ALM Refrigeration Air Dryer

ALM Refrigerant Dryers
Contents
ALMiG refrigeration dryers
Why use dry compressed air?
What is refrigeration drying?
Refrigeration dryer function
Overview of ALM refrigeration dryers
ALM refrigeration dryers
ALM 25 – 110
ALM 150 – 1100
ALM 1320 – 2150
ALM 2400 – 5300
Advantages of „energy-saving-speed controlled version“ ALM -E
Refrigeration dryer design
2
Why use dry compressed air?
Untreated compressed air

• results in increasing leakage of the pipe system
• affects highly compressed air applications (e.g. pneumatic tools)
• results in - high maintenance costs
- long production downtimes
- serious quality issues in the
Averageproduction process
water content of air
14
12
10
g/m³
8
6
4
2 Compressed air
0 pipe
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Pneumatic tool
3
The ability of compressed air to absorb water vapour

depends solely on temperature and not operating
pressure.
Ability of air to absorb water depending on temperature
T Moisture T Moisture
[°C] [g/m3] [°C] [g/m3]
-5 3.23 25 22.83
0 4.87 30 30.08
5 6.79 35 39.29
10 9.36 40 50.67
15 12.74 45 64.85
20 17.15 50 82.26
4
Classification of moisture reg. DIN ISO 8573-1:2010
Compressed air quality classes acc. to

DIN ISO 8573-1:2010
Application Residual water
Moisture classes acc. to
DIN ISO 8573-1:2010 Class Pressure dew point
Class Pressure dew point Microchip production 1-2 -70 / -40 °C
0 as specified by operator Varnishing

3-4 -20/ +3 °C
(spray guns)
1 ≤ -70 °C
Pharmac. industry 2-3 -40 / -20 °C
2 ≤ -40 ℃
Measurement and
3-4 -20/ +3 °C
3 ≤ -20 °C control technology
4 ≤ +3 ℃ Food and drink
conveyance systems 2-4 -40/ +3 °C
5 ≤ +7 °C
6 ≤ +10 ℃ Cleaning of forming
2-4 -40 / +3 °C
tools
General plant air 4 +3 °C
Area for refrigerant dryers
Breaker hammer 4-5 +3 / +7 °C
5
Main
drying procedures
Condensation Adsorption
Refrigeration dryer Adsorption dryer

(PDP ≥ +3°C) (PDP < 3°C to -70°C)
6
What is refrigeration drying?

Refrigeration drying is a process in which the compressed air is cooled
by a refrigerant in a heat exchanger. This condenses the water vapour in
the compressed air and separates it out.
The greater the difference between inlet and outlet compressed air
temperature, the greater the amount of water condensed.
The lower the compressed air's cooling temperature, the less moisture
remaining.
Drying comprises two phases:
First phase: The warm compressed air enters an air / air heat exchanger in
the opposite direction to the compressed air already cooled and exiting the
unit. No extra energy is required for this process. Around 70 percent of the
water vapour is removed as condensate.
Second phase: The compressed air flows through an air / refrigerant heat
exchanger and cools to the specified pressure dew point (e.g. 3°C). The
remaining moisture condenses before this point is reached, is removed and
discharged through a condensate drain.
7
Refrigeration dryer function
Route travelled by the compressed air
1 Precooling of the fully saturated, warm

1 4 compressed air in the air/air heat exchanger
2 Cooling to the pressure dew point in the

refrigerant / air heat exchanger
2
Condensate collected is discharged by the
3
separator / drain
Compressed
4 The dry compressed air exiting the unit is
air
approx. +3 heated by the compressed air entering in the
to +5°C
3 opposite direction
No condensate produced in compressed

Reduction in moisture to
ISO class 4, PDP: ≥ + 3°C ! air network unless the compressed air
temperature falls below +3° to +5°C!!
8
Overview of ALM type ALMiG refrigeration dryers
ALM 25 – ALM 110

5 models from 20 to 100 m³/h
ALM 150 – ALM 1100

ALM 1320 – ALM 2150

“E” version with energy-saving-speed control
ALM 2400 – ALM 5300

Larger types and special options on request !

