Heat recovery for hot air and hot water applications

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1 Heat recovery for hot air and hot water applications

2 Heat recovery Why recover heat? The question should in fact be: Why not? Amazingly, 100 percent of the (electrical) energy input to a compressor is converted into heat. Up to 6 % of this energy can be recovered and reused for space heating or hot water production purposes. This not only reduces primary energy consumption, but also signifi cantly improves the total energy balance. Saves money and benefits the environment Gas heating 24 up to 55,742 /year For plate heat exchanger systems Compressor size Small Medium Large Compressor model SM BSD 3 FSD 471 Approx. 5 % heat dissipation from the drive Approx. 76 % heat energy recoverable through fl uid cooling Approx. 6 % recoverable heat energy Up to 100 % total electrical power consumption Approx. % heat energy recoverable through compressed air cooling Up to % ambient heat Up to % compressed air energy potential Approx. 2 % heat dissipated by the compressor into the ambient air Approx. 2 % heat remaining in the compressed air Heat in the compressor Amazingly, almost 100 percent of the electrical drive energy input to a rotary screw compressor is converted into heat. The adjacent heat flow diagram (left) shows how this energy is distributed throughout the compressor system and how it can be recovered: Approximately 6 percent of the energy can be recovered for reuse, two percent remains in the compressed air and two percent radiates away from the compressor package into the ambient surroundings. So where does the usable energy in compressed air come from? The answer is actually quite simple and perhaps surprising: During the compression process and conversion of the electrical drive energy into heat, the compressor charges the air it draws in with energy potential. This corresponds to approximately percent of the compressor's electrical power consumption. This energy is only usable however once the compressed air expands at its point of use and in so doing absorbs heat energy from the ambient surroundings. Of course the amount of this energy that is available for use depends on the pressure and leakage losses within the compressed air system. Oil heating 331 up to 62,74 /year Electrical power consumption Heat recovery Up to 6% reusable heat energy Rated power kw kw 0 kw Annual savings potential with fuel oil 2 6,326 33, 3,26 24,644,126 See pages 10 and 11 for details regarding calculation of savings potential. 2 3

3 Heat recovery Minimise primary energy consumption for heating The enclosed, compact design of modern rotary screw compressors makes them especially suitable for heat recovery. Direct use of the recyclable heat via a ducting system enables up to 6 percent of the compressor's total energy requirement to be recovered and used for heating purposes. This is the case irrespective of whether fluid-injection cooled compressors or dry-running screw compressors are used. Up to 6% energy reusable for heating purposes Heat recovery a win Amazingly, 100 percent of the electrical drive energy input to a compressor is converted into heat. From that, up to 6 percent is available for heat recovery purposes. Use this potential to your advantage! Heating with hot air Warmed compressor cooling air can be ducted away to provide highly effective space heating. With this method, up to 6 percent of the compressor s input energy can therefore be recovered as heat. Heat neighbouring rooms When using recyclable heat for space heating, ducting simply feeds the warmed cooling air to where it is needed, e.g. in adjacent facilities, such as warehouses or workshops. 4 5

4 Heat recovery Minimise primary energy consumption for warming of process, heating and service water Using recyclable heat from the compressor, heat exchanger systems can provide on-demand heating and service water warmed to temperatures up to 70 C, or even 0 C, depending on requirement. Conventional warming of heating and service water using recyclable heat is performed by PTG plate heat exchanger systems. Special fail-safe heat exchangers are recommended for applications that have no other interconnecting water circuits and where it is essential that the water being warmed remains uncontaminated, as is the case with cleaning-water in the food industry for example. +70 C hot Process, heating and service water Hot water up to 70 C can be produced from reusable compressor heat via PWT heat exchanger systems. Please contact KAESER regarding higher temperature requirements. Feed heat energy to a heating system Up to 76 percent of the original input energy for the compressor system can be recovered for use in hot water heating systems and service water installations. This significantly reduces primary energy demand required for heating purposes. PTG plate heat exchanger High quality plate type heat exchangers are the fi rst choice when it comes to using recyclable heat from rotary screw compressors for warming process and service water, or for process heat production. 6 7

