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Cycling Refrigerated Air Dryers, 2,500 to 12,500 SCFM

Central-plant dryers for 600 to 3,000 hp of installed compressors

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Cycling Refrigerated Air Dryers, 2,500 to 12,500 SCFM

Central-plant dryers for 600 to 3,000 hp of installed compressors

Above 2,500 SCFM the dryer serves a central plant: four or six large screw compressors, or a centrifugal machine, on a sequencer that runs whatever the plant needs hour by hour. Demand in such a plant swings from a single machine on the night shift to every compressor loaded at the afternoon peak, which is precisely the profile that load-following refrigeration was built for.

Four current series use three approaches. Digital-scroll dryers unload their scroll compressors for part of every cycle, and the larger sizes split the duty across two to five refrigeration circuits. The variable-speed dryer drives inverter scroll compressors so refrigeration output tracks the air load continuously. The modular skid gangs two to six water-cooled phase-change modules behind a common header, with the redundancy a multi-module system brings.

Every model is 460 V three phase on 6 in to 12 in flanges, and every series except the skid is offered air-cooled or water-cooled.

  • Rated 2,500 to 12,500 SCFM at 100 psig, 100°F inlet and 100°F ambient
  • Digital-scroll, inverter-driven and modular phase-change capacity control
  • 6 in to 12 in flanged headers; 460/3/60 with other voltages on request
  • Networked controllers with energy monitoring on the digital-scroll and skid lines
HES Series refrigerated air dryer, three-quarter view

Every model from 2,500 to 12,500 SCFM

Fifty-two flanged models at 100 psig, 100°F inlet and 100°F ambient; a W in the part number marks a water-cooled build.

PART NUMBER SERIES SCFM CONNECTION VOLTAGE STATUS
AES-2500A AES Series 2,500 6 in flange 460/3/60 Current
AES-2500W AES Series 2,500 6 in 460/3/60 Current
AES-3000A AES Series 3,000 6 in flange 460/3/60 Current
AES-3000W AES Series 3,000 6 in 460/3/60 Current
AES-3500A AES Series 3,500 6 in flange 460/3/60 Current
AES-3500W AES Series 3,500 8 in 460/3/60 Current
AES-4000A AES Series 4,000 6 in flange 460/3/60 Current
AES-4000W AES Series 4,000 8 in 460/3/60 Current
AES-4500A AES Series 4,500 8 in flange 460/3/60 Current
AES-4500W AES Series 4,500 8 in 460/3/60 Current
AES-5250A AES Series 5,250 8 in flange 460/3/60 Current
AES-5250W AES Series 5,250 8 in 460/3/60 Current
AES-6000A AES Series 6,000 8 in flange 460/3/60 Current
AES-6000W AES Series 6,000 8 in 460/3/60 Current
AES-7000A AES Series 7,000 10 in flange 460/3/60 Current
AES-7000W AES Series 7,000 10 in 460/3/60 Current
AES-8000A AES Series 8,000 10 in flange 460/3/60 Current
AES-8000W AES Series 8,000 10 in 460/3/60 Current
AES-8750A AES Series 8,750 12 in flange 460/3/60 Current
AES-8750W AES Series 8,750 12 in 460/3/60 Current
AES-10000A AES Series 10,000 12 in flange 460/3/60 Current
AES-10000W AES Series 10,000 12 in 460/3/60 Current
FLX 3000 FLX Series 3,000 8 in RF flange 460/3/60 Current
FLX 4000 FLX Series 4,000 8 in RF flange 460/3/60 Current
FLX 6000 FLX Series 6,000 10 in RF flange 460/3/60 Current
FLX 8000 FLX Series 8,000 10 in RF flange 460/3/60 Current
FLX 10000 FLX Series 10,000 12 in RF flange 460/3/60 Current
FLX 12000 FLX Series 12,000 12 in RF flange 460/3/60 Current
HES2500 HES Series 2,500 6 in flange 460/3/60 Current
HES3000 HES Series 3,000 6 in flange 460/3/60 Current
HES3750 HES Series 3,750 8 in flange 460/3/60 Current
HES5000 HES Series 5,000 8 in flange 460/3/60 Current
HES6250 HES Series 6,250 10 in flange 460/3/60 Current
HES7500 HES Series 7,500 10 in flange 460/3/60 Current
HES8750 HES Series 8,750 12 in flange 460/3/60 Current
HES10000 HES Series 10,000 12 in flange 460/3/60 Current
HES11250 HES Series 11,250 12 in flange 460/3/60 Current
HES12500 HES Series 12,500 12 in flange 460/3/60 Current
VDR 2600 A VDR Series 2,600 6 in ANSI flange 460/3/60 Current
VDR 2600 W VDR Series 2,600 6 in ANSI flange 460/3/60 Current
VDR 3150 A VDR Series 3,150 6 in ANSI flange 460/3/60 Current
VDR 3150 W VDR Series 3,150 6 in ANSI flange 460/3/60 Current
VDR 3700 A VDR Series 3,700 6 in ANSI flange 460/3/60 Current
VDR 3700 W VDR Series 3,700 6 in ANSI flange 460/3/60 Current
VDR 4200 A VDR Series 4,200 6 in ANSI flange 460/3/60 Current
VDR 4200 W VDR Series 4,200 6 in ANSI flange 460/3/60 Current
VDR 5050 A VDR Series 5,050 6 in ANSI flange 460/3/60 Current
VDR 5050 W VDR Series 5,050 6 in ANSI flange 460/3/60 Current
VDR 6350 A VDR Series 6,350 8 in ANSI flange 460/3/60 Current
VDR 6350 W VDR Series 6,350 8 in ANSI flange 460/3/60 Current
VDR 8450 A VDR Series 8,450 8 in ANSI flange 460/3/60 Current
VDR 8450 W VDR Series 8,450 8 in ANSI flange 460/3/60 Current

