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CONVENTIONAL COOLING
AND
DESICCANT
Figure 39-1 compares conventional and desiccant cooling processes using the psychrometric chart. As shown on the chart, Process 1-2 in conventional vapor compression cycle systems consists exclusively of sensible cooling. Dehumidification (latent cooling) begins at Point 2 after the airstream has been cooled to saturation. Additional sensible cooling also occurs in Process 2-3. Finally, once
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ooling loads have both sensible and latent components. Sensible cooling is the removal of (dry) heat. Latent cooling is a dehumidification process for moisture (wet heat) removal. Desiccant technologies can often be effectively applied to provide latent cooling, or dehumidification, due to the ability to alternately attract and reject moisture. In desiccant dehumidification applications, moisture in an airstream is removed by passing the air over a substance that absorbs moisture. Desiccants are various solid or liquid substances that, due to their very strong affinity for moisture, attract water vapor directly from an airstream. Once the desiccant material has become saturated with moisture, the moisture can be driven off by applying heat to the desiccant. Heat can be applied by direct fuel-firing, steam, hot water, or waste heat. This process, which continually renews the desiccants ability to collect moisture, is referred to as regeneration. Desiccant dehumidification is a well-established technology for applications that call for low humidity levels. It provides for the ability to precisely control humidity levels in achieving very low dewpoint conditions. Mechanical (vapor compression) systems are challenged to economically achieve dewpoints below 40F (4C) coil frosting and the need for large coil surface areas are key limitations. Also, they must often overcool an airstream to achieve the desired humidity level and then reheat the air to meet acceptable space temperature conditions. In addition to potential thermal performance benefits, desiccant air drying can also remove harmful airborne pollutants and bacteria, reduce equipment corrosion due to moisture and impurities, and protect product integrity.
the desired dehumidification has been accomplished, reheating is often required (Process 3-4) to bring the discharge temperature up to the required level. In the desiccant system process, air entering the system is dehumidified and sensibly heated in Process 1-2. The air is then sensibly cooled, often with conventional vapor compression or absorption systems cooling, to the desired temperature indicated by Point 4. In the traditional air conditioning process, dehumidification is accomplished by passing the airstream to be conditioned over a cooling coil surface that is cold enough to cause condensation. If the cooling coil did not have to dehumidify as well as sensibly cool the airstream, the refrigeration system could operate at higher (suction) temperatures and would, therefore, be more thermally efficient. In addition, properly dehumidified air may be too cold to maintain the desired temperature in the conditioned space. Expenditure of energy to reheat the airstream may be needed to maintain comfortable conditions. Desiccant air drying is often a more effective way to reduce latent load than mechanical compression systems. Generally, the greater the requirement for dehumidification, the more thermally efficient desiccant systems are relative to conventional air conditioning (condensation) processes. In general, desiccants tend to be more effective than mechanical compression systems when:
Air enters the system at point 1 and leaves at point 4.
Ratio of latent to sensible load is high. Low humidity levels are required (or desired). Electric rates are high relative to fuel or recovered heat is available. Mold or mildew problems exist in the ductwork or building.
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Figs. 39-2a, b, and c Diagrammatic Representations of Desiccant Process. Source: Munters Cargocaire and Mason Grant Company
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The process of removing moisture from air with a desiccant is termed sorption. When water vapor is sorbed by a desiccant (sorbent), the water changes phase from vapor to sorbed liquid. This phase change releases energy, primarily the latent heat of condensation, plus a small additional amount (approximately 10 to 20%) due to the attraction between the sorbed water and the desiccant. The total heat released is referred to as the heat of sorption. The release of latent energy results in an increase in the temperature of the desiccant and the surrounding airstream. The thermodynamics of the sorption process are similar to the reverse of what happens in an evaporative cooler. As moisture is removed from the airstream, its sensible temperature rises. The rise in air temperature is directly proportional to the amount of moisture removed. The dryer the air, the warmer it will be. The critical element of the sorption process is reversibility. Desiccants are regenerated by being heated to temperatures above that in the sorption process, then placed in a different airstream. The high vapor pressure desiccant surface gives off, or desorbs, moisture to the air to equalize the vapor pressure differential. The dry, hot regenerated desiccant is then cooled to restore its low vapor pressure and is returned to the moist airstream. Typical regeneration temperatures range from 130 to 250F (54 to 121C). Thermal energy can be applied with direct firing of fuel or by steam, hot water, or waste heat. Figure 39-3 is a block diagram of the desiccant air conditioning process.
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The sorption cycle has three parts: 1. Exposing the desiccant to the airstream to be conditioned when it is cool and dry (low vapor pressure) and can attract moisture. 2. Heating the desiccant to further increase its vapor pressure to a point higher than that of the discharge airstream so that moisture will move off of the surface to the air to equalize the pressure differential. 3. Cooling the desiccant to restore its low vapor pressure so that it can begin attracting moisture once again.
