heat recovery for hot air and hot water applications · for heat recovery. direct use of the...
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Heat recovery forhot air and hot waterapplications
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Approx. 5 %heat dissipationfrom the drive
motor
Approx. 76 %heat energy recoverable
throughfl uid cooling
Approx. 2 %heat dissipated
by the compressor into the ambient air
Approx. 2 %heat remaining in the
compressed airApprox. 15 % heat energy recov-
erable throughcompressed air
cooling
Approx. 96 %recoverable heat energy
Up to 100 %total electrical power
consumption
Up to 25 %ambient heat
Up to 25 %compressed air energy potential
Heat in the compressor
Amazingly, almost 100 percent of the electrical drive energy input to a rotary screw compressor is convert-ed into heat.
The adjacent heat fl ow diagram (left) shows how this energy is distributed throughout the compressor system and how it can be recovered:Approximately 96 percent of the energy can be recovered for reuse, two percent remains in the com-pressed 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 approximately25 percent of the compressor's electricalpower consumption. This energy is only usable how-ever 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.
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 96 % 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 benefi ts the environment
For plate heatexchanger systems
Compressor size
“Small” “Medium” “Large”
Compressor model SM 15 BSD 83 FSD 471
Rated power 9 kW 45 kW 250 kW
Annual savingspotential withfuel oil
€ 982 € 6,326 € 33,916
3,826kg CO2
24,644kg CO2
132,126kg CO2
Gas heating294 up to 55,742 €/year
Heatrecovery
Up to 96%
reusableheat energy
Heat recovery
Electrical power consumption
Oil heating331 up to 62,784 €/year
► See pages 10 and 11 for details regarding calculation of savings potential.
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Heat recoveryMinimise primary energyconsumption for heating
Heat neighbouring rooms
When using recyclable heat for space heating, duct-ing simply feeds the warmed cooling air to where it is needed, e.g. in adjacent facilities, such as warehous-es or workshops.
Heating with hot air
Warmed compressor cooling air can be ducted away to provide highly effective space heating. With this method, up to 96 percent of the compressor’s input energy can therefore be recovered as heat.
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 96 percent of the compressor's total energy requirement to be recov-ered and used for heating purposes. This is the case irrespective of whether fl uid-injection cooled com-pressors or dry-running screw compressors are used.
Heat recovery a win
Amazingly, 100 percent of the electrical drive energy input to a compressor is converted into heat. From that, up to 96 percent is available for heat recovery purposes. Use this potential to your advantage!
Up to
energy reusable for heating purposes
blbl96%
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Heat recovery
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.
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 signifi cantly reduces primary energy demand required for heating purposes.
Minimise primary energy consumption for warming of process, heating and service water
+70°Chot
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 90 °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.
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Jan Mar Apr May Jun Jul Aug Sep Oct Nov DecFeb
100 %
Equipment
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 2000 hours per year.
Tube-type heat exchanger
Depending on the available water quality, either integrated plate or tube-type 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.
