Abstract: A water separator and system includes a compressed air aftercooler and water/moisture separator with a demister core comprising a plurality of offset fins. In one embodiment, the compressed air aftercooler comprises a compressed air core having an aftercooler inlet, an aftercooler outlet at the bottom of the compressed air core, and one or more heat transfer passages. In one aspect, the system comprises a moisture separator substantially integral to the aftercooler. In another aspect, the system includes a first generally horizontal region beneath and adjacent to the aftercooler outlet; and an expansion zone adjacent to and in fluid communication with the first region, the expansion zone being configured to reduce the horizontal velocity of compressed air passing therethrough. In another aspect, the demister core is in fluid communication with the expansion zone.

Abstract: A system for providing cooled compressed air free of entrained moisture. A housing surrounds a heat exchanger and has an inlet for passage of hot compressed air into an input plenum of the housing and an outlet plenum having an outlet for the cooled and dried compressed air. The bottom of the output plenum extends below the bottom of the heat exchanger to form a trough which collects condensate that collects on the plates of the heat exchanger, flows to the bottom of the heat exchanger, and is pushed by the flow of the compressed air to the output plenum. A shield is placed between the outlet and the heat exchanger to prevent condensate spewed from the plates of the heat exchanger from passing directly across the outlet opening or directly into the outlet opening.

Abstract: A water separator and system includes a compressed air aftercooler and water/moisture separator with a demister core comprising a plurality of offset fins. In one embodiment, the compressed air aftercooler comprises a compressed air core having an aftercooler inlet, an aftercooler outlet at the bottom of the compressed air core, and one or more heat transfer passages. In one aspect, the system comprises a moisture separator substantially integral to the aftercooler. In another aspect, the system includes a first generally horizontal region beneath and adjacent to the aftercooler outlet; and an expansion zone adjacent to and in fluid communication with the first region, the expansion zone being configured to reduce the horizontal velocity of compressed air passing therethrough. In another aspect, the demister core is in fluid communication with the expansion zone.

Abstract: A system for providing cooled compressed air free of entrained moisture. A housing surrounds a heat exchanger and has an inlet for passage of hot compressed air into an input plenum of the housing and an outlet plenum having an outlet for the cooled and dried compressed air. The bottom of the output plenum extends below the bottom of the heat exchanger to form a trough which collects condensate that collects on the plates of the heat exchanger, flows to the bottom of the heat exchanger, and is pushed by the flow of the compressed air to the output plenum. A shield is placed between the outlet and the heat exchanger to prevent condensate spewed from the plates of the heat exchanger from passing directly across the outlet opening or directly into the outlet opening.

Abstract: A precooler/chiller/reheater (PCR) system comprising a precooler/reheater counterflow heat exchanger and a chiller counterflow heat exchanger separated by a moisture removal section. Refrigerant is flashed through a perforated distribution manifold along the plates of the chiller. Warm, moist air is precooled in the precooler/reheater heat exchanger. A manifold conveys the precooled air to the chiller heat exchanger. Chilled air exits the chiller at a low point in the system. Moisture condensed in the precooler and chiller drains into a sump that also acts to convey air into the moisture removal section. Water droplets are stripped from the airflow and drain downwards into the sump. The chilled and dried air is conveyed to the second side of the precooler/reheater heat exchanger and passes downward in counterflow to the direction of air entering the system on the first side of the heat exchanger, then exits the system ready for use as reheated, dried air.

Abstract: A heat exchanger comprising a precooler and reheater core adjacent a chiller core, first heat transfer passages extending through both cores through which incoming air passes in a first direction, second heat transfer passages extending through the chiller core through which coolant passes in heat exchange relationship with incoming air and perpendicular to the first direction, and third heat transfer passages extending through the precooler and reheater core through which cooled air from the chiller core passes in heat exchange relationship with the incoming air and perpendicular to the first direction. A manifold contiguous with both cores conducts chilled air from the chiller core to the third set of heat transfer passages.Incoming air is chilled in the chiller core and thereafter exchanges heat with the incoming air in the precooler and reheater core to precool the incoming air to form water droplets and to raise the temperature of the chilled air to a usable temperature.

Abstract: A heat exchanger comprising a precooler and reheater core adjacent a chiller core, first heat transfer passages extending through both cores through which incoming air passes in a first direction, second heat transfer passages extending through the chiller core through which coolant passes in heat exchange relationship with incoming air and perpendicular to the first direction, and third heat transfer passages extending through the precooler and reheater core through which cooled air from the chiller core passes in heat exchange relationship with the incoming air and perpendicular to the first direction. A conduit conducts chilled air from the chiller core to the third set of heat transfer passages.Incoming air is chilled in the chiller core and thereafter exchanges heat with the incoming air in the precooler and reheater core to precool the incoming air to form water droplets and to raise the temperature of the chilled air to a usable temperature.