Direct Evaporative Cooler Warm Moist Air (Usually Cool Requires Dry Additional Air Cooling)
Indirect Evaporative Cooler Make-Up Air Exhaust Warm Moist Air Natural Gas Waste Heat Steam Warm Moist Air (Exhaust) Cool Dry Air Warm Air Cool Moist Air
Desiccant Dryer
Desiccant Regenerator
Fig. 39-4 Three Sensible Cooling Options for Use with Desiccant Systems.
Conditioned Space
Regeneration Air
In the sorption process, the removal of moisture from the air results in a release of heat (heat of sorption) that raises the air temperature as the process converts latent cooling load to sensible cooling load. Figure 39-4 shows three sensible cooling options that can be incorporated in desiccant systems to provide sensible cooling. The recuperative heat exchanger transfers heat to the air used to regenerate the desiccant. This can be supplemented by or replaced with a conventional chiller. The direct evaporative cooler evaporates water into the warm, dry air to cool it. Usually, this process cannot provide the full measure of required sensible cooling. The indirect evaporative cooler evaporatively cools a separate airstream and uses it to cool the dry air through an air-to-air heat exchanger.
strong molecular attraction (much like a sponge) and hold it on the surface of the material are called adsorbents. These are mostly solid materials such as silica gel. Other desiccants, called absorbents, undergo a physical change as they collect moisture. These are usually liquids, or solids that readily become liquids as they absorb moisture. Following is detail on various types of solid adsorbents and liquid absorbents.
SOLID ADSORBENTS
Solid desiccants are materials with a tremendous internal surface area per unit mass, such as silica gel, molecular sieves, activated alumina, or hygroscopic salts. The capacity of solid desiccants per unit mass, however, is usually less than that of liquids. Silica gels are formed by condensing soluble silicates from water or solvent solutions. They are relatively inexpensive and easy to customize. They are available in beads as large as 0.2 in (0.5 cm) in diameter or as fine powders. Zeolites are aluminosilicate minerals that occur in nature. They have an open crystalline lattice that attracts and traps molecules, such as water vapor, like objects in a cage. Particular atoms of the material determine the size of the openings or gaps in the cage-like structure, which in turn governs the size of
DESICCANT MATERIALS
There are many different types of solid and liquid desiccant materials. The common element is their capacity to collect moisture. Desiccants that collect moisture through
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the molecules that can be adsorbed. Synthetic zeolites (molecular sieves) are manufactured crystalline aluminosilicates. By controlling the temperature of the thermal manufacturing process and the materials used, the zeolites structure and surface characteristics can be closely controlled. While more costly than naturally occurring zeolites, this process can produce a more uniform product. Activated alumina are manufactured oxides and hydrides of aluminum. Their structures can be controlled by the gases, temperatures, and duration of the thermal manufacturing process. Carbons are usually used to adsorb gases other than water vapor, because they have an affinity for nonpolar molecules, such as organic solvents. Carbons have a large internal surface and very large capillaries. Solid polymers are long molecules twisted together like strands of string. The sodium ions in these molecules can each bind several water molecules, and the spaces between the strands can also contain condensed water. This polymer's capacity exceeds that of many solid adsorbents, particularly at high relative humidities.
above 33% it will become supersaturated and form solid salt. Compared with its use as a solid, liquid LiCl has a far greater ability to hold water molecules. In a solid state, each LiCl molecule can hold two molecules of water. As a solution in equilibrium with air at a 90% RH, each molecule can hold 26 molecules of water. Glycols exhibit similar characteristics to hygroscopic salt solutions, except that they require much higher equilibrium concentrations and tend to evaporate. Typical equilibrium concentrations are greater than 90%, which is more than double that of hygroscopic salts. Systems, therefore, require far more solution given that there is only a small percent of water to work with. Also due to the tendency to evaporate, requiring frequent solution replacement, glycols are more commonly used for lower temperature applications when evaporation rates are reduced. Commonly used glycols are triethylene glycol and propylene glycol. Propylene glycol is commonly used in food processing and frost-free applications due to its low toxicity. In other types of applications, triethylene glycol is used due to its lower evaporation rate.