Hot air heatrecovery
All KAESER rotary screw compressorscan be fi tted with exhaust ducting. The ducting is installed on-site. Neigh-bouring 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 compres-sor 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
Requiredheating
energy (%)
Required heating energy over the course of a year
Image: PTG plate heat exchanger Image: Tube-type heat exchanger
Image: Heat recovery process
Image: Internal layout of a compressor – system comprising plate heat exchanger, thermostatic valve and complete pipework
Shower
Hot water tank
Heat exchanger(Internal)
Air-cooledrotary screw compressor
Hot water heating
Cold waterHot water
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bei Schrauben-kompressor
bei max. Über-druck
Motor-nenn-
leistung
Maximal verfüg-bare Wärme-
leistung
nutzbare Warmluft-
menge
Kühl-luftauf-heizung
Heizöl-Einsparpotential Erdgas-Einsparpotential
Heizöl
l
CO2
kg
Heizkosten-Einsparung
€/Jahr
Erdgas
m³
CO2
kg
Heizkosten-Einsparung
€/JahrTyp bar kW kW MJ/h m³/h K (circa)
SX 3SX 4SX 6SX 8
8
2.234
5.5
2.83.54.56.1
10131622
1000100010001300
8111414
4735927611031
1290161420752812
331414533722
392490630854
78498012601708
294368473641
SM 9SM 12SM 15
85.57.59
6.89.011.8
253243
2100101317
114915211994
313341485438
8041,0651,396
95212611653
190425223306
714946
1,240
SK 22SK 25 8 11
1513.216.5
4859
25003000
1617
22312789
60847606
1,5621,952
18492311
36984622
1,3871,733
ASK 28ASK 34ASK 40
815
18.522
18.422.826.8
667896
400040005000
141716
311038544530
84811051012353
2,1772,6983,171
257731933754
515463867508
1,9332,3952,816
ASD 35ASD 40ASD 50ASD 60
8.5
18.5222530
20.223.828.334.9
7386102126
3800380045005400
16191919
4552536363787865
12413146251739321448
3,1863,7544,4655,506
3772444452856517
75448888
1057013034
2,8293,3333,9644,888
BSD 65BSD 75BSD 83
8.5303745
35.243.452.0
127156187
650080008000
161620
7932978011718
216312667031955
5,5526,8468,203
657381059711
131461621019422
4,9306,0797,283
CSD 85CSD 105CSD 125
8.5455575
506376
180227274
9400940010700
162021
112681419717127
307283871546705
7,8889,938
11,989
93371176514192
186742353028384
7,0038,824
10,644
CSDX 140CSDX 165 8.5 75
9085
102306367
1100013000
2324
1915522986
5223662683
13,40916,090
1587319048
3174638096
11,90514,286
DSD 142DSD 172DSD 202DSD 238
98.58.58.5
7590110132
8498
124150
302353446540
9000140001400021000
28212721
18930220852794433803
51622602267620392181
13,25115,46019,56123,662
15686183012315628011
31372366024631256022
11,76513,72617,36721,008
DSDX 245DSDX 305 8.5 132
160143176
515634 21000 20
253222639662
87880108158
22,55827,763
2670432866
5340865732
20,02824,650
ESD 352ESD 442 8.5 200
250221254
796914 34000 20
224980357240
135813156093
34,86240,068
4127047432
8254094864
30,95335,574
FSD 471FSD 571 8 250
315278341
10011228 40000 21
266264976846
170844209559
43,85453,792
5191463679
103828127358
38,93647,759
HSD 662HSD 722HSD 782HSD 842
8.5
360400450500
21232526
74828894
10000
6778
4642511655215904
12659139511505616100
3,2493,5813,8654,133
3847423945754893
7694847891509786
2,8853,1793,4313,670
bei Schrauben-kompressor
bei max. Über-druck
Motor-nenn-
leistung
Maximal verfügbare
Wärmeleistung
WarmwassermengeAufheizung auf 70 °C
Platzierung des PTG-Systems
Heizöl-Einsparpotential Erdgas-Einsparpotential
Heizöl
l
CO2
Einsparungkg
Heizkosten-Einsparung
€/Jahr
Erdgas
m³
CO2
Einsparungkg
Heizkosten-Einsparung
€/JahrTyp bar kW kW MJ/h(ΔT 25 K)
m³/h(ΔT 55 K)
m³/h int./ext.
SM 9SM 12SM 15
85.57.59
4.66.28.3
172230
0.160.210.29
0.070.100.13
External777
10481403
211928583826
544734982
644868
1162
128817362324
483651872
SK 22SK 25 8 11
159.4
12.03443
0.320.41
0.150.19 External 1589
202843335530
1,1121,420
13171681
26343362
9881,261
ASK 28ASK 34ASK 40
815
18.522
13.616.919.8
496171
0.470.580.68
0.210.260.31
Internal229928563347
626977889127
1,6091,9992,343
190523672773
381047345546
1,4291,7752,080
bei Schrauben-kompressor
bei max. Über-druck
Motor-nenn-
leistung
Maximalverfügbare
Wärmeleistung
Warmwassermenge Aufheizung auf 70 °C
Platzierung des PTG-Systems
Heizöl-Einsparpotential Erdgas-Einsparpotential
Heizöl
l
CO2
kg
Heizkosten-Einsparung
€/Jahr
Erdgas
m³
CO2
kg
Heizkosten-Einsparung
€/JahrTyp bar kW kW MJ/h (ΔT 25 K) m³/h
(ΔT 55 K) m³/h int./ext.
