Common faults of adsorption dryers

Adsorption dryers play a vital role in the industrial field. They are responsible for providing dry, pure compressed air to ensure the smooth progress of the production process. However, like any other mechanical equipment, adsorption dryers will also encounter various faults and common problems. The following is a comprehensive analysis of common faults and common problems of adsorption dryers, aiming to help users better understand and solve these problems.

1. Adsorbent related issues

1. Adsorbent failure

Phenomenon description:

If the adsorbent is used for too long, it may gradually lose its ability to absorb moisture, causing the outlet dew point of the dryer to increase and fail to provide dry compressed air that meets the requirements.

Cause analysis:

• Adsorbent saturation: After long-term use, the internal pores of the adsorbent are filled with moisture and can no longer absorb more moisture.

• Adsorbent contamination: If it is contaminated by oil or other impurities, its moisture absorption performance will be reduced.

• Poor adsorbent quality: Low-quality adsorbents may contain more impurities, affecting their service life and performance.

Solution:

• Regularly check the use of adsorbents and replace saturated or contaminated adsorbents in time.

• Choose high-quality adsorbents to improve their moisture absorption performance and service life.

• Optimize the use environment, such as setting up dehumidification equipment to reduce ambient humidity to extend the service life of the adsorbent.

2. Adsorbent blockage

Phenomenon description:

The adsorbent may block the airflow channel due to powdering, agglomeration, etc., affecting the pressure and drying effect of the working tower.

Cause analysis:

• Poor adsorbent quality: low-quality adsorbents are prone to powdering or agglomeration.

• Excessive moisture content in the intake air: Air with high moisture content will increase the load on the adsorbent and accelerate its blockage.

• Harsh use environment: If the temperature is too high or the humidity is too high, it will accelerate the blockage of the adsorbent.

Solution:

• Regularly check the use of the adsorbent and replace the severely blocked adsorbent in time.

• Optimize the intake conditions, such as reducing the moisture content of the intake air, increasing the intake temperature (but avoid too high), etc.

• Clean and maintain the adsorption dryer regularly to keep its interior clean and unobstructed.

2. Inlet temperature and pressure problems

1. Inlet temperature is too high

Phenomenon description:

If the compressed air temperature entering the adsorption dryer is too high, it will exceed the processing capacity of the adsorbent, resulting in an increase in the outlet dew point.

Cause analysis:

• Cooling system failure: such as cooler blockage, insufficient cooling water flow, etc.

• Ambient temperature is too high: such as high temperature in summer, poor heat dissipation of the equipment.

Solution:

• Install a cooler in front of the adsorption dryer to ensure that the compressed air temperature entering the dryer is moderate.

• Regularly check the operation of the cooling system, clean the cooler and replace the cooling water in time.

• Adjust the working parameters of the equipment according to the ambient temperature to ensure operation within the appropriate temperature range.

2. Inlet pressure is too low

Phenomenon description:

If the compressed air pressure entering the adsorption dryer is too low, the working tower pressure will not reach the system pressure, affecting the drying effect.

Cause analysis:

• Inlet filter element blockage: resulting in increased intake resistance.

• Pipeline leakage: resulting in a drop in system pressure.

• Compressor failure: such as insufficient compressor exhaust volume, unstable exhaust pressure, etc.

Solution:

• Regularly check the use of the air inlet filter element, and clean or replace the blocked filter element in time.

• Check whether there is air leakage at the pipe connection, and repair possible air leakage points in time.

• Maintain and service the compressor to ensure its normal operation and stable exhaust.

III. Regeneration system problems

1. Incomplete regeneration

Phenomenon description:

During the regeneration process, if the regeneration temperature is not enough, the regeneration time is insufficient, or the regeneration gas volume is insufficient, it may cause the adsorbent to be regenerated incompletely, affecting the drying effect of the next adsorption cycle.

Cause analysis:

• Regeneration heater failure: such as heater damage, short circuit or open circuit, etc.

• Regeneration valve failure: such as valve leakage, blockage or abnormal operation, etc.

• Control system failure: such as controller program error, sensor failure, etc.

Solution:

• Repair or replace the regeneration heater to ensure that it can heat normally.