9
ALM 25 – 110
On/Off
switch Dew point
indicator
Integrated
time-controlled
condensate drain
(standard)
With static condenser
Volume flow* Power consumption

ALM- Standard version Options
[m³/h] [kW]
25 20 0.24 • Digital display

• IP 55 protection
35 30 0.24 • Dew point indicator
• 60 HZ version
• Time-controlled
65 60 0.34 • Electronically level-controlled
condensate drain
condensate drain (A-DRAIN)
85 80 0.42 • Refrigerant: R134a
• Bypass
110 100 0.58 • Remote On/Off switch
* = inlet temperature 35°C; operating pressure 7 bar;

pressure dew point +3°C
10
Benefits of ALM 25 - 110:
•Static condenser (refrigerator principle):

 No fan required;
 quiet,
 fewer wearing parts,
 no air turbulence,
 no dust
 No influence from ambient temperature up to 45°C
 Time-controlled condensate drainage
 Warm outlet air (T-outlet = T-inlet + 5°C) thanks to exchange of relative heat
•Easy to install: connect piping, plug in power cable , job done!

•Integrated demister separator (function: metal wool "captures" and collects water droplets
from damp air)
•Long service life through use of quality components

•Using the heat produced by condensation means that there are no cold, damp pipes at the
air outlet
11
ALM 150 – 1100

A-Drain: standard,
electronically controlled
condensate drain

[m³/h] [kW]
150 140 0.58
180 160 0.60

260 240 0.87
• Dew point indicator
• IP 55 protection
350 315 1.10 • Electronically level-controlled
• 60 HZ version
condensate drain (A-DRAIN)
400 360 1.30 • Bypass
• Digital display (ALM-350 and
• Remote On/Off switch
500 470 1.48 higher)
• Potential-free fault
• Refrigerant: 150/180 R134a;
640 580 1.90 message
260-1100 R407c
740 680 2.45
900 820 2.55
1100 1000 2.70
12
Vorteile ALM 150 - 1100

 Crossflow stainless steel plate-type heat exchanger (copper soldered)
 Ensures optimum heat exchange and prevents condensation on cold pipes
 Newly developed constant pressure valve Crossflow

 Constant refrigerant supply stainless steel
 Constant vaporiser and dew point temperature heat exchanger
 High-quality cooling compressors

 Above average cooling rating
 Piping not prone to vibration

 Vibrations and oscillations are not transferred to connection points -> no
leaks
 Electronically level-controlled condensate drain

 Automatically discharges the condensate collected
 No compressed air losses
A-DRAIN
Electronically
 Connections made of stainless steel level-controlled
condensate drain
 Totally corrosion free system
 Housing designed for easy maintenance
13
Other benefits of ALM 150 - 1100:
•Compressed air inlet temperatures up to 55°C

•Ambient temperatures up to 45°C
•Maximum operating pressure of 16 bar(g) (higher pressures on request)
•Very low pressure losses
•Air / air heat exchanger with high effectiveness caused by small energy consumption
•Easy to install: connect piping, plug in power cable, job done!
•LED dew point indicator on control panel (ALM 350 and higher)
•Long service life through use of quality components
•As a safety pressure limiter, the constant pressure valve (CPV) provides an overload
shutdown mechanism:
If the coolant temperature increases, the cooling medium pressure increases too 
the dryer shuts down and an alarm is issued. This ensures that the dryer is not
damaged.
14
ALM 1320 – 2150

[m³/h] [kW]
1320 1200 2.55 • Dew point indicator • Plain text display

• Electronically level-controlled • IP 55 protection
condensate drain (A-DRAIN) • Special voltages
1530 1400 2.95
• Potential-free fault message • Cold air outlet mix
• Digital display • Bypass
1850 1700 5.70 • 50/60 HZ version • Remote On/Off switch
• Refrigerant: 1320/1530 • Water-cooled
2150 2000 5.80 R134a; 1850/2150 R404a • Sea water-cooled