ASD 35 ASD 40 ASD 50 ASD 60
8.5
18.5 22 25 30
15.2 18.1 21.6 26.6
55 65 78 96
0.52 0.62 0.74 0.92
0.24 0.28 0.34 0.42
Internal
3425 4079 4868 5994
9340 11123 13275 16346
2,398 2,855 3,408 4,196
2838 3380 4034 4967
5676 6760 8068 9934
2,129 2,535 3,026 3,725
BSD 65 BSD 75 BSD 83
8.530 37 45
27.1 33.5 40.1
98 121 144
0.93 1.15 1.38
0.42 0.52 0.63
Internal6107 7549 9037
16654 20586 24644
4,275 5,284 6,326
5061 6256 7488
10122 12512 14976
3,796 4,692 5,616
CSD 85 CSD 105 CSD 125
8.545 55 75
38.6 48.4 59.0
139 174 212
1.33 1.67 2.03
0.60 0.76 0.92
Internal8699
10907 13296
23722 29743 36258
6,0897,6359,307
7208 9038
11018
14416 18076 22036
5,406 6,779 8,264
CSDX 140 CSDX 165 8.5 75
9066 79
238 284
2.30 2.70
1.03 1.24 Internal 14873
1780340559 48549
10,411 12,462
12325 14753
24650 29506
9,244 11,065
DSD 142 DSD 172 DSD 202 DSD 238
98.58.58.5
75 90
110 132
66 76 97
118
238 274 349 425
2.30 2.60 3.30 4.10
1.03 1.19 1.52 1.85
Internal
14873 17127 21859 26592
40559 46705 59609 72516
10,411 11,989 15,301 18,614
12325 14192 18114 22035
24650 28384 36228 44070
9,244 10,64413,586 16,526
DSDX 245 DSDX 305 8.5 132
160105130
378468
3.604.50
1.642.04 Internal 23662
292966452679890
16,56320,507
1960824276
3921648552
14,70618,207
ESD 352 ESD 442 8.5 200
250172 198
619 713
5.90 6.80
2.69 3.10 Internal 38761
44620105701 121679
27,133 31,234
32120 36975
64240 73950
24,090 27,731
FSD 471 FSD 571 8 250
315215 266
774 958
7.40 9.20
3.37 4.17 External 48451
59944132126 163467
33,916 41,961
40149 49673
80298 99346
30,112 37,255
HSD 662 HSD 722 HSD 782 HSD 842
8.5
360400450500
291323348374
1048116312531346
10.011.112.012.9
4.565.065.455.86
Internal
65578727907842384283
178831 198498 213860 229840
45,90550,95354,89658,998
54342603176498669841
108684 120634 129972 139682
40,75745,23848,74052,381
Forrotary screwcompressor
At max.operatingpressure
Ratedmotorpower
Maximumavailable
heat capacity
Heated water volumeHeated to 70 °C
Installationof the PTG
system
Potential fuel oil saving Potential natural gas saving
Fuel oil
l
CO2
savingkg
Heating costsaving€/Year
Natural gasm³
CO2
savingkg
Heating costsaving€/YearModel bar kW kW MJ/h
(ΔT 25 K)m³/h
(ΔT 55 K) m³/h Int./ext.
