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www.kaeser.com For hot air and hot water applications Heat recovery

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  • www.kaeser.com

    For hot air and hot water applications

    Heat recovery

  • Saves money and benefits the environmentWhy recover heat?Heat recovery

    The question should in fact be: Why not? Amazingly, 100 percent of the (electrical) energy input to a compressor is convert-ed into heat. Up to 96 % of that energy can be reused for heating purposes. This not only reduces primary energy consump-tion, but also significantly improves the total energy balance.

    SavingsGas heating € 284 to € 47,759/year

    Oil heating € 274 to € 46,108/year

    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 air

    Approx. 15 %

    heat energy recoverable

    through compressed air

    cooling

    Approx. 96 %recoverable heat energy

    100 %total electrical power

    consumption

    25 %ambient heat

    25 %compressedair energypotential

    Heat in the compressorAmazingly, almost 100 percent of the electrical drive energy input to a rotary screw compressor is convert-ed 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 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 approximately 25 percent of the compressor's electrical power 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.

    Electrical power

    ► See pages 10 and 11 for details regarding calculation of savings potential.

    For plate-type heat exchanger systemsCompressor size

    “Small” “Medium” “Large”

    Compressor model SM 15 BSD 83 FSD 471

    Motor rated capacity 9 kW 45 kW 250 kW

    Potential savings per year: heating oil€ 842 € 5,422 € 29,071

    3,826 kg CO2 24,644 kg CO2 132,126 kg CO2

    Up to 96 %

    reusable heat energy

    Heat recovery

    32

  • Up to

    usable for heating96 %

    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 en-ables up to 96 % of the compressor’s total energy require-ment 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.

    Heat adjacent rooms When using recyclable heat for space heating, ducting simply feeds the warmed cooling air to where it is needed, e.g. adjacent facilities, such as warehouses or workshops.

    Heat recovery a winAmazingly, 100 percent of the electrical 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!

    Heating with hot airWarmed 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 – either for space heating or for use as process heat.

    Minimise primary energy consumption for heating

    Heat recovery

    54

  • Up to

    +70°Chot

    Using recyclable heat from the compressor, heat exchang-er 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 cir-cuits and where it is essential that the water being warmed remains uncontaminated, as is the case with cleaning-wa-ter in the food industry for example.

    PTG plate heat exchanger High quality plate-type heat exchangers are the first 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 waterHot water – up to 70 °C – can be produced from reusa-ble compressor heat via PWT heat exchanger systems. Please contact KAESER regarding higher temperature requirements.

    Feed heat energy to a heating systemUp 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.

    Minimise energy consumption for warming of process, heating and service water

    Heat recovery

    76

  • Jan Mar Apr May Jun Jul Aug Sep Oct Nov DecFeb

    100 %

    Required heating energy (%)

    Hot air heat recovery All KAESER-rotary screw compressors can be fitted with exhaust ducting. The ducting is installed on-site. Adjacent rooms and warehouse space, for example, can be heated with the warmed cooling air. Application: Drying processes, heating of halls and buildings, air curtain systems, pre-heating of burner air.

    Heat is not only needed in winterIt goes without saying that heating is necessary during the winter months, but it is also required for significant periods at other times of the year, such as in spring and autumn. This means that heating energy is actually required for approxi-mately 2000 hours per year.

    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-cooled rotary screw compressor

    Hot water heating

    Cold water

    Hot water

    Equipment

    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 exter-nally. Fields of application: Feed into central heating systems, laundries, electro-plating, general process heating, cleaning water in the food industry, swimming pool heating, hot water for shower and washroom facilities

    Tube-type heat exchangerDepending on the available water quality, either integrated plate or tube-type heat exchangers can be used in water-cooled systems. Our compressed air spe-cialists can advise you about which design is right for your particular application.

