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COMPRESSED AIR DRYING
UNEXPECTED WAYS
IN ENERGY SAVINGS
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
k
Wh
/ m
³
Compressor’s load in %
GA55 VSD IFD
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%
k
Wh
/ m
³
18% load
Air flow [m³/h] 94
Specific energy for compr. air
[kWh/m³]
0.173
Total power consumption [kW] 16.3 kW
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%
k
Wh
/ m
³
63% load
Air flow [m³/h] 381
Specific energy for compr. air
[kWh/m³]
0.114
Total power consumption [kW] 43.4 kW
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!
MAXIMIZING COMPRESSOR’S LOAD
REDUCES
SPECIFIC ENERGY COSTS
OF COMPRESSED AIR
FACT 1
STANDARD COMPRESSED AIR DRYER
0
50
100%
Heating
Compressed Air
80°C 180°C Energy requirement at:
2-CIRCUIT COMPRESSED AIR DRYER
0
50
100%
Heating
Compressed Air
80°C 180°C Energy requirement at:
2-CIRCUITS COMPRESSED AIR DRYER
0
50
100%
Heating
Compressed Air
Standard Two-circuits
80°C
80°C
180°C
180°C
Energy requirement:
ONLY POSSIBLE THROUGH PATENTED CARD-SYSTEM
CARD M CARD L
THE MAJOR TASK OF DRYING IS TO HEAT-UP!
2-CIRCUIT SYSTEM
DRASTICALLY REDUCES
ENERGY COSTS
OF COMPRESSED AIR DRYING
FACT 2
METHODS OF ENERGY RECOVERY
High-level
placement of CARD
reduces
energy costs
up to 10%
METHODS OF ENERGY RECOVERY
0
50
100%
Heating
Compressed Air
20°C 35°C Secondary air inlet temperature:
ENERGY CONSUMPTION OF
A DRYING PROCESS
WITH 80°C
METHODS OF ENERGY RECOVERY
Heat recovery from plant’s energy resources
METHODS OF ENERGY RECOVERY
Heat recovery
from integrated
air compressor
CARD R
METHODS OF ENERGY RECOVERY
0
50
100%
Heating
Compressed Air
w/o with Heat recovery:
ENERGY CONSUMPTION OF
A DRYING PROCESS
WITH 80°C
METHODS OF ENERGY RECOVERY
Heat and air recovery on blow-molding applications
METHODS OF ENERGY RECOVERY
0
50
100%
Heating
Compressed Air
w/o with Air and heat recovery:
ENERGY CONSUMPTION OF
A DRYING PROCESS
WITH 80°C
0
50
100%
36%
22%
Standard Two-circuits High-level Heat recovery Heat & air
recovery
METHODS OF ENERGY RECOVERY
100%
38%
0,1%
CARD (2-CIRCUIT-SYSTEM)
ENABLES UNIQUE WAYS
OF ENERGY RECOVERY
TO LOWER
ENERGY REQUIREMENTS
FACT 3
0
25
50
75
100
Desiccant dryernew
Desiccant dryer20% less efficiency
CARD2-circuits
CARDhigh-level
CARDheat recovery
%
ANALOGY TO COMMON DRYING SYSTEMS
TOTAL ENERGY CONSUMPTION
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
kW
h /
m³
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
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
DRYING WITH
COMPRESSED AIR
IS NOT EXPENSIVE!
FACT 4
THANK YOU!