LIQUID ABSORBENTS
Liquid desiccants have a vapor pressure lower than water at the same temperature. The air passing over the solution approaches this reduced vapor pressure and is dehumidified. If the vapor pressure of the solution is greater than that of the water, the air is humidified. At a given concentration and temperature, liquid desiccant solutions are in equilibrium with air at a fixed humidity. The vapor pressure of liquid absorption solution is directly proportional to its temperature and inversely proportional to its concentration. If concentration is reduced or the temperature is increased, the vapor pressure increases. If concentration is increased or temperature reduced, the vapor pressure decreases. Hygroscopic salt solutions are water solutions with salts such as lithium chloride (LiCl) or calcium chloride (CaCl). While more costly than CaCl, LiCl is more commonly used because it is more effective and less corrosive. At 40% concentration and 70F (21C), LiCl is in equilibrium with air at 19.3 grains/lbm (0.0027 kg/kg). The concentration is determined by the specific gravity. Concentration limits determine the maximum and minimum allowable solutions. If cooled sufficiently, LiCl will form ice at concentrations below 33%. At concentrations
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150 140 130 120 110 Moisture Removal (LBS/Hr/Sq Ft) 100 90 80 70 60 50 40 30
IR 80 % RH 70 CO 60 % N % 50 D. % LV G
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air and keep the desiccant solution at a fixed concentration, a small amount of solution is transferred from the conditioner to the regenerator. Heated desiccant solution contacts a scavenger airstream and is concentrated by evaporation of water from the solution to the air. Heat flow to the heat exchanger is modulated to match the moisture load in the conditioner. The amount of moisture
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Fig. 39-7 Regenerator Capacity in Moisture Removed vs. Temperature/Pressure. Source: Kathabar Systems
Fig. 39-6 Small Packaged LiCl Liquid System. Source: Kathabar Systems
absorbed in the conditioner is released in the regenerator to maintain solution concentration. A small amount of the concentrated solution is then transferred back to the condenser. Liquid systems typically range in capacity from 1,000 to 85,000 cfm (28 to 2,400 m3/m). RH levels ranging from 90 to 18% can be achieved by adjusting the solution concentration. Liquid systems are generally more expensive than solid systems, especially in smaller capacities. However, operating cost efficiency is generally equal to or better than any other desiccant system in this range. They are very controllable under part loads. They also tend to be more complex and require more maintenance. Commercial coolants, well, river, and pond water, cooling tower water, and direct expansion systems may all be used for cooling. Heat can be supplied to the regenerator in many forms, including direct fuel-firing, steam, hot water, hot air, or exhaust gases. Regenerators can operate effectively with heat source temperatures of as low as 100F (38C), providing opportunities for effective use of recovered low-grade heat. Figure 39-7 shows the regenerator capacity for a liquid system in moisture removal versus water temperature or steam pressure. As indicated on the performance curves, with 200F (93C) hot water and 25% RH air, regenerator capacity is 40 lbm/h/ft2 (195 kg/h/m2). Figure 39-8 is a nomograph used to calculate regenerator heat requirements
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Fig. 39-9 Illustration and Equilibrium Diagram of Liquid Spray Tower Process. Source: Munters Cargocaire and Mason Grant Company
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Desiccant Heater
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Fig. 39-10 Solid Packed Tower System Illustration with Equilibrium Diagram. Source: Munters Cargocaire and Mason Grant Company
for a LiCl liquid system. In this example, the regenerator load of 35.8 lbm/h/ft2 (175 kg/h/m2) is located on the left-hand scale. A line is drawn through the two RH curves at the bottom of the chart at 25% RH. From the RH curves on the right, a line is extended upward from 25% RH to the 55F (13C) conditioner leaving temperature. Lines are extended from both the RH curves at the bottom left and the conditioner leaving temperatures. These lines intersect at 2,075 Btu/lbm (1.34 kWh/kg). Multiplying this by the total regenerator load in lbm/h (or kg/h) yields the total regenerator heat input requirement for a given application. Figure 39-9 illustrates a representative liquid spray tower and shows the process graphically on an equilibrium chart. In the sorption process (1-2), the desiccant absorbs water in the conditioner, becoming warmer and rising in vapor pressure. At Point 2, the desiccant is in the sump. It has absorbed a relatively large amount of water and its surface vapor pressure is too high to attract more moisture. In the desorption process (2-3), the dilute desiccant passes through the heater and its vapor pressure rises. When it is sprayed into the reactivation air, the high pressure forces the water out of the desiccant and into the air. The desiccant returns from the regenerator to the sump dry and concentrated, though still warm and at a high vapor pressure. In the cooling process (3-1), part of the liquid is
pulled out of the sump and circulated through a heat exchanger connected to a chiller or tower. It exits the process both dry and cool and is then circulated back through the conditioner to start the process again.
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1 Sorption
2 Desorption
Desiccant heater Horizontal rotating desiccant bed 250 F 200 F Vapor Pressure at the Desiccant Surface 150 F
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Fig. 39-11 Illustration and Equilibrium Diagram of Rotating Horizontal Bed System. Source: Munters Cargocaire and Mason Grant Company
points as low as -60F (-51C). These systems may range in capacity from as low as a few cfm to 5,000 cfm (1 to 140 m3/m). The sorption process (1-2) occurs in one tower, while the desorption process (2-3) occurs in the other. The thermal energy that drives the desiccant cycle is added to the process by heating and cooling the reactivation and process airstreams. The tower design can result in a changing outlet condition. As the desiccants begin to approach saturation, they do not dry the air as well as when they are fully reactivated. If this is not acceptable, the airflow must be changed to a fresh tower before the first tower becomes saturated. Tower systems tend to be large because air velocities are kept very low to avoid lifting and damaging the desiccant.
ROTATING BEDS
Rotary dehumidifiers have one or more beds with solid granular desiccants. The beds handle air to be dried and regeneration air simultaneously. The two airstreams are separated by seals to prevent mixing, and the beds are physically rotated within the casing to expose one portion of the desiccant to the process stream and one portion to the regeneration stream.