Four series for central plants

FLX Series refrigerated air dryer, three-quarter view

FLX Series:

6 models here: 3,000 to 12,000 SCFM

  • 3,000 to 12,000 SCFM
  • Cycling
  • 225 psig max inlet
HES Series refrigerated air dryer, three-quarter view

HES Series:

10 models here: 2,500 to 12,500 SCFM

  • 2,500 to 12,500 SCFM
  • Digital Scroll Cycling
  • 232 psig max inlet
AES Series refrigerated air dryer, three-quarter view

AES Series:

22 models here: 2,500 to 10,000 SCFM

  • 600 to 10,000 SCFM
  • Digital Scroll Cycling
  • 232 psig max inlet
VDR Series refrigerated air dryer, three-quarter view

VDR Series:

14 models here: 2,600 to 8,450 SCFM

  • 2,600 to 8,450 SCFM
  • Variable Speed Cycling
  • 203 psig max inlet

Sizing a plant, not a compressor

Sum the delivery of the compressors the sequencer can load at once and size the dryer to that, with margin for the summer inlet temperature. A plant with four 450 hp screws and one on standby is an 8,000 SCFM duty; if all five can run in August it is 10,000. Where the plant has grown in stages the dryer can too: the modular skid and the larger digital-scroll systems are built from modules, and the digital-scroll interface lets up to five cabinets share one header.

Modulate, invert or stop

Digital-scroll control unloads a running compressor for part of each cycle, which at 5,000 SCFM means several circuits sharing the load and no starts. Variable-speed control turns the compressor slower instead, and its inverter cuts power in proportion to load with the lowest part-load draw of the three. The modular skid stops and starts whole phase-change modules, so at 40 percent load only two of five modules run. All three hold a 37 to 38°F pressure dew point; the difference is in part-load power and in what happens when one circuit fails.

Air-cooled or water-cooled at this scale

A 5,000 SCFM air-cooled dryer rejects on the order of 100 kW into the compressor room and needs a fan deck and ducted exhaust to match. The water-cooled builds absorb roughly a third less power, stand in a smaller footprint, and use the tower loop a plant of this size already runs for its compressors; the modular skid is water-cooled only. Specify water-cooled wherever the loop exists and the water is below 85°F; specify air-cooled where the compressor room is a separate building with its own ventilation.

Redundancy and control

A single dryer on a central header is a single point of failure, so the multi-circuit machines can lose one refrigeration circuit and keep drying at reduced capacity, and the skid can have a module isolated for service while the rest run. Controllers on the digital-scroll and skid lines report energy use and dew point over Ethernet or RS485; the variable-speed dryer has a touch-screen controller with a standby mode on loss of airflow. The central plant section covers the header layout; the large non-cycling dryers are the alternative up to 4,200 SCFM for plants that never idle.

2,500 to 12,500 SCFM dryer questions

About 2,800 hp of rotary screw capacity, for example six 450 hp machines with one on standby. Centrifugal plants are sized from delivered SCFM on the compressor data sheets rather than from horsepower.

The variable-speed dryer has the lowest part-load draw because its inverter slows the compressor rather than unloading it, and it runs air- or water-cooled from 2,600 to 8,450 SCFM. The digital-scroll and modular skid systems save nearly as much and reach 12,500 SCFM.

No. The skid is built from water-cooled phase-change modules only, from 3,000 to 12,000 SCFM, and needs tower or chilled water. The digital-scroll and variable-speed series cover the same capacities air-cooled.

On the multi-circuit digital-scroll machines and the modular skid the remaining circuits or modules keep running at reduced capacity, so the plant loses some dew point margin rather than all of its dry air. A single-circuit dryer of this size should have a full-flow bypass and a service contract.

460 V three phase, with 380 to 420 V 50 Hz, 230 V and 575 V available on several series. Air connections run from 6 in flanges on the smallest units to 12 in on the largest, and water-cooled units add 2-1/2 in or larger water connections; the exact sizes are on each part number page.

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Quotes - Engineering - Sales