SM 9SM 12SM 15
SK 22SK 25
ASK 28ASK 34ASK 40
Savings with PTG plate heat exchanger system
Forrotary screwcompressor
At max. operating pressure
Ratedmotorpower
Maximumavailable
heat capacity
Heated water volumeHeated to 70 °C
Installationof the PTG
system
Potential fuel oil saving Potential natural gas saving
Fuel oil
l
CO2
kg
Heating costsaving€/Year
Natural gasm³
CO2
kg
Heating costsaving€/YearModel bar kW kW MJ/h
(ΔT 25 K)m³/h
(ΔT 55 K) m³/h Int./ext.
ASD 35ASD 40ASD 50ASD 60
BSD 65BSD 75BSD 83
CSD 85CSD 105CSD 125
CSDX 140CSDX 165
DSD 142DSD 172DSD 202DSD 238
DSDX 245DSDX 305
ESD 352ESD 442
FSD 471FSD 571
HSD 662HSD 722HSD 782HSD 842
Savings with PTG heat exchanger systems
Technical specifi cations
For rotary screw compressor
At max.operatingpressure
Ratedmotorpower
Maximum availableheatingcapacity
Usablevolume ofheating air
Amountcooling air is
heated
Potential fuel oil saving Potential natural gas saving
Fuel oil
l
CO2
kg
Heating costsaving€/Year
Natural gas
m³
CO2
kg
Heating costsaving€/YearModel bar kW kW MJ/h m³/h K (approx.)
SX 3SX 4SX 6SX 8
SM 9SM 12SM 15
SK 22SK 25
ASK 28ASK 34ASK 40
ASD 35ASD 40ASD 50ASD 60
BSD 65BSD 75BSD 83
CSD 85CSD 105CSD 125
CSDX 140CSDX 165
DSD 142DSD 172DSD 202DSD 238
DSDX 245 DSDX 305
ESD 352ESD 442
FSD 471FSD 571
HSD 662 HSD 722 HSD 782 HSD 842
Savings through hot air heat recovery
Calculation example for ASD 35
For fuel oil
Maximum available heat capacity: 15.2 kWFuel value per litre of fuel oil: 9.861 kWh/lFuel oil heating effi ciency: 0.9Price per litre of fuel oil: 0.70 €/l 1 kW = 1 MJ/h x 3.6
Cost saving: x 0.70 €/l = € 2,398 per year15.2 kW x 2000 h0.9 x 9.861 kWh/l
For natural gas
Maximum available heat capacity: 15.2 kWFuel value per m³ natural gas: 10.2 kWh/m³Natural gas heating effi ciency: 1.05Price per m³ of natural gas: 0.75 €/m³ 1 kW = 1 MJ/h x 3.6
Cost saving: x 0.75 €/m³ = € 2,129 per year15.2 kW x 2000 h1.05 x 10.2 kWh/m³
Calculation example for ASD 35
For fuel oil
Maximum available heat capacity: 20.2 kWFuel value per litre of fuel oil: 9.861 kWh/lFuel oil heating effi ciency: 0.9Price per litre of fuel oil: 0.70 €/l 1 kW = 1 MJ/h x 3.6
Cost saving: x 0.70 €/l = € 3,186 per year20.2 kW x 2000 h0.9 x 9.861 kWh/l
For natural gas
Maximum available heat capacity: 20.2 kWFuel value per m³ natural gas: 10.2 kWh/m³Natural gas heating effi ciency: 1.05Price per m³ of natural gas: 0.75 €/m³ 1 kW = 1 MJ/h x 3.6
Cost saving: x 0.75 €/m³ = € 2,829 per year20.2 kW x 2000 h1.05 x 10.2 kWh/m³
Note: The highlighted potential energy savings are based on 8 / 8.5 / 9 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 8 / 8.5 / 9 bar compressors at operational temperature and at max. working pressure. Values may diff er for other pressures.
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KAESER – The world is our home
KAESER KOMPRESSOREN SEP.O. Box 2143 – 96410 Coburg – GERMANY – Tel +49 9561 640-0 – Fax +49 9561 640-130e-mail: [email protected] – www.kaeser.com
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 effi ciency. 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.
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