As the desiccant leaves the reactivation side, it is still warm. It is cooled by the process air during the first few degrees of rotation through the process side. The desiccant then dries the rest of the process air. As the desiccant is rotated into the hot reactivation air, it is heated, thus releasing moisture. Typically, rotating bed systems range in capacity from 60 to 20,000 cfm (2 to 570 m3/m) and offer dewpoint temperatures ranging from -5 to 60F (-21 to 16C). They can range as low as -60F (-51C) using zeolites. These systems have the lowest capital costs of all desiccant systems. They have a simple design that is expandable and that can be easily repaired. In smaller systems, they are generally more cost-effective than liquid systems, since the low first cost tends to outweigh operating cost. However, the process and reactivation airflows are parallel rather than counterflow. This is done to minimize pressure differences and, therefore, leakage within the bed. This arrangement reduces the heating efficiency in reactivation, which raises operating costs above other types of desiccant systems. Figure 39-11 illustrates a rotating horizontal bed system with an equilibrium chart. In the sorption process (1-2), the desiccant dries out the process air and picks up moisture. As the trays rotate into the hot reactivation air
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(2-3), the desiccant is heated and releases moisture in the reactivation/desorption process. The desiccant exits dry, but still warm from the reactivation process. In the cooling process (3-1), the desiccant is cooled by the process air during the first few degrees of rotation through the process side. The dry cool desiccant is then ready to dry the rest of the process air.
ROTATING WHEEL
The desiccant wheel functions much like the rotating
bed. The difference is that the rotating bed type uses a wheel of granular desiccant in a packed bed and the wheel type uses a wheel of corrugated heat exchanger type surface. This results in different heat and mass transfer and pressure drop characteristics. The rotating desiccant wheel structure is lightweight and porous and can use several kinds of solid desiccants. The corrugated design combines high surface area with low total mass and presents minimal air pressure resistance, resulting in good efficiency. The surface can also be loaded with more than one type of desiccant in order to match very specific air treatment requirements. Figure 39-13 provides an illustration and equilibrium diagram of a rotating desiccant wheel. In the sorption process (1-2), the desiccant picks up moisture as the process air flows through the flutes formed by the corrugations, becomes saturated, and its surface vapor pressure is elevated. As the wheel rotates into the reactivation airstream (2-3), the hot reactivation air causes its surface vapor pressure to rise farther, causing the desiccant to release its moisture in the desorption process. As the hot desiccant rotates into the process air (3-1), a small portion of the process air cools the desiccant, allowing it to collect more moisture from the rest of the process airstream.
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Fig. 39-12 Illustration of Multiple Vertical Bed System. Source: Munters Cargocaire and Mason Grant Company
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Fig. 39-13 Illustration of Rotating Wheel with Equilibrium Diagram. Source: Munters Cargocaire and Mason Grant Company
Rotating wheel systems are becoming increasingly more common as they serve all conditions down to -60F (-51C) dewpoint. They are similar in cost to multiple vertical beds and offer similar or superior efficiencies under most loads. They are generally less costly than liquid systems and dry tower systems down to -30F
(-34C) dewpoint. When solid adsorbent, rather than absorbent, salts are used in the wheel, maintenance is potentially the lowest of all types of desiccant system. This technology is also becoming popular for use in conjunction with commercial space cooling systems. Figure 39-14 shows a plan view and Figure 39-15 is a
Fig. 39-14 Plan View of Double Rotating Wheel System. Source: ICC Technologies
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180F D.B.
Regeneration Hot Water Coil 137F D.B. 68F D.B. Evaporative Cooler
Outdoor or Return Air 95F D.B./75F W.B. 98 gr/lb Desiccant Wheel 150F D.B. 52 gr/lb Thermal Wheel 81F D.B. 52 gr/lb
Fig. 39-15 Illustration of Double Rotating Wheel System. Source: ICC Technologies
cutaway illustration of a double rotating wheel system, with representative air conditions shown. This system features two wheels. First, the air is dried in the desiccant wheel, then the air temperature is reduced in the second (thermal wheel) before it is delivered to the conditioned space. The second wheel, which is metal, serves as a heat exchanger. Most of the heat from the air leaving the desiccant wheel is removed to preheat the regeneration airstream, thereby reducing the external heat source requirement. As the wheel gives off heat to the incoming air on the regeneration side, it is cooled and rotates back to the conditioning side to extract heat from the hot dry airstream. As shown, outdoor or building exhaust air entering the regeneration side of the system first passes through an evaporative cooler, which cools the incoming air and raises its RH. The cooler incoming air serves to increase the efficiency of the
Fig. 39-16 Installation of Packaged Rooftop Unit Featuring Double Rotating Wheel System. Source: ICC Technologies
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Fig. 39-17 Cut-Away View of Packaged Double Rotating Wheel System Showing Rotating Wheel Technology. Source: ICC Technologies
thermal wheel. Figure 39-16 shows an installation of this technology in a packaged rooftop unit. Figure 39-17 is an open-case view, showing the rotating wheel.
