CURING & DRYING SPECIALISTS     WASTE HEAT RECOVERY              AND    HEAT UTILIZATION SYSTEM
Why recover waste heat? In many cases the amount of waste heat recovered from the kilns is sufficient tosatisfy the heat ...
What can CDS offer? Design, consultation and feasibility study concerning the viability of the project. Factory survey i...
Q: Where can the waste heat be claimed from?  A: Waste heat can be reclaimed from all available sources on both  Tunnel Ki...
Q: What medium is used to convey the recovered energy?     A: The heat may either be transferred in the form of ducted ‘ho...
Q: How does the system work?A: The following diagrams show:-• How the ‘waste’ heat is recovered• How the ‘waste’ heat is t...
Typical Control ArchitectureFactory Network Providing            Ethernet Switch     VPN Connection                       ...
Product Dryers
Environmental Air Handling
Continuous Product Dryers
Heat Recovery Data                                                       YEARLY FIGURES (based on 1 x 7 day working week p...
Heat Recovery Data                      High Temperature Circuit                                                          ...
Payback Period•   Maximum available heat recovery per annum = 18,689,328 kw/hr’s•   Combined usage of heat recovery per an...
There can be NOCOMPROMISE when itcomes to QUALITY &RELIABILITY.
CDS Heat Recovery Presentation
CDS Heat Recovery Presentation
CDS Heat Recovery Presentation
CDS Heat Recovery Presentation
CDS Heat Recovery Presentation
CDS Heat Recovery Presentation
CDS Heat Recovery Presentation
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CDS Heat Recovery Presentation

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A Comprehensive Presentation on Energy Recovery in Ceramics Manufacturing

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CDS Heat Recovery Presentation

