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2015 11-19-card unexpected-wies_farragtech

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InnEEPlas workshop 'Energy efficient peripherals and ancillaries in plastics processing' 19 November 2015
Compressed Air Drying - unexpected ways in energy savings, FarragTech

Publié dans : Technologie
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2015 11-19-card unexpected-wies_farragtech

  1. 1. COMPRESSED AIR DRYING UNEXPECTED WAYS IN ENERGY SAVINGS
  2. 2. SPECIFIC ENERGY FOR COMPRESSED AIR 0,100 0,110 0,120 0,130 0,140 0,150 0,160 0,170 0,180 18 39 63 76 100 kWh/m³ Compressor’s load in % GA55 VSD IFD
  3. 3. SPECIFIC ENERGY FOR COMPRESSED AIR 0,100 0,110 0,120 0,130 0,140 0,150 0,160 0,170 0,180 18 39 63 76 100% kWh/m³ 18% load Air flow [m³/h] 94 Specific energy for compr. air [kWh/m³] 0.173 Total power consumption [kW] 16.3 kW
  4. 4. SPECIFIC ENERGY FOR COMPRESSED AIR 0,100 0,110 0,120 0,130 0,140 0,150 0,160 0,170 0,180 18 39 63 76 100% kWh/m³ 63% load Air flow [m³/h] 381 Specific energy for compr. air [kWh/m³] 0.114 Total power consumption [kW] 43.4 kW
  5. 5. SPECIFIC ENERGY FOR COMPRESSED AIR 18% load 63% load Differenc e Air flow [m³/h] 94 381 287 Specific energy for compr. air [kWh/m³] 0.173 0.114 0,095 Total power consumption [kW] 16.3 kW 43.4 kW 27.1 kW LOWER SPECIFIC ENERGY through ADDITIONAL compressed air equipment!
  6. 6. MAXIMIZING COMPRESSOR’S LOAD REDUCES SPECIFIC ENERGY COSTS OF COMPRESSED AIR FACT 1
  7. 7. STANDARD COMPRESSED AIR DRYER 0 50 100% Heating Compressed Air 80°C 180°CEnergy requirement at:
  8. 8. 2-CIRCUIT COMPRESSED AIR DRYER 0 50 100% Heating Compressed Air 80°C 180°CEnergy requirement at:
  9. 9. 2-CIRCUITS COMPRESSED AIR DRYER 0 50 100% Heating Compressed Air Standard Two-circuits 80°C 80°C 180°C 180°C Energy requirement:
  10. 10. ONLY POSSIBLE THROUGH PATENTED CARD-SYSTEM CARD M CARD L
  11. 11. THE MAJOR TASK OF DRYING IS TO HEAT-UP!
  12. 12. 2-CIRCUIT SYSTEM DRASTICALLY REDUCES ENERGY COSTS OF COMPRESSED AIR DRYING FACT 2
  13. 13. METHODS OF ENERGY RECOVERY High-level placement of CARD reduces energy costs up to 10%
  14. 14. METHODS OF ENERGY RECOVERY 0 50 100% Heating Compressed Air 20°C 35°CSecondary air inlet temperature: ENERGY CONSUMPTION OF A DRYING PROCESS WITH 80°C
  15. 15. METHODS OF ENERGY RECOVERY Heat recovery from plant’s energy resources
  16. 16. METHODS OF ENERGY RECOVERY Heat recovery from integrated air compressor CARD R
  17. 17. METHODS OF ENERGY RECOVERY 0 50 100% Heating Compressed Air w/o withHeat recovery: ENERGY CONSUMPTION OF A DRYING PROCESS WITH 80°C
  18. 18. METHODS OF ENERGY RECOVERY Heat and air recovery on blow-molding applications
  19. 19. METHODS OF ENERGY RECOVERY 0 50 100% Heating Compressed Air w/o withAir and heat recovery: ENERGY CONSUMPTION OF A DRYING PROCESS WITH 80°C
  20. 20. 0 50 100% 36% 22% Standard Two-circuits High-level Heat recovery Heat & air recovery METHODS OF ENERGY RECOVERY 100 % 38% 0,1%
  21. 21. CARD (2-CIRCUIT-SYSTEM) ENABLES UNIQUE WAYS OF ENERGY RECOVERY TO LOWER ENERGY REQUIREMENTS FACT 3
  22. 22. 0 25 50 75 100 Desiccant dryer new Desiccant dryer 20% less efficiency CARD 2-circuits CARD high-level CARD heat recovery % ANALOGY TO COMMON DRYING SYSTEMS TOTAL ENERGY CONSUMPTION
  23. 23. ANALOGY TO COMMON DRYING SYSTEMS ENERGY REQUIREMENT FOR DRY AIR ON DESICCANT SYSTEM 23.2 kW for 1000kg air = 0.028 kW/m³ 36.0 kW for 1000kg air = 0.043 kW/m³ Density of air: 1,2041 kg/m³ ENERGY REQUIREMENT FOR COMPRESSED AIR 0.110 kW/m³ 0.150 kW/m³ 0,100 0,120 0,140 0,160 0,180 kWh/m³
  24. 24. ANALOGY TO COMMON DRYING SYSTEMS 225L DRYING HOPPER Desic. Dry. new Desic. Dry. 20% CARD 2-circuit CARD High-level CARD Recovery Energy for dry air 2.0 kW 2.4 kW 2.0 kW 2.0 kW 2.0 kW Energy to heat-up material 1.5 kW 1.5 kW 1.5 kW 1.1kW 0.0 kW Total 3.5 kW 3.9 kW 3.5 kW 3.1 kW 2.0 kW
  25. 25. ADVANTAGES ON CARD(2-CIRCUITS)-SYSTEM  THE LONGER THE OPERATING TIME THE HIGHER THE ENERGY SAVINGS  NO MAINTENANCE COSTS  CONSTANT DRYING EFFICIENCY FOR FULL LIFE-TIME
  26. 26. DRYING WITH COMPRESSED AIR IS NOT EXPENSIVE! FACT 4
  27. 27. THANK YOU!

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