InnEEPlas workshop 'Energy efficient peripherals and ancillaries in plastics processing' 19 November 2015
Compressed Air Drying - unexpected ways in energy savings, FarragTech
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. 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. 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. 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!
13. METHODS OF ENERGY RECOVERY
High-level
placement of CARD
reduces
energy costs
up to 10%
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. METHODS OF ENERGY RECOVERY
Heat recovery from plant’s energy resources
16. METHODS OF ENERGY RECOVERY
Heat recovery
from integrated
air compressor
CARD R
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. METHODS OF ENERGY RECOVERY
Heat and air recovery on blow-molding applications
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
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. 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. 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