15
•Space-saving installation thanks to narrow, vertical design

•Low power consumption
•Heat exchanger version optimised for compressed air applications:
 Sinusoidal, large, smooth air ducts
 Low pressure loss through dryer
•Outstanding accessibility for service as sheet metal panels can be removed

on all four sides
•Robust, reliable refrigeration control (HGBV: hot gas bypass valve)

•Use of R134a or R404A refrigerants, typically used by industry
•Temperature displays for compressed air inlet, compressed air outlet and
dew point
16
ALM 2400 – 5300

[m³/h] [kW]
2400 2200 5.50 • IP 55 protection

• Special voltages
• Cold air outlet mix
2650 2500 7.00 • Dew point indicator • Bypass
• Electronically level-controlled • Remote On/Off switch
condensate drain (A-DRAIN) • Water-cooled
3550 3200 8.70 • Potential-free fault message • Sea water-cooled
• Multi-functional, digital • Marine specification
4000 3650 9.20 display • Integrated separator
• 50/60 HZ version • Integrated separator and
4900 4600 10.80 • Refrigerant: R404a fine filter
• Low temperature
(until Tamb =-20°C)
5300 5100 13.40 • Digital scroll (EM**)
* = inlet temperature 35°C; operating pressure 7 bar; ** = energy management
17

•Plate-type stainless steel heat exchanger, copper soldered
• Heat exchanger version optimised for compressed air application:
Sinusoidal, large, smooth air ducts Digital Scroll
 Low drop in pressure through dryer (Otion)
•Use of R404A refrigerant as standard

•Low installation cost; easy to maintain as panels can be removed
•High reliability, efficiency and durability
•Dryers can be positioned with one side facing the wall, which reduces the installation
area required
• Cold air output: no need for an air/air heat exchanger on the output side if very cold
compressed air is required.
• Filter separator and/or coalescence filter Demister

separator
Very fine oil filtration
in cold air flow
• Energy saving from use of Digital Scroll:

If the dryer runs without load, the scroll wheels move apart thereby reducing internal
resistance. Energy saving compared with standard refrigeration dryers: up to 80% !!
18
Overview of
ALMiG-Energy-Saving-Drier“
type ALM E
ALM 1320 – ALM 2150

ALM 2400 – ALM 5300

19
Energy-Saving-Drier
ALM 1320 – 5400 E:
ALM E: Constructive difference to the ALM series
• Replacement of the Danfoss "standard cooling unit" with a Danfoss high efficiency
"speed-controlled cooling unit" and a "Danfoss frequency converter" that also has to
be fitted
• In technical terms, this means:

 minor design changes resulting from simply replacing the cooling unit using a
"plug’n play" system.
 all other components are identical.
20
Energy-Saving-Drier
ALM 1320 – 5400 E:
Note:
ALM – E has:
• same max. volume flow
• same pressure dew point
• same pressure losses
• same dimensions
• lower power consumption
The power consumption depending on the utilisation (30 - 100%) consists of 3 factors::
1.Savings due to intelligent energy‐saving speed control
2.Savings by reducing the amount of heat sucked into the energy ‐saving refrigeration dryer based on Summer
time and Winter time (warm/cold)
3.Savings by reducing the amount of heat sucked into the energy ‐saving refrigeration dryer based on
a lower outlet compressed air temperature in normal operations, for speed ‐controlled compressors.
21
Refrigeration driers can work in very different ways, for

example:
Refrigeration dryer with Standard refrigeration dryers

energy-saving control
In the case of these refrigeration dryers an In the case of standard refrigerant driers the
intelligent energy-saving speed control ensures current consumption is always 100%.
that the electrical power consumption always rises
no matter whether the compressed air
or falls almost proportionally to the compressed air
throughput through the refrigeration dryer is
throughput
at 100%, varies, or is zero

The electrical power consumption is always at
the optimum level, in energy terms
once it is switched on, the refrigeration dryer
always uses 100% energy

Unnecessary energy costs are avoided
If the compressed air production goes into stand-
a standard refrigeration dryer causes
unnecessary energy costs
by or is switched off:

the energy-saving dryer also goes into stand-by
operation

the electricity uptake is reduced to a minimum
Important:

•The refrigeration dryer is not completely switched
off, but is permanently ready for use but with
reduced electricity uptake

