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

1. COMPRESSED AIR DRYING
UNEXPECTED WAYS
IN ENERGY SAVINGS

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!

6. MAXIMIZING COMPRESSOR’S LOAD
REDUCES
SPECIFIC ENERGY COSTS
OF COMPRESSED AIR
FACT 1

7. STANDARD COMPRESSED AIR DRYER
0
50
100%
Heating
Compressed Air
80°C 180°CEnergy requirement at:

8. 2-CIRCUIT COMPRESSED AIR DRYER
0
50
100%
Heating
Compressed Air
80°C 180°CEnergy requirement at:

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. ONLY POSSIBLE THROUGH PATENTED CARD-SYSTEM
CARD M CARD L

11. THE MAJOR TASK OF DRYING IS TO HEAT-UP!

12. 2-CIRCUIT SYSTEM
DRASTICALLY REDUCES
ENERGY COSTS
OF COMPRESSED AIR DRYING
FACT 2

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

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. CARD (2-CIRCUIT-SYSTEM)
ENABLES UNIQUE WAYS
OF ENERGY RECOVERY
TO LOWER
ENERGY REQUIREMENTS
FACT 3

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. 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

26. DRYING WITH
COMPRESSED AIR
IS NOT EXPENSIVE!
FACT 4

27. THANK YOU!