Case Study - Single Tower Freedom Dryer for an Iron Foundry

At an iron foundry in Biscoe, North Carolina, a Van Air Systems compressed air treatment equipment cools, dries and cleans the compressed air supplied to over 100 air cylinders and valves essential to mixing, molding, and finishing operations.

Prior to the installation of a Van Air Systems air-cooled after-cooler, a model D60 Freedom Dryer, and a F101 series particulate after-filter, freeze-ups occurred in the main air line that serves three production areas. Freeze-ups occurred because the plant’s air compressors are located in a separate power house building, resulting in the exposure of piping to outdoor ambient temperatures. Costly downtime and excessive repair and replacement of valves and cylinders were serious problems in winter months.

After reviewing their air system requirements, foundry officials selected the Van Air after-cooler, dryer, and particulate filter to prevent the condensation of moisture and resulting freeze-ups. An added benefit is that the Freedom Dryer consumes zero electricity for operation.

Since installation, no freeze-ups have been reported and costly valve repair and replacement have been reduced by 85%. Plant engineers estimate a savings of about $300 per week, or $15,000 per year, since the Van Air equipment was installed.