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| Van Air Systems |
2950 Mechanic Street
Lake City, PA 16423 USA |
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Phone: 800-840-9906
Corporate Fax: 814-774-0778
Order Entry Fax: 814-774-3482 |
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Case Study - EMCON II Energy Management Control for a Heatless Dryer
Van Air's EMCON II energy management control conserves energy by reducing the amount of compressed air used in heatless-type regenerative dryers. Unlike fixed-cycle dryers, the purge of an EMCON II-equipped dryer is automatically adjusted to the actual moisture load and operating conditions. This makes EMCON II ideal in situations where compressed air usage or moisture load tends to fluctuate. In such cases, the heatless regenerative dryer's energy consumption is reduced. EMCON II-equipped regenerative desiccant dryers are extremely dependable, supplying dry instrument or process air to a pressure dew point of -40ºF.
The benefits of the EMCON II, which is an option on all Van Air heatless regenerative desiccant compressed air dryers 200 scfm and larger, are illustrated at a number of major switching yards of Norfolk Sothern where reliable, -40ºF pressure dew points are being provided. Increased efficiency and dramatically reduced operating costs have also been noted.
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| Problem |
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Compressed air is used in railway switching yards in braking systems to facilitate the efficient hook-up of cars. Freeze-ups are one problem since compressed air line are situated outdoors. Still another problem is the variable use of compressed air, as pneumatic power is required only when switching is in progress. Fixed-cycle regenerative desiccant air dryers are costly to operate under such circumstances. Thus, EMCON II is an ideal candidate for these and similar operations. |
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| Solution |
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Using the example of one Norfolk Sothern yard in southeastern Ohio, four compressors are used to generate approximately 2,500 scfm of compressed air. After 5,154 hours in service, the dryer had been in EMCON mode and not purging for 2,691 hours, or 48% of the time. Thus, purge air loss was also reduced by 48%.
On average a fixed-cycle regenerative desiccant compressed air dryer purges at a constant rate of 15%. Thus to operate Norfolk Sothern's 2,500 scfm dryer in a fixed cycle mode, a constant 375-(.15 x 2,500)-cubic-feet-per-minute of compressed air would be purged or lost. The yearly fixed cycle cost can be then be calculated as follows:
375 scfm purge x 60 minute/ hr x 24hr/day x 365 days/yr = 197,100,000 scf/yr
197,100,000 scf/yr x $.30/1,000scf = $59,130
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| Results |
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With a purge air reduction of 48%, an annual savings of over $28,000 (.48 x $59,130) at this installation is realized. Five more dryers with EMCON II have been installed at other Norfolk Southern switching operations.
Norfolk Southern Corporation recognizes still other benefits. These include effective moisture removal and no freeze-ups in their outdoor compressed air lines, normally a big problem during winter months. The results are improved switching efficiency and a substantial reduction in the maintenance of air-operated equipment.
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Case Study - Portable Single Tower Dryer for Switching Operations
The Triple Crown trucking branch of Norfolk and Southern in Sandusky, Ohio manages day-to-day switching operations as tractor trailers are shipped by rail. Triple Crown must charge rail car air brakes with compressed air. Air brakes on railcars required clean, dry compressed air.
Before contacting Van Air, Triple Crown used an aging skid-mounted heatless regenerative desiccant air dryer. While this heatless unit adequately dried compressed air, it posed pressure drop and purge loss problems.
Triple Crown chose to replace its heatless regenerative dryer with a Van Air Blast Pak model FD-400. The Blast Pak, with an integrated air-cooled after-cooler, reduces the temperature of hot compressed air to within a few degrees of the ambient air. Compressed air then flows through a bed special drying tablets called Dry-O-Lite, which absorb water vapor. Lifting lugs and fork lift slots give the Blast Pak maximum portability for mobile applications. Plus, no electricity is required for operation of the Blast Pak drying system. The Blast Pak's simple and rugged design means dependability and easy maintenance.
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| Have a question? Call toll free or contact us: 1-800-840-9906| Email Us |
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