air dryer location

[mcmental]

afternoon all, i have just picked up a refrigerated air dryer and im starting to plan out the air system before it gets to the hypertherm.

compressor
some type of filter
dryer (https://www.r-techwelding.co.uk/compres ... er-at1000/)
hyperthem

is that the best sequence ??

thanks

chris

[djreiswig]

I don't think the at1000 is a refrigerated dryer, looks more like a filter.
But, that's the sequence I use. Make sure you use large enough air lines depending on the distance you are running them.

[mcmental]

Sorry that filter link I put up is a filter I’m going to put straight onto the plasma. I’m running 25mm polyethylene pipework

[weldguy]

That is the best sequence but it is important to install the refrigerated dryer 20' or further from your compressor to allow the hot compressed air to cool before it reaches it. Do this and your dryer will work so much more efficiently and deliver dryer air to your plasma.

[Rodw]

I might have different ideas but:
1. A precooler before the storage tank will ensure the air is at room temperature before its stored (I used a transmission cooler)
2. Auto drain on the storage tank and probably on a drop leg before it enters the tank.
3. The refrigerated drier close coupled to the storage tank.
4. Pre and post filters on the refrigerated drier.
5. No other filters required anywhere in the shop. I threw out my at1000 filter so there is no added restriction.

Now I never have to think about air.....

[weldguy]

I might have different ideas but:
1. A precooler before the storage tank will ensure the air is at room temperature before its stored (I used a transmission cooler)
2. Auto drain on the storage tank and probably on a drop leg before it enters the tank.
3. The refrigerated drier close coupled to the storage tank.
4. Pre and post filters on the refrigerated drier.
5. No other filters required anywhere in the shop. I threw out my at1000 filter so there is no added restriction.

Now I never have to think about air.....

Great suggestions from Rodw, the cooler you can get the air before your drier the better so it all depends on how much effort you want to put into your air system but clean and dry air cannot be overstated enough if you want to have good success.

[robertspark]

I use a water cooler. (think still.... the copper bit in this picture)

https://www.lovebrewing.co.uk/alembic-p ... -oQAvD_BwE

[Rodw]

Thanks, I think the main thing to understand about refrigerated driers is that the hotter air is, the more water it can hold.
Refrigerated driers operate by chilling the air to the dew point at which point it can't hold any water....
BUT:
There is a finite limit to how many degrees the drier can reduce the air temperature. If the air is too hot when it enters the drier, it will not be able to hit that dew point and some moisture will remain in the air.Finding a pool of water

The other factor to consider is compressor duty cycle and mine is undersized. That means the compressor is heating the air a lot more and it does not have time to cool in the storage tank before its used.

Finding a pool of water under the filters at the plasma table and not being able to cut in our hot, humid climate was a pretty powerful incentive to get this right. So I basically replicated a commercial installation recommended in the air drier manual.

Adding 20' of airline with associated friction losses just to cool the air never made sense to me. If you did that, you'd need to build in some long drain legs to remove what water you can before the drier. But air line and fittings are expensive and making it up takes time to make. Using a 12" x 12" heat exchanger was much more efficient space wise. In fact it worked far better than I expected. You can't hold the inlet pipe with your bare hand yet the outlet is cool to the touch!

[robertspark]

if you get an oil cooler (for a car) and stick it in a bucket or trough of water it will help the dryer efficiency.

(I was a bit busy and didn't mention that my "still" water cooled condenser is up stream of my three stage filter and air dryer.

I say "air dryer" as I've got two (options)... I have a membrane dryer and a dessicant air dryer.

in the past I have used the membrane dryer, but you have to remember that they require a bleed air supply so they require a fair air compressor to run (I have 2x3hp air compressors that run in parallel to provide enough air for sand blasting)

membrane dryer is a Sharpe one as shown here
https://www.google.com/search?q=sharpe+ ... YvKbIBw7:0

I have recently changed to a double dessicant air dryer arrangement using water filter enclosures and a custom 3d printed sparge pipe to improve air flow, it has a mesh gause at the inlet which is cable ties in place and I used some epoxy resin to glue the edge so it will never move.

[Rodw]

if you get an oil cooler (for a car) and stick it in a bucket or trough of water it will help the dryer efficiency.

Even better is mount it at the compressor pulley so air is drawn through the cooler by the fins on the pulley.