in those parameters. The range of vapor pressures that may be encountered varies widely. For example, consider the range of vapor pressures for a constant dry-bulb (db) temperature of 70F (21C). At 100% RH, the dewpoint temperature is 70F (21C) and the corresponding vapor pressure is 0.74 in. Hg (2.5 kPa). At 10% RH, the dewpoint temperature is 12F (-11C) and the corresponding vapor pressure is 0.07 in. Hg (0.24 kPa). Each desiccant has a different sorption characteristic that affects system performance. With liquid absorption solutions, vapor pressure is directly proportional to its temperature and inversely proportional to its concentration. A graphical representation of the relationship of moisture capacity to RH when desiccant and air are at the same temperature can be shown as a capacity isotherm. Figure 39-18 shows representative capacity isotherms of four desiccants at 77F (25C). Capacity is expressed as the weight of water retained as a percentage of the dry weight of the desiccant. As shown, at 20% RH, molecular sieve holds about 20%, while LiCl holds 35%. Note that large variations from these isotherms occur because manufacturers use different optimization methods for a given desiccant, depending on the particular application. Also note that these capacity figures assume that the desiccant has enough time to absorb the moisture. In practice, capacities are lower due to the need to
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Desiccant system performance depends on several factors. These include: The sorption/desorption characteristics of the particular desiccant used. The amount of desiccant exposed to the reactivation and process airstreams by the system. The process and reactivation air velocity through the desiccant. The process air moisture and temperature levels. The reactivation air moisture and temperature levels. Each type of system will offer varied performance depending largely on the operating conditions. Some systems are more effective at higher dewpoint temperatures, while others perform better at very low dewpoint temperatures. The best desiccant for a particular application will depend on the range of water vapor pressures that will occur in the air, the temperature level of the available regeneration heat source, and the moisture sorption and desorption characteristics of the desiccant operating with-
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Fig. 39-18 Representative Capacities of Various Desiccants. Source: Munters Cargocaire and Mason Grant Company
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remove water from a fast-moving airstream. Regeneration energy requirement consists of the sum of the heat required to raise the desiccants vapor pressure higher than that of the surrounding air, plus the heat required to vaporize its moisture content, plus the heat from desorption of the water from the desiccant. For a given system, desiccant performance will be affected by the reactivation temperature level. Liquid desiccants, for example, can achieve a high level of performance at low reactivation temperatures, while the performance of solid desiccants improves considerably with increasing temperatures. Consider the performance of the rotating wheel system. Figure 39-19 illustrates the changes in moisture and db temperature throughout the desiccant system on both the process air and reactivation air sides and shows the corresponding performance curves. On the process
side, air enters at conditions of 70F (21C) and 56 gr/lbm (0.0080 kg/kg) at about 50% RH. The process air exiting the dehumidifier is both warmer and dryer at 109F (43C) and 13 gr/lbm (0.0018 kg/kg). On the reactivation side, outside air passes through a heater and proceeds to heat the desiccant in the wheel. As the desiccant gives up its moisture, the air becomes moist and cool. System performance is plotted graphically in Figure 39-20. With this system, performance is optimized with high initial moisture in the process air, high reactivation air temperature, and low process air velocity:
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Fig. 39-20 Performance Plots for System Shown in Fig. 39-19. Source: Munters Cargocaire and Mason Grant Company
Reactivation heater Legend SCFM F Gr/Lb
Process air
Fig. 39-19 Airflow Temperature and Humidity Change Diagram of Rotating Wheel System With Performance Curves. Source: Munters Cargocaire and Mason Grant Company
As the moisture content of the entering process air is decreased, the final moisture level will also decrease, but so will the total amount of moisture removed. As the process inlet air temperature is reduced, the moisture leaving the process will also be reduced. This is due to the fact that performance is improved because the desiccant is cooler and, therefore, has a lower surface vapor pressure which allows it to attract more moisture. As the air velocity through the system decreases, so does the outlet moisture level. However, lower air velocity requires a larger, more costly system. In most cases, the trade-off is not economical, except when very low moisture levels are required. Generally, the hotter the desiccant, the more easily it
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gives up moisture. The dryer the desiccant, the more moisture it can absorb when it rotates into the process airstream. Thus, performance increases with increased reactivation temperature.
DESICCANT APPLICATIONS
Generally, the potential benefits achieved with desiccant systems include energy savings, increased productivity, equipment and product protection, and improved environmental conditions. In industry, desiccant technology has been widely used for several decades for applications that require very low specific humidity in the range of 45 gr/lbm (0.0064 kg/kg) and less such as the case with clean rooms and other specialty operations. Given recent improvements in desiccant technologies, desiccant systems are being used more often and for more types of applications every year, inclusive of commercial space conditioning. Following are some common types of desiccant applications.