•A constant low pressure dew point is guaranteed,
even if the compressor goes into operation for a
short time
Field of applications for „energy-saving-speed control“

drier?
1) Production of compressed air using a speed-controlled compressor,

refrigeration dryer installed before compressed air receiver
The compressed air generated by the variable speed compressor varies depending on the air
requirement
„Energy-saving-drier“ adjusts its power requirement to the air output
„Standard drier“ operates with 100% power consumption.
Compressor is turned off or in standby (no FAD)

„Energy-saving-drier“ is in stand-by, energy consumption reduced to a minimum, ready to operate
„Standard drier“ operates with 100% power consumption even if no air is passing through the drier

drier?
2.) Production of compressed air using a fixed speed compressor,

refrigeration dryer installed before compressed air receiver
Constant FAD (100%) from the compressor

„Energy-saving-drier“ operats with 100% power consumption
„Standard drier“ operates with 100% power consumption


drier?
3.) Production of compressed air using a fixed speed or speed controlled

compressor, refrigeration dryer installed after compressed air receiver
The FAD generated by the compressor passes into the compressed air tank. In response to the
compressed air demand the FAD after the tank varies.
„Energy-saving-drier“ adjusts its power requirement to the air output
„Standard drier“operates with 100% power consumption

Calculation of the energy saving potential
Example:
ALM 1320 vs ALM 1320 "E"
Energy price: € 0.15/kWh
Working hours compressor station: 4000
Drier utilisation: 70%
Calculation of the energy saving potential
Example:
ALM 5300 vs ALM 5300"E"
Energy price: € 0.15/kWh
Working hours compressor station: 4000
Drier utilisation: 70%
Market overview „Energy saving dryer“

In addition to the energy saving dryers with "Speed control“ the market offers also
energy-saving dryer with "Cold accumulator”.
Function description according to manufacturer:
The cold accumulator with high specific capacity is cooled by the refrigerant circuit and extracts the
compressed air heat. If necessary, the coolant compressor cools down the accumulator again.
Note ALMiG:
Very often normal sand is used as „cold accumulator“
1 Cooling compressor on, cools compressed air +
'cooling reservoir'  Pressure dew point falls
Cooling compressor off. Cooling of compressed air

2
depends solely on cooling reservoir  Pressure dew
point rises
Result: More moisture in the compressed air network
3 If more compressed air is needed suddenly when the

cooling compressor is off (see point A), the system
oscillates in response.
Pressure dew point rises very fast; the system is
too slow to absorb these fluctuations!
Result: Much more moisture in the compressed air
network
ALMiG measurement protocol of a "refrigerated dryer with cold accumulator

Installation upstream or downstream of receiver?
or
Installation upstream of receiver Installation downstream of receiver

+ Dryer is always subject to constant - In the event of high consumption, the
volume flow by compressor refrigeration dryer can be "bypassed" – especially
(dryer is not "bypassed"). if there are a only few, but large compressed air
consumers.
+ No condensate is collected in the
compressed air receiver - Condensate collects in the receiver  Inner
 Receiver remains dry. walls must be protected from rust.
- High compressed air inlet temperature + Compressed air cooling up to dryer inlet
because short cooling section (install larger (smaller dryer available if required).
dryer if required).
29
Refrigeration dryer design
The ALMiG refrigeration dryer design is based on:

the compressed air inlet temperature in the refrigeration
dryer
 the higher the inlet temperature, the lower the
throughput
the ambient temperature at the dryer installation site
 the higher the ambient temperature, the lower the
throughput
the operating pressure of the compressed air
 the higher the operating pressure, the greater the
In throughput
accordance with DIN ISO 7183, as a rule,
all standard refrigeration dryer details relate to
• compressed air inlet temperature of +35°C
• ambient temperature of +25°C
• operating pressure of 7bar
30
Example of dryer design:

• Specified parameters
Volume flow: 725 m3/h
Pressure dew point: +3℃
Compressed air inlet temperature: 40°C
Ambient temperature: 30℃
Operating pressure: 11bar
• Design
Advance dryer selection: ALM 900 where V=689 m 3/h
Volume flow correction: Vcorr= V x ftu x fpu
 689 x 0.94 x 1.13 =732 m3/h
ALM 900 fits the bill !! (with a reserve !)
Ambient temperature (°C) 25 30 35 40 45
Factor ftu 1 0.94 0.89 0.83 0.78
Operating pressure 3 4 5 6 7 8 9 10 11 12 13 14
(bar)
Factor fpü 0.79 0.87 0.92 0.96 1 1.03 1.07 1.1 1.13 1.16 1.18 1.21
31
The „game“ with parameters:

If the pressure dew point is not decisive and can be
set on +10°C, the calculation will be as follows:
• Specified parameters
Volume flow: 725 m3/h
PDP: +10°C
Compressed air inlet temp.: 40°C
Ambient temperature: 30°C
Operating pressure: 11bar
• Design
Advance dryer selection: ALM 740 where V=685
m /h
3
Volume flow correction: Vcorr= V x ftu x fpu

 685 x 0,94 x 1,13 =728 m3/h
ALM 740 fits !!
Result: If temperatures inside the pipe system never fall below +10°C, there will be
no condensate, and customer may choose a smaller dryer type..
32
Comparison pressure losses

∆P for ALM 740: 0,23 bar
∆P for ALM 900: 0,16 bar
Difference in price:
ALM 900 : ALM 740  ca. 15%
Result: Customer may choose, if he prefers a smaller

pressure loss or a lower price for the dryer.
33
ALMiG Kompressoren GmbH

Adolf-Ehmann-Strasse 2 • 73257 Köngen
Sales tel. no.: +49 (0)7024 9614-240
Sales e-mail address: sales@almig.de
www.almig.de
34

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ALM Refrigerant Dryers

ALM Refrigerant Dryers

Why use dry compressed air?

Untreated compressed air

The ability of compressed air to absorb water vapour

Ability of air to absorb water depending on temperature

Classification of moisture reg. DIN ISO 8573-1:2010

Compressed air quality classes acc. to

Class Pressure dew point Microchip production 1-2 -70 / -40 °C

0 as specified by operator Varnishing

Refrigeration dryer Adsorption dryer

What is refrigeration drying?

Refrigeration dryer function

Route travelled by the compressed air

1 Precooling of the fully saturated, warm

2 Cooling to the pressure dew point in the

No condensate produced in compressed

Overview of ALM type ALMiG refrigeration dryers

ALM 25 – ALM 110

ALM 150 – ALM 1100

ALM 1320 – ALM 2150

ALM 2400 – ALM 5300

Larger types and special options on request !

With static condenser

Volume flow* Power consumption

25 20 0.24 • Digital display

* = inlet temperature 35°C; operating pressure 7 bar;

Benefits of ALM 25 - 110:

•Static condenser (refrigerator principle):

•Easy to install: connect piping, plug in power cable , job done!

•Long service life through use of quality components

ALM 150 – 1100

Volume flow* Power consumption

150 140 0.58

180 160 0.60

Vorteile ALM 150 - 1100

 Newly developed constant pressure valve Crossflow

 High-quality cooling compressors

 Piping not prone to vibration

 Electronically level-controlled condensate drain

 Housing designed for easy maintenance

Other benefits of ALM 150 - 1100:

•Compressed air inlet temperatures up to 55°C

ALM 1320 – 2150

Volume flow* Power consumption

1320 1200 2.55 • Dew point indicator • Plain text display

* = inlet temperature 35°C; operating pressure 7 bar;

Benefits of ALM 1320 - 2150:

•Space-saving installation thanks to narrow, vertical design

•Outstanding accessibility for service as sheet metal panels can be removed

•Robust, reliable refrigeration control (HGBV: hot gas bypass valve)

ALM 2400 – 5300

Volume flow* Power consumption

2400 2200 5.50 • IP 55 protection

Benefits of ALM 2400 - 5300:

•Use of R404A refrigerant as standard

• Filter separator and/or coalescence filter Demister

• Energy saving from use of Digital Scroll:

ALM 1320 – ALM 2150

ALM 2400 – ALM 5300