[robertspark]

I don't pay for water... as I pay a fixed water charge so... I have a trickle of water going through the still and as the water is always cool or cold it improves the efficiency more than air. an air dryer if the air is 30 Deg C plus won't help much at all. water at 4 Deg C will work a lot better.

18 years ago when I started with a hand plasma cutter and sand blaster I use to use just a coil of copper tube dumped in an ice cooled bucket.

[robertspark]

I work around Manchester at the moment and the saying goes....

it's either raining, just finished or just about to start.... lots of water (for water cooling and in the air)

[Rodw]

I don't pay for water... as I pay a fixed water charge so... I have a trickle of water going through the still and as the water is always cool or cold it improves the efficiency more than air. an air dryer if the air is 30 Deg C plus won't help much at all. water at 4 Deg C will work a lot better.

18 years ago when I started with a hand plasma cutter and sand blaster I use to use just a coil of copper tube dumped in an ice cooled bucket.

We pay for water so leaving a tap on is not an option, plus it would be closer to 20 deg C..

5:30 am here and 96% humidity,18 deg C so will see 30 again today. You'd be surprised how efficient a decent heat exchanger oil cooler is if you are forcing air through it with a fan. Maybe our environment is why local company PWR has grown to become one of the leading automotive transmission cooler manufacturers in the world. We need every bit of efficiency we can get!

[mcmental]

thanks for all the replies, i will be starting at the weekend to build it all. 1 thing i did stumble across which are low cost are these https://www.ebay.co.uk/itm/Air-Dryer-fo ... SwMSxflAm8 thought at that price a few of them may assist too???? or has the whiskey kicked in too early????

[Rodw]

Might not handle the high pressure.... so maybe it was the whiskey

[weldguy]

Don't listen to the whiskey talkin, even if it didn't explode it wouldn't dry much air volume. I would want a good 5lbs of desiccant to prevent myself from having to dry it out too frequently. This is a popular unit here shop/dryer_sharpe6760.html Filters and dryer all in 1

[robertspark]

I use two of these in line,

https://www.ebay.co.uk/itm/10-in-line-W ... 890.l49292

DONT get blue dessicant as it contains cobalt

I think I got 3kg 6 lb of orange dessicant and it used most of them.....

[SeanP]

Seems to be most ways of taking out moisture talked about here so might as well add my method as well, so I'm not alone running a trickle of water, I do pay for it as well
Working really well, every time compressor stops it drains that amount of water out and some oil residue. (see video)
https://photos.app.goo.gl/5733tErad5eDoRm27

[robertspark]

nice setup

[mcmental]

I use two of these in line,

https://www.ebay.co.uk/itm/10-in-line-W ... 890.l49292

DONT get blue dessicant as it contains cobalt

I think I got 3kg 6 lb of orange dessicant and it used most of them.....

@robertspark did you make a tube inside it and put some gauze in?

[robertspark]

I use two of these in line,

https://www.ebay.co.uk/itm/10-in-line-W ... 890.l49292

DONT get blue dessicant as it contains cobalt

I think I got 3kg 6 lb of orange dessicant and it used most of them.....

@robertspark did you make a tube inside it and put some gauze in?

I 3d printed these with gauze in them

viewtopic.php?f=123&t=31905&sid=ca9e5fa ... 90#p194329

[mcmental]

I use two of these in line,

https://www.ebay.co.uk/itm/10-in-line-W ... 890.l49292

DONT get blue dessicant as it contains cobalt

I think I got 3kg 6 lb of orange dessicant and it used most of them.....

@robertspark did you make a tube inside it and put some gauze in?

I 3d printed these with gauze in them

viewtopic.php?f=123&t=31905&sid=ca9e5fa ... 90#p194329

perfect! dont suppose you still have the stl do you? pretty please

[robertspark]

yes, I'll upload it later with an explanation.

it is printed as one part but has a sliding ring which acts as a lock for the mesh which is glued in place.

it is 250mm high and printed vertically, that way it remains hollow.... so you need a tall enough 3d printer

I guess you could do it as a split print and be glued together.

I used epoxy resin to glue the mesh in place

it also has a groove for the mesh to sit in

[mcmental]

ive got ender 3 pro, think its 200mm max, if i can split it in half and do that i will. thank you

[robertspark]

https://www.thingiverse.com/thing:4752056