CONDENSATION
AND
CORROSION PREVENTION
Desiccant systems are used to protect heavy machinery from rusting and light equipment, such as computers and telecommunication gear, from microscopic level corrosion. Ferrous metals, such as iron and steel, can be protected by desiccants from moisture related corrosion. They are also used to eliminate sweating due to water vapor condensation on cold surfaces. Air drying is used to blanket the mold surface in plastic injection molding to protect the equipment and the product. It also allows for lower coolant temperatures, which reduces cycle time, thereby increasing productivity. Ice rink surface temperatures are colder than the dewpoint of the conditioned air, causing condensation that softens and distorts the ice surface. Desiccant systems can reduce operating costs and refrigeration capacity requirements, improve the quality of the ice and surrounding conditioned air, and eliminate corrosion of structural members. Hospital operating rooms are maintained at low temperatures to ensure surgeon comfort and productivity in spite of the heavy gowning necessary to avoid transmission of infectious diseases. Desiccant systems allow compliance with humidity specification required by licensing authorities at such low temperatures. Refrigerated warehouse loading docks can be hazardous for workers who load and unload trucks at high speed across floors that are slippery with condensation.
Desiccant systems remove condensed moisture, providing safety while removing the latent load from the warehouse refrigeration system. Breweries and many other food processing facilities use coolant and process temperatures at or below freezing. Desiccant systems are used to prevent condensation, frost, and ice build-up and to prevent product degradation due to condensation or frost. In supermarkets (which are highly energy intensive facilities), desiccants eliminate sweating from display cases and products, reduce reheat and defrost requirements, and improve the efficiency of the mechanical compression refrigeration systems. Typically, desiccants are used to lower the specific humidity of the facility below the dewpoint temperature of the medium-temperature cases. This also serves to reduce the defrost cycle time on the low-temperature cases. Sophisticated systems can be built around the rotary wheel dehumidifier to take advantage of hot gas for winter heat and use a desuperheating coil to preheat regeneration air. Capital costs of supermarket desiccant systems are now comparable to conventional electric-driven vapor compression systems in new construction where the benefits of reduced ductwork, fan capacity, and refrigerated case requirements can be attained. Fan usage can also be reduced because the airflow requirements are reduced to handle only the sensible load.
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scopic. Processing becomes extremely difficult when they absorb moisture and become sticky. Desiccant systems can improve processing efficiency and protect the products during storage. All types of powder, flour, vegetables, coffee, gum, and dozens of other products can be protected to improve processing time and/or storage. Desiccant systems are used in clean rooms for production of microcircuits. They prohibit moisture absorption by the polymers used to mask the circuit, which would interfere with the etching process that forms the circuit lines. Desiccants also speed up the curing of laminated circuit boards and protect the thin transparent films used for many applications from absorbing moisture and bubbling. Other industries that use desiccants to prevent moisture regain include chemical preparation, rubber and plastic fabrication, metals treatment, photographic production, wood processing, cosmetic manufacturing, printing, painting, and glass lamination. Figure 39-21 shows a packaged 2,250 cfm (64 m3/m) gas-fired desiccant dehumidification system that is commonly applied in moisture regain prevention applications. This unit can be installed directly in the product room and used to circulate air without special ductwork.
peratures and low dewpoints. Dozens of food and drug products ranging from seeds and cereal to food powders are produced with higher quality when dried at low temperature and low humidity levels. Desiccants allow the drying process to be accelerated by establishing a deep wet-bulb (wb) depression. This refers to the difference between the db and wb temperatures of the air surrounding the product and the vapor pressure at the surface of the material being dried and the vapor pressure in the air.
PRODUCT DRYING
Desiccant systems can be effectively applied for product drying, regardless of the temperature, whenever there is a need for a low dewpoint. Additionally, they are effective for speeding product drying under conditions where temperature must be limited to 120F (49C) or less to avoid product damage. Enzymes and other food preserving ingredients, such as yeast, are protected from damage by drying at low tem-
Fig. 39-21 2,250 cfm Packaged Gas-Fired Desiccant Dehumidification Unit Commonly Applied for Moisture Regain Prevention. Source: Munters Cargocaire
building and is dried to a point that satisfies the full latent load. This can be integrated into a down-sized (smaller capacity) chiller or DX system with fan coil air handling units (AHUs). This arrangement allows the refrigeration system to operate at the increased thermal efficiency allowed by higher suction temperatures. When airflow can be reduced, duct and fan capacities can be reduced, lowering associated capital and operating costs. Determination of the economic viability of incorporating a desiccant unit into a mixed system will depend on many factors. Mixed system strategies are more likely to be cost-effective when large quantities of humid outside air are required due to high exhaust rates, or for facilities with high internal latent gains from crowds of people. As general rules of thumb, a mixed system featuring a desiccant unit may prove economical under any of the following circumstances: Conventional cooling alone cannot meet year-round dehumidification requirements. Electric power costs are high and/or thermal energy costs are low. Latent heat loads are high relative to sensible heat loads. Latent and sensible heat loads peak at different times.
The system is required to operate dry with very low RH or no condensation on the cooling coils. Given one or more of these circumstances, several mixed system configurations may be possible. Figure 39-22 illustrates four different configurations that can be used in mixed systems: In System 1, the desiccant is used only to dry precooled makeup air. In System 2, the desiccant is used to dry a blend of precooled makeup air and return air. In System 3, the desiccant is used to dry a blend of makeup air and return air which is precooled. In System 4, the desiccant is used to dry a blend of makeup air and return air that is not precooled.