  1. 1. CURING & DRYING SPECIALISTS WASTE HEAT RECOVERY AND HEAT UTILIZATION SYSTEM
  2. 2. Why recover waste heat? In many cases the amount of waste heat recovered from the kilns is sufficient tosatisfy the heat demands of the Product Dryers and Curing Processes as well asproviding enough energy to heat the workshops via Air Handling Units. The system can be used for both continuous Tunnel kilns and intermittent ShuttleKilns The system can be applied to both existing and new Kilns and then utilized intoeither new or existing Dryers and equipment. The system can be installed with virtually no disruption to the factory process. The return on investment period can be as little as two years, with every Kw(Therm) of energy saved after than being a direct contribution to profit.
  3. 3. What can CDS offer? Design, consultation and feasibility study concerning the viability of the project. Factory survey identifying the potential energy users. Report of the Investment return period. Flexibility of contract structure. Complete equipment supply from the UK or part ‘local’ content. Supervision of ‘local’ labour or complete installation by CDS Selection of control options. Comprehensive commissioning service. After sales service from the UK contribution to profit.
  4. 4. Q: Where can the waste heat be claimed from? A: Waste heat can be reclaimed from all available sources on both Tunnel Kilns and Shuttle Kilns. Depending on the design of Tunnel Kiln, waste heat can be recovered from the ‘cooling’, ‘centre’ and ‘exhaust’. On Shuttle Kilns, heat is recovered during the cooling part of the curve.
  5. 5. Q: What medium is used to convey the recovered energy? A: The heat may either be transferred in the form of ducted ‘hot air’ or alternatively by means of hot water via pipe work. When used to heat dryers, the hot water system is preferable so as not to compromise the humidity balance within the dryers. Also transferring a large mass of energy is usually uneconomical using ductwork.  Photos show waste heat being collected from a Tunnel Kiln and distributed into Dryers and a pre-kiln Glaze Dryer with residual used for space heating the factory via Air Handling Units.
  6. 6. Q: How does the system work?A: The following diagrams show:-• How the ‘waste’ heat is recovered• How the ‘waste’ heat is transferred• How the ‘waste’ heat is utilized
  7. 7. Typical Control ArchitectureFactory Network Providing Ethernet Switch VPN Connection RSView SCADA PC for Remote Access Located ‘remote’ from the users Ethernet to PLC’s PLC PLC PLC PLC Allen BradleyPanel View C600 HMISet point and process variable monitoring Heat Recovery Ware Dryers Mould Dryers Environmental systems
  8. 8. Product Dryers
  9. 9. Environmental Air Handling
  10. 10. Continuous Product Dryers
  11. 11. Heat Recovery Data YEARLY FIGURES (based on 1 x 7 day working week per month) High Temp Circuit (kw/hrs) Low Temp Circuit (kw/hrs) Additional Heat Additional Heat Month Waste Heat Available Total of Heat Users Surplus Heat Waste Heat Available Total of Heat Users Surplus Heat Required Required January 217,710 321,743 5,932 65,821 170,324 340,234 5,644 205,021 February 217,710 311,872 7,321 54,993 172,325 310,652 5,644 165,032 March 217,710 291,263 11,032 49,321 173,654 245,823 5,644 112,032 April 217,710 264,924 16,832 38,112 168,554 158,773 6,435 60,145 May 217,710 239,015 20,883 25,734 165,923 125,712 7,432 35,003 June 217,710 227,774 22,732 24,987 167,083 105,982 12,732 20,821 July 217,710 226,046 23,463 25,832 167,367 116,003 15,943 20,043 August 217,710 233,821 24,632 27,635 166,943 138,664 14,843 35,773 September 217,710 239,732 21,772 29,863 165,773 169,663 6,437 43,921 October 217,710 262,811 17,663 36,832 168,345 200,735 5,644 77,447 November 217,710 290,212 7,322 48,721 173,882 252,994 5,644 133,932 December 217,710 311,084 5,232 57,021 171,992 318,643 5,644 183,032 TOTALS = 2,612,520 3,220,297 184,816 484,872 2,032,165 2,483,878 97,686 1,092,202 YEARLY FIGURES (based on 338 days per annum) High Temp Circuit (kw/hrs) Low Temp Circuit (kw/hrs) Additional Heat Additional Heat Month Waste Heat Available Total of Heat Users Surplus Heat Waste Heat Available Total of Heat Users Surplus Heat Required Required January 876,024 1,294,633 23,869 264,851 685,351 1,369,037 22,710 824,965 February 876,024 1,254,914 29,458 221,281 693,403 1,250,004 22,710 664,057 March 876,024 1,171,987 44,391 198,458 698,751 989,145 22,710 450,795 April 876,024 1,066,004 67,729 153,355 678,229 638,872 25,893 242,012 May 876,024 961,751 84,029 103,549 667,643 505,841 29,905 140,845 June 876,024 916,519 91,469 100,543 672,310 426,451 51,231 83,780 July 876,024 909,566 94,411 103,943 673,453 466,774 64,152 80,649 August 876,024 940,851 99,114 111,198 671,747 557,958 59,725 143,944 September 876,024 964,636 87,606 120,163 667,039 682,692 25,901 176,730 October 876,024 1,057,501 71,073 148,205 677,388 807,719 22,710 311,632 November 876,024 1,167,758 29,462 196,044 699,668 1,018,000 22,710 538,917 December 876,024 1,251,743 21,053 229,442 692,063 1,282,159 22,710 736,486 TOTALS = 10,512,283 12,957,862 743,664 1,951,033 8,177,045 9,994,652 393,070 4,394,813 Total Combined Waste Heat Available = 18,689,328 kw/hrs HT Waste Heat Utilised = 9,768,618 kw/hrs LT Waste Heat Utilised = 7,783,975 kw/hrs %age HT Waste Heat Utilised = 92.93% %age LT Waste Heat Utilised = 95.19% HT Additional Energy Reqd = 1,951,033 kw/hrs LT Additional Energy Reqd = 4,394,813 kw/hrs MAXIMUM AVAILABLE HEAT RECOVERY PER YEAR = 18,689,328 kw/hrs COMBINED USAGE OF HEAT RECOVERY PER YEAR = 17,552,594 kw/hrs %age WASTE HEAT UTLISATION IN THE DRYERS = 93.92% SURPLUS ENERGY PER YEAR = 1,136,734 kw/hrs ADDITIONAL ENERGY REQUIRED PER YEAR = 6,345,845 kw/hrs Note: The surplus 6.08% heat can be used for ancillary heating such as canteen, office space, warehouse etc...
  12. 12. Heat Recovery Data High Temperature Circuit Low Temperature Circuit 1,400,000 1,400,000 1,200,000 1,200,000 1,000,000 1,000,000 Kw/Hrs per month Kw/Hrs per month 800,000 800,000 600,000 600,000 400,000 400,000 200,000 200,000 0 0 January February March April May June July August September November October December January February March April May June JulyAugust September November October December Waste Heat Available Total of Heat Users Waste Heat Available Total of Heat Users Surplus Heat Additonal Heat Required Surplus Heat
  13. 13. Payback Period• Maximum available heat recovery per annum = 18,689,328 kw/hr’s• Combined usage of heat recovery per annum = 17,552,594 kw/hr’s• Percentage waste heat utilisation in the factory = 93.92%• The remaining 6.08% waste heat can be used in the warehouse, canteen, offices etc…• Surplus energy per annum = 1,136,734 kw/hr’s• Additional energy required per annum = 6,345,845 kw/hr’s• Assumed cost of natural gas per kw = $0.033• Estimated annual fuel cost saving = $579,236• Investment cost for waste heat system = $1,500,000• Return on investment period = 2.59 years
  14. 14. There can be NOCOMPROMISE when itcomes to QUALITY &RELIABILITY.

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