  wherein each of said at least two of said columns having a filtration chamber houses a replaceable filter. 
     
     
         15 ) The modular compressed-gas dryer system of  claim 14  wherein one said at least two of said columns having a filtration chamber houses a replaceable filter and conducts said gas from said inlet module to a first of said at least one precooler/reheater modules. 
     
     
         16 ) The modular compressed-gas dryer system of  claim 15  wherein one said replaceable filter is a particulate/coalescing filter. 
     
     
         17 ) The modular compressed-gas dryer system of  claim 14  wherein one said at least two of said columns having a filtration chamber houses a replaceable filter and conducts said gas from said sump module to said at least one precooler/reheater module. 
     
     
         18 ) The modular compressed-gas dryer system of  claim 17  wherein one said replaceable filter is a coalescing filter. 
     
     
         19 ) The modular compressed-gas dryer system of  claim 9  wherein said at least one precooler/reheater module for housing a gas-to-gas heat exchanger is two precooler/reheater modules for housing two gas-to-gas heat exchangers; and wherein said at least one evaporator module for housing a refrigerant-to-gas heat exchanger is two evaporator modules for housing two refrigerant-to-gas heat exchangers; and wherein said at least two of said columns have a filtration chamber for housing a filter is two filtration chambers each housing a filter. 
     
     
         20 ) The modular compressed-gas dryer system of  claim 9  further comprising a sensor port for insertion of a level sensor and a dew point port for insertion of a dew point sensor.