AND
BUILDING
In addition to energy cost saving HVAC applications, desiccants can be used to reduce many biological hazards. Hospitals and health-care facilities are especially sensitive to such hazards. Commercial buildings, hotels, and other public facilities are also vulnerable. Buildings can have
Desiccant Unit
System 1 Pre-cool the make-up air and dehumidify it with a desiccant unit before the air blends with return air from the room. When the system requires a large proportion of makeup air, this schematic is generally the most economical to install and operate.
Return Air System 2 Pre-cool the make-up air, then blend it with the return air before dehumidifying with a desiccant unit. If the system does not use enough make-up air to provide complete dehumidification using system 1, this configuration is often the most economical choice. Desiccant Unit Sensible Heating & Cooling Cooling Coil Make-up Air
Return System 3 Pre-cool the blended make-up air and return air before dehumidifying with a desiccant unit. Cool air improves the performance of the dehumidifier, increasing the capacity of the system, and in some cases allowing the designer to use a smaller unit.
Return Air System 4 Blend the make-up air and return air before dehumidifying with a desiccant unitno precooling. If the make-up air does not carry a significant proportion of the moisture load, it may not be useful to pre-cool in front of the desiccant unit. Desiccant Unit Sensible Heating & Cooling Make-up Air
Return Air
Figure 39-22 Representative Mixed System Configurations. Source: Munters Cargocaire and Mason Grant Company
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problems with microbiological Humid Air to Weather contamination (i.e., mold, mil253 MBtu/h dew, fungus, bacteria) in stag1,730 cfm nant condensate pans and the 95 insulation in ducts down110 gr/lb stream of cooling coils. Heater Purge Fresh Air 400 cfm 4,600 cfm In HVAC applications, 120 5,000 cfm 4,600 cfm 2,400 cfm desiccants keep evaporator 29 gr/lb 83 130 95 81 gr/lb 29 gr/lb coils dry to minimize the 110 gr/lb Heat Pipe Desiccant Post Cooler Bed opportunity for microbiological growth on HVAC coils, 10,000 cfm 5,400 cfm 65 drain pans, and duct work. 72 43 gr/lb 55 gr/lb Chilled Drying with desiccants upReturn Air 45% rh Water 8,000 cfm stream of cooling coils can 72 55 gr/lb result in improved indoor air quality, reduced solvent emis- Fig. 39-24 Energy Balance Schematic of Desiccant Bed System for Operating Rooms. sions into the air, and protec- Source: Munters DryCool tion from mold and mildew a few hours during the day and the unit is sized for peak growing on building structures and furnishings. Desiccant systems are sometimes used in hospital demand, the sensible load is quickly satisfied and the unit operating rooms to minimize moisture. Figure 39-23 turns off, circumventing dehumidification and keeping the shows a desiccant bed system used for hospital operating moisture load high. Moisture can continue to build up, rooms. Figure 39-24 shows an energy balance schematic creating mold growth and odor problems. of this type of system. Liquid desiccant systems are sometimes used to remove bacteria, while providing dehumidification. This is accomplished by passing air directly DESICCANT DEHUMIDIFICATION EXAMPLES Consider an industrial application in which pharmathrough the system. ceutical mixing, tableting, and packaging operations are When combined with the benefits of air quality and building protection, desiccant systems may be effectively carried out and require a moisture level of 10% RH and a applied at hotels and motels. Typically, room thermostats temperature of about 70F (21C) in a 9,600 ft2 (892 m2) responding to the db temperature turn on the packaged internally located room. To maintain these conditions, the terminal air conditioner only when the sensible temperature absolute humidity is specified at a 13F (-11C) dewrises above the setpoint. Since the room is only occupied for point, which corresponds to 11 gr/lbm (0.0015 kg/kg). The internal sensible heat gain is 41,000 Btu/h (12 kW) and the moisture load from people and door openings totals 105,000 gr/h (6.8 kg/h). Due to exhaust requirements, 800 cfm (23 m3/m) of makeup air is required at a design condition of 91F (33C), with a moisture level of 147 gr/lbm (0.0210 kg/kg). The incoming air is precooled to 50F (10C) and 54 gr/lbm (0.0077 kg/kg), adding 154,800 gr/h (10.0 kg/h) to the moisture load, which must be removed by the dehumidifiers. The airflow required to overcome the sensible heat load can be calculated as:
Fig. 39-23 Desiccant Bed System Applied in Hospital Operating Room. Source: Munters DryCool
(cfms ) =
Qs 1.08(T1 T2 )
(39-1)
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Where: 1.08 = Btu/h per cf of air per min. per F Thus, 41,000 Btu/h 1.08(70 F 60 F) = 3,796 cfm (107 m 3/min)
