Convert your fixed cycle dryer
to a Dewpoint Demand Cycle

All regenerative dryers, whether they are regenerated by purging air or by using heaters or blowers, consume energy during regeneration. The amount of energy required to operate a dryer may be very substantial. You can significantly reduce the energy consumption and, thus, the operating cost of your regenerative dryer by converting from a fixed time cycle to a Dewpoint Demand Cycle.

Most dryers are normally designed to function at the maximum operating conditions: highest flow rate, highest temperature, and lowest pressure. Fixed cycle dryers are constantly switching towers and are regenerating based on the worst case load when your actual operating conditions may be quite less. In fact, your air system could be turned off, yet the dryer is "dumb". It doesn't know this and keeps on regenerating; consuming energy and wasting money.

The SAHARA Dewpoint Demand Controller Series II (DDC II) converts a "dumb" dryer into a smart dryer that constantly matches the dryer's operations to the actual operating conditions. Air flow, pressure, temperature, and relative humidity are all variables that determine the actual amount of moisture that enters your dryer. With a fixed cycle dryer, the regeneration is constant and was designed for the maximum incoming water load while in actual practice the operating conditions are constantly varying, reducing the average amount of moisture entering the dryer.

Fixed cycle dryers cannot take advantage of a reduced water load. They keep on regenerating, purging your profits right down the drain. In most applications, the average water load into a dryer is about half of the maximum design load. This means that on the average you are only putting in half as much water as the dryer was designed to remove. By converting from a fixed cycle to a Dewpoint Demand Cycle, you allow the dryer to utilize it's full capacity regardless of water load and actually cut your operating cost in half.

Not only are your operating conditions varying, but the actual capacity of the desiccant in the dryer is also changing with time. Most dryers are provided with about twice as much desiccant as is really required to dry your air at the worst operating conditions. The reason for this is the desiccant loses capacity over time. For example, activated alumina, the preferred desiccant for regenerative dryers, starts out with a 25% dynamic design capacity. In other words, 4 pounds of alumina will hold 1 pound of water. Unfortunately, alumina loses capacity due to thermal shock in heat reactivated dryers, pressure shock in heatless dryers, and if the dryer is used with a lubricated compressor, it will quickly become contaminated with oil. Alumina loses it's water holding capability fairly rapidly; usually during the first year of operation, the actual dynamic capacity is reduced by half.

Every time a fixed cycle dryer switches towers it slightly damages the desiccant, reducing it's useful life. In addition, all of the switching valves are experiencing increased wear with every tower shift. If you convert from a fixed cycle to a demand cycle, you would increase the effective life of your desiccant, as well as reduce the maintenance required on the dryer's switching valves. Energy savings, reduced maintenance, increased profitability; all benefits of the SAHARA Dewpoint Demand Controller.

An added benefit of the system is the ability to keep a permanent record of dryer performance. The dewpoint meter has a 4-20 mA output, which can be connected to a strip chart recorder. By constantly monitoring dryer performance, you will see any change in performance before it's too late. Without an accurate indication of your dryer's dewpoint, you wouldn't know if there was a failure until there was wet, contaminated air caused by an instrument failure downstream, and that's simply too late. The SAHARA Dewpoint Demand Controller assures you of optimum dryer performance; any possible failure activates a high dewpoint alarm, notifying you of high dewpoint conditions at the dryer, before wet air goes downstream.

Installation of the conversion is done by simply connecting five wires from the controller to your dryer's electrical enclosure. The system will work with any regenerative dryer, heatless or heat reactivated, made by any dryer manufacturer.

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