5 Equipment Hot air heat recovery All KAESER rotary screw compressors can be fi tted with exhaust ducting. The ducting is installed on-site. Neighbouring rooms and warehouse space, for example, can be heated with the warmed cooling air. Fields of application Drying processes Heating of halls and buildings Air curtain systems Pre-heating of burner air PTG plate heat exchanger system Rotary screw compressors from the SM series (from 5.5 kw) upwards can be equipped with PTG systems. Depending on the size of the compressor system, the PTG heat exchanger is either integrated within the unit or is installed externally. Fields of application Feed into central heating systems Laundries Electroplating General process heating Cleaning water in the food industry Swimming pool heating Hot water for shower and washroom facilities Tube-type heat exchanger Depending on the available water quality, either integrated plate or tubetype heat exchangers can be used in water-cooled systems. Our compressed air specialists can advise you regarding which design is right for your particular application. Air-cooled rotary screw compressor Hot water heating Heat exchanger () Hot water Hot water tank Cold water Shower Image: Heat recovery process Image: PTG plate heat exchanger Image: Tube-type heat exchanger Required heating energy (%) 100 % Required heating energy over the course of a year Heat is not only needed in winter It goes without saying that heating is necessary during the winter months, but it is also required for signifi cant periods at other times of the year, such as in spring and autumn. This means that heating energy is actually required for approximately 00 hours per year. Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Image: layout of a compressor system comprising plate heat exchanger, thermostatic valve and complete pipework

