Two-stage air dryer system

1. A two-stage dryer system comprising:

a pre-heater configured to receive a first compressed air and a second compressed air, the pre-heater including a first heat exchanger configured to transfer a first amount of heat from the first compressed air to the second compressed air;

a cooling dehumidifier configured to receive the first compressed air from the pre-heater, the cooling dehumidifier including:

a freezer in which a refrigerant circulates through a refrigeration cycle, and

a second heat exchanger including a first channel through which the first compressed air flows, a second channel through which the refrigerant of the freezer flows, and a static phase change material disposed between the first channel and the second channel,

wherein the second heat exchanger is configured to transfer a second amount of heat from the first compressed air to the refrigerant via the phase change material, whereby the transfer of the second amount of heat from the first compressed air causes a first amount of moisture in the first compressed air to condense and thereby removed from the first compressed air; and

a deliquescent dehumidifier configured to receive the first compressed air from the cooling dehumidifier, the deliquescent dehumidifier configured to bring the first compressed air discharged from the cooling dehumidifier in contact with a deliquescent agent to remove a second amount of moisture contained in the first compressed air through a process of deliquescence caused by the deliquescent agent, the deliquescent agent having a moisture absorption ratio of less than or equal to 50% (≤RH 50), and then discharge the first compressed air with the second amount of moisture removed, the discharged air defining the second compressed air,

wherein the second compressed air is entirely transferred from the deliquescent dehumidifier to the pre-heater.

2. The two-stage dryer system of claim 1 , wherein the cooling dehumidifier further includes a gas-liquid separator configured to separate and discharge the condensed first amount of moisture from the first compressed air.

3. The two-stage dryer system of claim 2 ,

wherein the deliquescent dehumidifier includes a dehumidifying tank, into a lower portion of which the first compressed air discharged from the cooling dehumidifier flows, and an upper portion from which the first compressed air is discharged upward,

wherein an inside of the dehumidifying tank is divided into the upper portion and the lower portion by a perforated screen,

wherein a pressure distribution layer filled with a granular material having a predetermined size or larger and a dehumidifying layer filled with the deliquescent agent that is disposed over the pressure distribution layer are disposed over the perforated screen, and

wherein the first compressed air flows from an under side of the perforated screen and is then discharged sequentially through the pressure distribution layer and the dehumidifying layer.

4. The two-stage dryer system of claim 3 , wherein the deliquescent agent includes calcium (Ca), kalium (K), and natrium (Na).

5. An air drying system for drying a compressed air flow comprising:

a pre-heater configured to receive a first compressed air flow and a second compressed air flow, the pre-heater including a first heat exchanger configured to transfer a first amount of heat from the first compressed air flow to the second compressed air flow;

a first dehumidifier configured to receive the first compressed air flow from the pre-heater, the first dehumidifier configured to condense and remove a first amount of moisture contained in the first compressed air flow, the first dehumidifier including:

a freezer in which a refrigerant flow circulates through a refrigeration cycle, and

a second heat exchanger including a first channel and a second channel, the first channel circulating the first compressed air flow and the second channel circulating the refrigerant flow, and a phase change material disposed between the first channel and the second channel,

wherein the second heat exchanger is configured to transfer a second amount of heat from the first compressed air flow to the refrigerant via the phase change material, whereby the transfer of the second amount of heat from the first compressed air flow causes the first amount of moisture in the first compressed air flow to condense and thereby removed from the first compressed air flow; and

a second dehumidifier including a dehumidifying tank carrying a deliquescent agent, the deliquescent agent having a moisture absorption ratio of less than or equal to 50% (≤RH 50), the second dehumidifier configured to further absorb a second amount of moisture from the first compressed air flow discharged from the first dehumidifier, the second dehumidifier configured to discharge the first compressed air flow with the second amount of moisture removed, the discharged first compressed air flow defining the second compressed air flow,

wherein the second compressed air flow is entirely transferred from the second dehumidifier to the pre-heater.

6. The air drying system of claim 5 , wherein the first dehumidifier further includes a gas-liquid separator configured to separate and discharge the condensed first amount of moisture condensed by the second heat exchanger.

