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If a dryer does not have a hot air circulation system, it typically doesn't need to be moved after installation and adjustment. However, dryers with hot air circulation systems, although more complex to adjust, offer significant energy-saving benefits. The following data demonstrates this advantage. The drying unit operates under the conditions of an ambient air temperature of 15°C, hot air temperature of 80°C, a 2.2 kW fan, and a standard air volume of 31–33 m³/min at 20°C.
When designing a hot air circulation system, the first thing to consider is the solvent content in the gas, as certain concentrations of organic solvents can lead to explosions. Table 1 lists the volumetric explosion limits for common solvents. These limits are divided into upper and lower thresholds, with any concentration between them being potentially explosive. The lower explosive limit (LEL) is a critical factor in dryer design. When using LEL100, it refers to the lower limit of the explosion concentration. Some imported printers or advanced machines will sound an alarm when the solvent vapor reaches LEL25, and automatically stop if it rises to LEL50.
So, how much airflow is required to ensure safe operation? It's straightforward to calculate. The amount of solvent evaporated per unit time is the basis for determining the airflow needed. For example, to dry 1000 grams of solvent, we calculate the volume of air required. According to Table 2, for ethyl acetate at LEL25, the concentration is 38 g/m³. To dilute 1000 grams of ethyl acetate to LEL25, about 26 m³ of air is needed. Different solvents have different vapor volumes and explosion limits, so taking an average from four solvents, we find that 83 m³ of air is required per kilogram of evaporated solvent. This aligns with foreign standards, where 74 m³ of air is used per liter of solvent, and with a proportion of around 0.9, confirming that LEL12.5 is a suitable design standard.
Next, let’s look at a composite machine dryer. With a maximum dry base coating of 4 g/m², a working concentration of 25%, and a compounding speed of 120 m/min, the drying system evaporates 1440 grams of ethyl acetate per minute when the width is 1 meter. Therefore, the required air flow for the dryer would be:
83 × 1.44 = 119.5 m³/min
Typically, the drying oven of a composite machine is divided into three sections, with each section requiring approximately 40 m³/min of air. A 30 m³/min fan is commonly used for a 120 m/min machine, but the speed may drop below 80 m/min when dealing with thinner materials. However, the machine can still reach 120 m/min when the coating weight is around 3 g/m².
This is a rough estimate for equipment configuration. In reality, the drying process is more complex, especially in multi-stage ovens where evaporation isn’t evenly distributed. Adjusting the air circulation is therefore very precise.
A hot air circulation dryer has three main valves: an exhaust valve, a recirculating air valve, and a fresh air intake valve. Surprisingly, the main factor affecting the recycling rate is the amount of exhaust air. Since the exhaust air volume equals the total air intake, most of the incoming air comes from the fresh air inlet, with some drawn in by the negative pressure on the drying oven’s surface.
The air intake and exhaust volumes relate to the "metabolism" of the gas within the system. While the exhaust volume is usually slightly higher than the incoming hot air, the pressure might be lower. When adjusting the dryer, start by setting the exhaust valve to achieve a static pressure of 400–500 Pa near the exhaust butterfly valve. Once this is stable, adjust the recirculating air valve. The recirculation duct connects to the fan’s inlet, and its negative pressure is higher than the exhaust valve area. Opening the recirculating air valve allows hot air to enter the duct, while the fresh air inlet acts like a "hole." If the recirculating valve is closed, the hole is "plugged," reducing nozzle airflow. If open, the airflow increases.
This analogy simplifies a complex system involving pipe size, resistance, and airflow distribution. For instance, Italian equipment often lacks dedicated fresh air inlets, relying instead on the negative pressure of the drying chamber to pull in air. The hot air entering the circulation duct is already mixed with fresh air, and the recycling rate is controlled by the exhaust valve. When the exhaust volume is high, more fresh air is drawn in; otherwise, less.
Finally, what is the purpose of the fresh air intake valve? Compared to Italian designs, many systems use the fresh air inlet to prevent large amounts of air from flowing directly to the bottom of the drying cabinet, which could disturb printing. The fresh air intake valve and the recirculating air damper work together to regulate the hot air circulation rate. Generally, when the recirculating valve is open, the fresh air valve should be closed, resulting in a high circulation rate. Conversely, when the fresh air valve is open, the recirculating valve should be closed, leading to a lower circulation rate. This balance ensures minimal changes in nozzle airflow.
October 06, 2025