6 Technical specifications Savings through hot air heat recovery Savings with PTG plate heat exchanger system bei For rotary Schraubenkompressor screw compressor bei At max. operating Überdruck pressure Motor- Rated nenn- leistung power Maximum Maximal available verfügbare heating Wärmeleistung capacity nutzbare Usable Warmluftmengeair volume of heating Amount Kühl- cooling luftauf- heizung air is heated Typ Model bar kw kw MJ/h K K (approx.) (circa) Potential Heizöl-Einsparpotential fuel oil saving Fuel Heizöl oil l Potential Erdgas-Einsparpotential natural saving Natural Erdgas gas m³ bei For Schraubenkompressor rotary screw compressor bei At max. operating Überdruck pressure Motor- Rated nenn- leistung power Maximum Maximal verfügbare available Wärmeleistung heat capacity Model Typ bar kw kw MJ/h Heated Warmwassermenge water volume Aufheizung Heated to auf C C (ΔT K) (ΔT 55 K) Int./ext. int./ext. Fuel Heizöl oil l Potential Heizöl-Einsparpotential fuel oil saving Potential Erdgas-Einsparpotential natural saving Natural Erdgas gas m³ Platzierung Installation of des the PTG- Systems system SX 3 SX 4 SX 6 SX SM SM 12 SM SK SK ASK 2 ASK 34 ASK 40 ASD 35 ASD 40 ASD 50 ASD 60 BSD 65 BSD BSD 3 CSD 5 CSD 105 CSD 1 CSDX 140 CSDX 5 DSD 142 DSD 2 DSD 2 DSD 23 DSDX 2 DSDX 5 ESD 352 ESD 442 FSD 471 FSD Savings potential for 00 hrs ,065 1,36 1,562 1,52 2,7 2,6 3,1 3, 3,4 4,465 5,506 5,552 6,46,3 7,,3 11, 13,40,00 13,1,460 1,561 23,662,55 27,763 34,62 40,06 43,54 53, Savings potential for 00 hrs ,240 1,37 1,733 1,33 2,35 2, 2,2 3,333 3,64 4, 4, 6,07 7,23 7,003,24 10,644 11,05 14,26 11,765 13,726,367,00,02 24,650,53 35,574 3,36 47, SM SM 12 SM SK SK ASK 2 ASK 34 ASK For bei rotary Schraubenkompressor screw compressor bei At max. operating Überdruck pressure Motor- Rated nenn- leistung power Maximum Maximal verfügbare available Wärmeleistung heat capacity Model Typ bar kw kw MJ/h ASD ASD ASD ASD ASD ASD ASD ASD BSD BSD BSD BSD BSD BSD 3 3 CSD CSD 5 5 CSD CSD CSD CSD 1 1 CSDX CSDX 5 5 DSD DSD DSD DSD 2 2 DSD DSD 2 2 DSD DSD DSDX 2 2 DSDX 5 5 ESD ESD ESD ESD FSD FSD FSD FSD Savings with PTG heat exchanger systems Heated Warmwassermenge water volume Aufheizung Heated to auf C C (ΔT K) (ΔT 55 K) External External Int./ext. int./ext. External Fuel Heizöl oil l Potential Heizöl-Einsparpotential fuel oil saving Savings potential for 00 hrs ,112 1,4 1,60 1, 2,343 2,3 2,55 3,40 4,16 4,2 5,24 6,326 6,0 7,635,7 10,411 12,462 10,411 11,,1 1,614,563,507 27,133 31,234 33, 41, Potential Erdgas-Einsparpotential natural saving Natural Erdgas gas m³ Savings potential for 00 hrs ,261 1,42 1,7 2,00 Platzierung Installation of des the PTG- Systems system /Year /Jahr /Year /Jahr 2,12 2,535 3,026 3,7 3,76 4,62 5,6 5,406 6,77,264,244 11,065,244 10,644 13,56,526 14,706 1,7 24,00 27,731,112 37,5 HSD 662 HSD 7 HSD 72 HSD ,24 3,51 3,65 4, ,5 3, 3,431 3,670 HSD HSD HSD HSD 7 7 HSD HSD HSD HSD ,05 50,53 54,6 5, ,7,23 4,740 52,31 Calculation example for ASD 35 Calculation example for ASD 35 For fuel oil For natural gas For fuel oil For natural gas.2 kw Fuel value per litre of fuel oil:.61 kwh/l Fuel oil heating effi ciency: 0. Price per litre of fuel oil: 0.70 /l 1 kw = 1 MJ/h x kw Fuel value per m³ natural gas: 10.2 kwh/m³ Natural gas heating effi ciency: 1.05 Price per m³ of natural gas: 0. /m³ 1 kw = 1 MJ/h x kw Fuel value per litre of fuel oil:.61 kwh/l Fuel oil heating effi ciency: 0. Price per litre of fuel oil: 0.70 /l 1 kw = 1 MJ/h x kw Fuel value per m³ natural gas: 10.2 kwh/m³ Natural gas heating effi ciency: 1.05 Price per m³ of natural gas: 0. /m³ 1 kw = 1 MJ/h x kw x 00 h Cost saving: x 0.70 /l = 3, per year 0. x.61 kwh/l Cost saving:.2 kw x 00 h 1.05 x 10.2 kwh/m³ x 0. /m³ = 2,2 per year.2 kw x 00 h Cost saving: x 0.70 /l = 2,3 per year 0. x.61 kwh/l Cost saving:.2 kw x 00 h 1.05 x 10.2 kwh/m³ x 0. /m³ = 2,12 per year Note: The highlighted potential energy savings are based on / / bar compressors at operational temperature and at max. working pressure. Values may diff er for other pressures. Note: The highlighted potential energy savings are based on / / bar compressors at operational temperature and at max. working pressure. Values may diff er for other pressures

7 KAESER The world is our home As one of the world s largest compressed air systems providers and compressor manufacturers, KAESER KOMPRESSOREN is represented throughout the world by a comprehensive network of branches, subsidiary companies and authorised partners in over 100 countries. With innovative products and services, KAESER KOMPRESSOREN s experienced consultants and engineers help customers to enhance their competitive edge by working in close partnership to develop progressive system concepts that continuously push the boundaries of performance and compressed air efficiency. Moreover, the decades of knowledge and expertise from this industry-leading system provider are made available to each and every customer via the KAESER group s global computer network. These advantages, coupled with KAESER s worldwide service organisation, ensure that all products operate at the peak of their performance at all times and provide maximum availability. KAESER KOMPRESSOREN SE P.O. Box Coburg GERMANY Tel Fax productinfo@kaeser.com P-6ED Specifi cations are subject to change without notice..1/

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