PuK - Process Technology & Components 2024

FILTECH
This variant of heat recovery is also possible
with primary water-cooled rotary screw compressors.
Heat recovery is principally worthwhile
when the compressors in question feature
a power output of at least 5.5 kW.
Establishing actual requirement
Since very few operators know their exact
air demand, it is worth conducting a compressed
air audit before installing a compressor
system. Performed swiftly and seamlessly
using state-of-the-art analysis tools such as
the ADA/KESS (Air Demand Ana lysis/Kaeser
Energy Saving System), this audit can determine
the precise demand data for a project.
The web-based system transmits measured
data and system data for the audited station,
and rapidly provides an initial report for the
operator. These data can then be transferred
to the KESS system and subsequently used to
determine the planning steps for the air station
operator, as well as the investment costs
and potential for energy savings. In the case
of a completely new installation, optimised solutions
are devised and suggested from the
outset so that the operator can compare independently
between different system variants
and select the most cost-efficient choice.
Where building management systems are
used, it is recommended to conduct a thermal
audit in conjunction with the compressed
air audit so that the heat balance can be determined
in parallel with the air consumption.
This allows thermal data such as temperature
flow and return to be investigated in addition
to compressed air data such as volume, pressure
and required air quality.
Once these details are established, it can
be determined what percentage of the compressor
exhaust heat can be absorbed into
the normal heat requirement of the project.
This in turn allows the size of the storage vessel
and the required temperature to be calculated.
In the best-case scenario, 96 % of the
heat output can be used.
What to consider
A few points must be taken into account when
planning or optimising a compressed air station.
For example, compressors and heating
systems should not be placed in the same
room, since optimal use of these requires
different room climate conditions and the
compressor must not be permitted to draw
in dangerous admixtures. The compressor
room needs to be well venti-lated; the room
for the heating system does not. In an ideal
world, the two rooms would be separate but
situated near to one another, so that the ducting
route between compressors and heating
system can be as short as possible. Even
when the two systems are positioned apart,
the heat from the compressors can be used
to heat the burner intake air for the heating
system.
Since the volume of accumulating heat
and the heat requirement are rarely identical,
it is im-portant to ensure that there is sufficient
thermal storage potential in the form of
large vessels. This guarantees optimum sup-
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Fig. 3: Compressed air station with air ducts for heat recovery. The ducts convey hot air to neighbouring spaces.
PROCESS TECHNOLOGY & COMPONENTS 2024
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