1.

1 Basic phenomena of mold dryer:

In injection molding machines, chilled water circulation takes place that can cause condensation if the
temperature of water is under the dew point of the ambient air. If we increase the chilled water’s
temperature cycle time will be increased which decreases the productivity. To overcome this problem
mold dryers are used. Mold dryer is a device that takes air from environment , dry it and decrease its
dew point to -10 C and send to the machine where this dry air prevents machine from condensation.

Air from environment Mold dryer Dry air to machine

1.2 Mold dryers in GIL:

M/C#1 M/C#2 M/C#3 M/C#4 M/C#5 M/C#6
ML1100E DSH2400 RPA2400 DSH2400 DSH2400 DSH2400

1.3 Process description of mold dryer:

In mold dryers silica gel is used as an absorbent which capture the humidity of air, but there is a limit of
absorption of silica gel, for that we have to regenerate it by passing hot air from it ,which as a result
removes the moisture content from silica gel. So the process description of mold dryer can be divided
into the following phases.

1.3.1 Process Phase:

PROCESS FILTER PRE-COOLING BATTERY

Air from environment
Dry air to machine
TOO-POST COOLING
BATTERY
Here the air is filtered in order to
guarantee a high heat exchange
efficiency of the drying process.
Chilled water circulates in this which
exchange heat with air, air loses 10 C
and part of its humidity through
condensation, condensate is collected
in a tank and then it is drained
through pipes.

It is optional and DEHUMIDIFICATION ROTOR

water operated PROCESS FAN
battery, it increases Silica gel is present there, which
Air is then sucked by the process fan
efficiency of absorbs air’s humidity, that causes
which increases its pressure and send
dehumidifier but lowering the dew point of air.Process
it to the dehumidification rotor.
currently not phase occurs in ¾ of rotor. Rotor
operational in GIL. revolutes 10-12 times/hour.
1.3.2 REGENERATION PHASE:

From the outlet of cooling battery 25% of air is separated which is used for regeneration phase. It is send
to the heating chamber.
DEHUMIDIFICATION ROTOR
HEATING CHAMBER
Hot air flows through the
Here the air is heated to 71 C. dehumidification rotor ¼ long
removing the humidity, it had
absorbed during the process phase.
Finally air is released in environment
at 51 C.

1.4 CALCULATIONS REGARDING COOLING BATTERY:

Water data: Air data:

Chilled water inlet temp = Tw1= 7 C Air inlet temp = Ta1 = 35 C

Chilled water outlet temp = Tw2=?
Volumetric flow rate of water = 11000 lit/hr
Density of water = 1kg/l
Mass flow rate of water = Mw = 11000kg/hr
Heat gained by water= Q = 41 KW = 147600kj
Specific heat = Cw = 4.19 kj/kg C
Q=Mw C (Tw2-Tw1)
147600 = (11000)(4.19)(Tw2-7)
Tw2 = 10.2 C
Air outlet temp = Ta2 = 25 C
Specific heat = Cpa = 1.005 kj/kg C
Humid air volumetric flow rate=2400 m3/hr
Density of air= 1.2kg/m3
Humid air mass flowrate=Ma=2880 kg/hr
Condensate produced=Mb=?
Heat of condensation=L=2257kj/kg
Energy lost by air=41kw=147600 kj/hr
Q=(Ma-Mb) Cpa (Ta1-Ta2) + Mb(L)
147600=(2880-Mb)(1.005)(35-25)+Mb(2257)
Mb=52.80 kg/hr
2.1 BASIC PHENOMENA OF CHIP RESIN DRYER:
PET is a hygroscopic material, having a lot of moisture which has to be removed before going to the
injection unit. Chips are loaded in an hopper where , drying of chips takes place. Hot air comes to the
hopper which absorbs moisture content of chips, that air after absorbing moisture goes to a
dehumidifier, where it comes in contact with molecular sieves (absorbent) and loses it’s humidity and
come back to the hopper to dry the chips. Outlet temperature of chips is about 170 C where it enters at
room temperature. Process temperature is about 175 C.

2.2 CHIP RESIN DRYERS IN GIL:

M/C#1 M/C#2 M/C#3 M/C#4 M/C#5 M/C#6
DS525HE DS528 DS530 DR224HT DR224HT DR224HT

2.3 PROCESS DESCRIPTION OF CHIP RESIN DRYER:

There are two towers present in dehumidifier, in which one is busy in dehumidification of air and the
other is in regeneration of molecular sieves.

2.3.1 DEHUMIDIFICATION OF AIR: From hpper air goes to the process filter, for the removal of solid
particles, then through the by-pass valve goes to the air air heat regenerator where the air pre-heated
the air that is coming from tower. The air from here goes to the secondary filter which is at the entrance
of de-humidifier. Then it goes to the cooling battery where it is more cooled by the water. From here it is
sucked by the blower then from distributing valve it goes to the tower. In tower air first goes through
the heating chamber, which is fitted with a number of heating elements not energized at this stage.
Then it goes upward through a suitable mass of molecular sieves that capture the humidity contained in
air. Then from distribution valve it goes to the air-air heat regenerator where it is pre-heated from air
flowing back from the hopper. From there it goes to the heating chamber. From heating chamber it goes
towards hopper to dry the chips.

HOPPER HOPPER PROCESS DEHUMIDIFICATION COOLING

FILTER PROCESS FILTER BATTERY

BLOWER
HEATING
CHAMBER
DISTRIBUTION
VALVE
 TOWER PROCESSING MOLECULAR SIEVES RESISTOR TOWER
DISTRIBUTING VALVE
2.3.2 REGENERATION OF MOLECULARTOWER
SIEVES: There are two phases of regeneration (1) Heating
phase regeneration (2) Cooling phase regeneration. Air from environment goes to the regeneration
filter, then from regeneration valve through blower it goes to the heat regenerator, here it is heated up
by hot regeneration air,rich in humidity which is discharge of tower, here it meets a number of heating
elements. Thus air is heated upto a suitable temperature. Then from bottom to upwards it passes
through the mass of molecular sievesthat are saturated with the humidity absorbed from the process air
during the dehumidification cycle. The regeneration and heating phase continoues until the molecular
sieves reach a set temperature. Now heating elements are disconnected and the cooling phase of
regeneration cycle starts. The microprocessor controls the cursor of regeneration valve and changes its
position. In this way the air that is coming back from the regeneration tower passes through the
regeneration heat exchanger where it is cooled down.

AIR-AIR REGENERATION DISTRIBUTING RESISTOR MOLECULAR

PARTIALINZATION VALVE TOWER SIEVE TOWER

LOWER
BLOWER
DISTRIBUTING
VALVE

SAFETY
REGENERATION THERMOCOUPLE
THERMOSTAT
DISTRIBUTION VALVE

FILTER AIR FROM ENVIRONMENT

PROCESS DESCRIPTION OF INJECTION MOLDING
MADE BY : REHAN KHAN ALI (TRAINEE ENGINEER)