7. The air drying system of claim 5 , wherein the dehumidifying tank includes a lower portion and an upper portion separated by a perforated screen, the lower portion receiving the first compressed air flow from the first dehumidifier, and the upper portion including a pressure distribution layer and a dehumidifying layer composed by the deliquescent agent, the dehumidifying layer being disposed over the pressure distribution layer and the pressure distribution layer being disposed over the perforated screen,

wherein the first compressed air flow transfers from the lower portion sequentially through the pressure distribution layer and the dehumidifying layer, a surface of the deliquescent agent configured to react with moisture from the first compressed air flow and melt into a deliquescent condensed water, the deliquescent condensed water flowing to the lower portion.

8. The air drying system of claim 7 , wherein the dehumidifying tank includes a drain valve configured to discharge the deliquescent condensed water when the deliquescent condensed water at the lower portion of the dehumidifying tank is collected over a predetermined level.

9. The air drying system of claim 5 , wherein the deliquescent agent includes calcium (Ca), kalium (K), and natrium (Na).

10. The air drying system of claim 5 , wherein the freezer is configured to operate when the phase change material is in a liquid state and cease operation when the phase change material is in a solid state.

11. The air drying system of claim 5 , further including a pre-filter disposed between the first dehumidifier and the second dehumidifier, the pre-filter configured to remove particles from the first compressed air flow prior to entering the second dehumidifier.

12. An air drying system for drying a compressed air flow comprising:

a first dehumidifier configured to condense and remove a first amount of moisture contained in the compressed air flow, the first dehumidifier including:

a freezer in which a refrigerant flow circulates through a refrigeration cycle, and

a first heat exchanger including a first channel and a second channel, the first channel circulating the compressed air flow and the second channel circulating the refrigerant flow, and a phase change material disposed between the first channel and the second channel,

wherein the heat exchanger performs a first heat exchange and a second heat exchange, where during the first heat exchange, the refrigerant flow absorbs heat from the phase change material and changes the phase of the phase change material, and during the second heat exchange the phase change material directly absorbs heat from the compressed air flow;

a second dehumidifier including a dehumidifying tank carrying a deliquescent agent, the deliquescent agent having a moisture absorption ratio of less than or equal to 50% (≤RH 50), the second dehumidifier configured to further absorb a second amount of moisture from the compressed air flow discharged from the first dehumidifier; and

a second heat exchanger configured to perform a third heat exchange between the compressed air flow prior to flowing into the first dehumidifier and the compressed air flow discharged from the second dehumidifier, the second heat exchanger receiving the compressed air flow discharged from the second dehumidifier in its entirety.

13. The air drying system of claim 12 , wherein the first dehumidifier further includes a gas-liquid separator configured to separate and discharge the first amount of moisture condensed by the first heat exchanger.

14. The air drying system of claim 12 , wherein the deliquescent agent includes calcium (Ca), kalium (K), and natrium (Na).

15. The air drying system of claim 12 , wherein the dehumidifying tank includes a lower portion and an upper portion separated by a perforated screen, the lower portion receiving the compressed air flow from the first dehumidifier, and the upper portion including a pressure distribution layer and a dehumidifying layer composed by the deliquescent agent, the dehumidifying layer being disposed over the pressure distribution layer and the pressure distribution layer being disposed over the perforated screen,

wherein the compressed air flows from the lower portion sequentially through the pressure distribution layer and the dehumidifying layer, a surface of the deliquescent agent configured to react with the second amount of moisture from the compressed air flow and melt into a deliquescent condensed water, the deliquescent condensed water flowing to the lower portion and the dehumidified compressed air flow flowing to the second heat exchanger.

16. The air drying system of claim 15 , wherein the dehumidifying tank includes a drain valve configured to discharge a deliquescent condensed water when the deliquescent condensed water at the lower portion of the dehumidifying tank is collected over a predetermined level.

17. The air drying system of claim 12 , wherein the freezer is configured to operate when the phase change material is in a liquid state and cease operation when the phase change material is in a solid state.

18. The air drying system of claim 12 , further including a pre-filter disposed between the first dehumidifier and the second dehumidifier, the pre-filter configured to remove particles from the compressed air flow prior to entering the second dehumidifier.