Given an estimated return airflow rate of 3,000 cfm (85 m3/m) at 70F (21C), the blended supply air temperature is: (3,000 cfm x 70 F)+(800 cfm x 50 F) 3,800 cfm and the blended moisture condition is: 3,800 cfm = 20 gr/lbm (0.0028 kg/kg) The condition of the supply air required to remove the room moisture load of 105,000 gr/h (6.80 kg/h) with 3,800 cfm (108 m3/m) can be determined based on the following equation: Capacity = Airflow x Air Density x Moisture Difference (39-2) Given a return air moisture level of 11 gr/lbm (0.0015 kg/kg), the required moisture level of the supply air can be calculated from the following series of equations: 105,000 gr/h = 3,800 cfm x 60 min/h x 0.075 lbm/cf/min x (11 gr/lbm x gr/lbm); 11 gr/lbm 105,000 gr/h 17,100 lbm/h Thus, the 3,800 cfm (108 m3/m) of supply air must be at a moisture level of 4.9 gr/lbm (0.0007 kg/kg). To allow for about 15% excess capacity, a desiccant unit with a capacity of about 120,000 gr/h (7.77 kg/h) is desired. From the performance curves for a rotary LiCl dehumidifier, it is shown that air entering the unit at 72F (22C) and 20 gr/lbm (0.0028 kg/kg) can exit between 1.5 and 5 gr/lbm (0.0002 and 0.0007 kg/kg), depending on the velocity of the air through the desiccant bed. A unit with 7.5 ft2 (0.7 m2) of free face area will process 3,800 cfm (108 m3/m) with a velocity of 506 ft/min (154 m/min) so = 4.9 gr/lbm (0.0007 kg/kg) = 66 F (19 C)
that air will leave the unit at a moisture level of 4 gr/lbm (0.0005 kg/kg). The total capacity of this unit would be 119,700 gr/h (7.76 kg/h). This example is shown in Figure 39-25 and the performance is plotted in Figure 39-26. As shown, the precooling of the 800 cfm (23 m3/m) of outside air reduces the moisture level from 147 to 54 gr/lbm (0.0210 to 0.0077 kg/kg) and the temperature from 91 to 50F (33 to 10C). The outside air then blends with the return airflow to produce 3,800 cfm (108 m3/m) of supply air at a moisture level of 20 gr/lbm (0.0029 kg/kg) and a temperature of 66F (19C). This airstream exits the desiccant unit at 4 gr/lbm (0.0006 kg/kg) and 86F (30C). It is important to note that had the outside air not been precooled, the desiccant unit specified would be about twice the capacity and the application would be less economical. Since conventional refrigeration cycle systems perform more effectively at high temperature and high moisture contents and desiccants are more effective at lower temperatures and drier conditions, combining the two technologies to dehumidify fresh air can be less costly than using either technology exclusively. Given the condition of the air exiting the desiccant unit of 4 gr/lbm (0.0006 kg/kg) and 86F (30C), the post-cooling requirement is calculated as: 3,800 cfm x 1.08 x (86 F 60 F) 12,000 Btu/ton = 8.9 tons (31 kW r)
Figure 39-27 is a schematic diagram of the entire HVAC system serving the conditioned space. The summary table lists values for airflow, temperature, and moisTemperature Moisture Airflow CFM F Gr/Lb 150 Temperature (F) Moisture (gr/lb)
100
50
3000 70 11
Return air
Fig. 39-25 Changes of Temperature and Moisture of Air Moving Through System. Source: Munters Cargocaire and Mason Grant Company
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Te m pe ra tu re
75 70 65
2 50
40-55
10
20
30
40
50
60
Pr o (f c e ee s t sA pe i r rV m e in lo ut cit e) y
Fig. 39-26 Performance Plots for System Example. Source: Munters Cargocaire and Mason Grant Company
ture at various locations. Note that the 800 cfm (22.6 m3/m) of incoming outside air (Location A) balances 500 cfm of exhaust (14.2 m3/m) at Location G and 300 cfm (8.5 m3/m) of air leakage. This systems controls are as follows: Room air pressure is controlled by a differential pressure controller, which automatically adjusts the
fresh air intake damper. As air pressure exceeds the set differential, the damper begins to close to reduce incoming air. Dehumidifier capacity is controlled by a bypass damper that passes air around the system as humidity levels are less than design conditions. As a dewpoint controller signals a humidity change, the bypass damper is modulated. Desiccant system energy use is controlled by a temperature controller in the reactivation airstream. This minimizes energy use by reducing the energy of the reactivation heaters when the temperature rises above the set point of 120F (49C), which indicates that all of the moisture absorbed on the process air side has been desorbed in reactivation. Chilled water flow through the outside air precooling coil is controlled by a three-way valve, which responds to a controller located downstream of the coil that is set at 50F (10C). The post-cooling coil, which sets the final delivered air temperature, is controlled in the same manner, with the temperature sensor located in the conditioned space to maintain constant temperature. In a variable flow system, two-way valves could be used to accomplish this control function more economically. A supply air heating coil is used to provide heat whenever room temperature drops below 68F (20C). This is controlled by the same sensor that controls the post-cooling coil.
Re
ac
tiv
at
io n
C D F E C T A
F C C T H 300 cfm leaves the room through cracks and doors Bypass only at low load
B
F
P
C G
Airflow Location ( cfm ) A B C D E F G 800 3800 3800 3800 3800 3800 500
Fig. 39-27 Schematic Diagram of HVAC System. Source: Munters Cargocaire and Mason Grant Company
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