As a key post-treatment equipment of compressed air system, icing and overheating failure of
refrigerated Air Dryer will lead to higher dew point of air source, equipment shutdown, and even affect the operation of production line. As a ZAKF
Screw Air Compressor manufacturer with 20 years of industry experience and 60,000 square meters of production base, our monthly production capacity of refrigerated air dryers reaches 2,000 units, supporting CE/ASME and other global certifications and customization, and relying on 7 overseas warehouses to achieve 15 days of speedy delivery in Southeast Asia / Middle East. The following is the analysis of the core technology of anti-icing and overheating from principle to program.
I. Anti-icing Technology: Full Chain Control from Design to Operation and Maintenance
1. Intelligent Control of Evaporator Temperature
Dual Sensor Linkage Control: ZAKF adopts PT100 temperature sensors to monitor the temperature of the evaporator inlet and outlet in real time, and the PLC automatically starts the bypass of the electric heating when the outlet temperature is ≤2℃ to prevent condensate from icing. In the case of an automobile parts factory, this system reduces the icing failure rate from 15% to 0.3%.
Pre-cooler energy recovery: Recover the heat of inlet air to dry air through plate-fin pre-cooler, raise the outlet temperature of evaporator by 3-5℃, together with the brazing process of 60,000m2 production base, ensure that the heat exchange efficiency is 20% higher than that of traditional tube design.
2. Optimization of condensate drainage system
Automatic drain valve upgrade: Adopting ZAKF self-developed electronic drain valve, combined with liquid level sensor to achieve “zero air consumption discharge”, the drain cycle is shortened to 5-10 minutes (traditional mechanical valve takes 30 minutes), avoiding condensate accumulation and icing. This component is ASME certified and has a life expectancy of over 500,000 cycles.
Piping slope design: ZAKF customized solutions, according to the customer site design of condensate piping slope ≥ 3 °, and configured with electric heat tracing (-10 ℃ below the environment), a Russian oilfield project to solve the problem of icing of drainage water in extremely cold weather.
Second, anti-overheating solution: double guarantee of heat dissipation system and intelligent monitoring
1. Condenser heat dissipation efficiency enhancement
Inverter fan control: EC inverter fan is adopted to automatically adjust the speed according to the condensation temperature (normal ≤50℃), and when the temperature is more than 55℃, the fan speed is increased to 120%, and together with the fin stamping process of the 60,000 square meters base, the heat dissipation area is increased by 30% compared with the traditional design.
Water softening treatment: For areas with high hardness water quality (such as the Middle East), ZAKF dryer is equipped with electronic descaler as standard to prevent the condenser from scaling and leading to poor heat dissipation, and after the application of a Saudi petrochemical project, the overheating faults dropped by 80%.
2. Precise monitoring of the refrigerant system
Pressure sensor linkage: High and low pressure sensors monitor the refrigerant pressure in real time (normal high pressure 1.2-1.6MPa, low pressure 0.3-0.5MPa), and when the high pressure exceeds 1.8MPa, the system will automatically start the cooling fan and send out an early warning. ZAKF's CE-certified models support the remote alarm to be sent to the APP of the cell phone.
Optimization of the refrigerant charging: Adoption of quantitative charging equipment (accuracy ±1.5mm). Refrigerant charging optimization: adopting quantitative charging equipment (accuracy ±5g) to avoid overheating due to overcharging or undercharging. 20 years of experience in the industry has accumulated charging curves, so that the refrigerant leakage rate of the dryer in a Vietnamese electronics factory is less than 0.5%/year.
ZAKF Customization Advantage: Certification Strength and Global Service Support
Global Certification Model Customization
Support CE, ASME, ISO and other certification customization, for example, provide EU customers with dryers complying with PED 2014/68/EU, and optimize the structural strength through FEM analysis to ensure the stable operation under the environment of -20℃~+50℃. The annual output value of 500 million yuan of production capacity to ensure that the customization cycle ≤ 28 days.
Extremely fast delivery and after-sales network
7 warehousing bases reserve core spare parts (such as compressor, heat exchanger) for the dryer, 15 days of extremely fast shipment in Southeast Asia / Middle East; 3 overseas operating companies provide 24-hour after-sales response, when the dryer of a Thai food factory breaks down, ZAKF's local team completes the repair in 4 hours, which is 70% faster than the average in the industry.
Industry Application Cases: Practical Value of ZAKF Solutions
Anti-icing in the Electronics Industry: Customized CE-certified dryer for a semiconductor factory in Suzhou, stabilizes the dew point at -40℃ through the combination of pre-cooler + electric heating, and avoids the evaporator from icing, so as to guarantee the clean air source for the chip encapsulation process.
Overheating prevention in high temperature environments: The ASME dryer designed for an aluminum plant in the United Arab Emirates, equipped with an enlarged condenser and a desert-type dust screen, has operated continuously for 2 years without overheating faults in 50°C environments, with an 18% increase in efficiency compared to conventional models.