• Check the working condition of the regeneration valve and repair or replace the faulty valve in time.

• Troubleshoot and repair the control system to ensure that the regeneration cycle can start and stop normally.

2. Regeneration valve leakage

Phenomenon description:

The regeneration valve may leak, resulting in the loss of regeneration gas and affecting the regeneration effect.

Cause analysis:

• Poor valve sealing: such as valve sealing surface wear, impurity blockage, etc.

• Abnormal valve operation: such as valve jamming, actuator failure, etc.

Solution:

• Repair or replace the leaking valve to ensure that it is well sealed.

• Check the working condition of the valve actuator and repair or replace the faulty actuator in time.

IV. Electrical and control system problems

1. Power failure

Phenomenon description:

The adsorption dryer may have a power failure, such as loose power cord, open circuit or short circuit, etc.

Cause analysis:

• Aging or damage of the power cord: After long-term use, the power cord may fail due to aging or wear.

• Power switch failure: such as poor contact and damage of the switch, etc.

Solution:

• Check whether the power cord is firmly connected. If there is any problem, repair or replace it in time.

• Check whether the power switch is working properly. If it is damaged, replace it in time.

2. Controller failure

Phenomenon description:

The controller may have program errors, sensor failures and other problems, resulting in the regeneration cycle not being able to start or stop normally.

Cause analysis:

• Program error: such as disorder or error in the internal program of the controller.

• Sensor failure: such as failure of temperature sensor, pressure sensor, etc.

Solution:

• Troubleshoot and repair the controller. If necessary, reprogram or replace the controller.

• Check the working condition of the sensor and replace the faulty sensor in time.

V. Other common problems

1. Filter blockage

Phenomenon description:

Filter blockage will cause the intake pressure to decrease, affecting the working efficiency of the adsorption dryer, and may also increase the outlet dew point.

Cause analysis:

• The filter has not been cleaned for a long time: resulting in the accumulation of impurities and dirt.

• Poor intake air quality: such as containing a large amount of dust, oil and other impurities.

Solution:

• Check the use of filters regularly, and clean or replace clogged filters in time.

• Improve the quality of intake air, such as installing a pre-filter, etc.

2. Abnormal noise

Phenomenon description:

The adsorption dryer may generate abnormal noise during operation, affecting the normal operation and working environment of the equipment.

Cause analysis:

• Mechanical failure: such as valve damage, muffler damage, etc.

• Airflow impact: such as the impact sound generated when the airflow encounters an obstacle or the flow rate changes suddenly.

• Electrical failure: such as motor overload, poor contact, etc.

Solution:

• Check and maintain mechanical parts, and replace damaged parts in time.

• Adjust the installation position of the equipment to reduce the noise caused by resonance.

• Check the working condition of the electrical system and repair the fault in time.

VI. Preventive measures and maintenance strategies

In order to reduce the failure rate of adsorption dryers and extend their service life, a series of preventive measures and maintenance strategies need to be taken:

1. Regular maintenance: Develop a detailed maintenance plan, including daily inspections, regular cleaning and preventive maintenance.

2. Train operators: Ensure that operators receive adequate training and understand the working principle, operating procedures and safety measures of the equipment.

3. Use original accessories: When replacing worn or damaged parts, original accessories should be used as much as possible to ensure the performance and reliability of the equipment.

4. Environmental control: Try to maintain the stability of the equipment working environment and avoid extreme temperature and humidity changes.

5. Fault monitoring: Install appropriate monitoring equipment, such as pressure sensors, temperature sensors, etc., to monitor the working status of the adsorption dryer in real time.

6. Fault records: Establish a maintenance record system to record in detail the time, cause, solution and result of each fault.

7. Spare parts reserve: Maintain an appropriate amount of common spare parts inventory so that they can be quickly replaced when a fault occurs.

In summary, adsorption dryers may encounter a variety of faults and common problems during operation. By deeply understanding the causes and solutions of these faults and taking effective preventive measures and maintenance strategies, the failure rate of equipment can be significantly reduced and its service life can be extended. At the same time, this also helps to improve production efficiency and product quality, creating greater economic benefits for the enterprise.