    Required heating energy over the course of a year

    98

  • Typ bei max. Über-druck

    Motor-nenn-

    leistung

    Maximal verfüg-bare Wärme-

    leistung

    nutzbare Warmluft-

    menge

    Kühl-luftauf-heizung

    Heizöl-Einsparpotential Erdgas-Einsparpotential

    Heizöl CO2 Heizkosten-Einsparung Erdgas CO2Heizkosten-Einsparung

    bar kW kW MJ/h m³/h K (circa) l kg €/Jahr m³ kg €/Jahr

    SX 3SX 4SX 6SX 8

    8

    2.234

    5.5

    2.73.44.46.0

    10121622

    1000100010001300

    8101314

    456575744

    1014

    1244156820292765

    274345446608

    378476616840

    756952

    12321680

    284357462630

    SM 9SM 12SM 15

    85.57.59

    6.89.011.8

    253243

    2100101317

    114915211994

    313341485438

    689913

    1,196

    95212611653

    190425223306

    714946

    1,240

    SK 22SK 25 8

    1115

    13.216.5

    4859

    25003000

    1617

    22312789

    60847606

    1,3391,673

    18492311

    36984622

    1,3871,733

    ASK 28ASK 34ASK 40

    815

    18.522

    18.422.826.8

    668296

    400040005000

    141716

    311038544530

    84811051012353

    1,8662,3122,718

    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

    2,7313,2183,8274,719

    3772444452856517

    75448888

    1057013034

    2,8293,3333,9644,888

    BSD 65BSD 75BSD 83

    8.5303745

    35.243.452.0

    127156187

    650080008000

    161620

    79329780

    11718

    216312667031955

    4,7595,8687,031

    657381059711

    131461621019422

    4,9306,0797,283

    CSD 85CSD 105CSD 125

    8.5455575

    506275

    179223270

    9400940010700

    162021

    112231397216902

    306053810246092

    6,7348,383

    10,141

    93001157814006

    186002315628012

    6,9758,684

    10,505

    CSDX 140CSDX 165 8.5

    7590

    84101

    302364

    1100013000

    2323

    1893022761

    5162262069

    11,35813,657

    1568618861

    3137237722

    11,76514,146

    DSD 145DSD 175DSD 205DSD 240

    98.58.58.5

    7590110132

    8296120145

    295346432522

    11000130001700020000

    22222122

    18479216342704332676

    50392589967374689107

    11,08712,98016,26619,606

    15313179272240927077

    30626358544481854154

    11,48513,44516,80720,308

    DSDX 245DSDX 305 8.5

    132160

    143176

    515634 21000

    2025

    3222639662

    87880108158

    19,33623,797

    2670432866

    5340865732

    20,02824,650

    ESD 352ESD 442 8.5

    200250

    221254

    796914 34000

    2022

    4980357240

    135813156093

    29,88234,344

    4127047432

    8254094864

    30,95335,574

    FSD 471FSD 571 8

    250315

    278341

    10011228 40000

    2126

    6264976846

    170844209559

    37,58946,108

    5191463679

    103828127358

    38,93647,759

    HSD 662HSD 722HSD 782HSD 842

    8.5

    360400450500

    21232526

    74828894

    10000

    6778

    4642511655215904

    12659139511505616100

    2,7853,0703,3133,542

    3847423945754893

    7694847891509786

    2,8853,1793,4313,670

    Typ bei max. Über-druck

    Motor-nenn-

    leistung

    Maximal verfüg-bare Wärme-

    leistung

    WarmwassermengeAufheizung auf 70 °C

    Platzierung des PTG-Systems

    Heizöl-Einsparpotential Erdgas-Einsparpotential

    Heizöl CO2Heizkosten-Einsparung Erdgas CO2

    Heizkosten-Einsparung

    bar kW kW MJ/h (ΔT 25 K) m³/h (ΔT 55 K) m³/h int./ext. l kg €/Jahr m³ kg €/Jahr

    SM 9SM 12SM 15

    85.57.59

    4.66.28.3

    172230

    0.160.210.29

    0.070.100.13

    External777

    10481403

    211928583826

    466629842

    6448681162

    128817362324

    483651872

    SK 22SK 25 8

    1115

    9.412.0

    3443

    0.320.41

    0.150.19 External

    15892028

    43335530

    9531,217

    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

    1,3791,7142,008

    190523672773

    381047345546

    1,4291,7752,080

    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

    2,055 2,4472,9213,596

    2838 3380 4034 4967

    5676 6760 8068 9934

    2,129 2,5353,0263,725

    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

    3,664 4,5295,422

    5061 6256 7488

    10122 12512 14976

    3,796 4,6925,616

    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

    5,219 6,5447,978

    7208 9038 11018

    14416 18076 22036

    5,406 6,7798,264

    CSDX 140 CSDX 165 8.5

    75 90

    66 80

    238 288

    2.30 2.80

    1.03 1.25 Internal

    14873 18028

    40559 49162

    8,92410,817

    12325 14939

    24650 29878

    9,244 11,204

    DSD 145DSD 175DSD 205DSD 240

    98.58.58.5

    75 90

    110 132

    61 7188

    107

    220 256 317 385

    2.102.40 3.003.70

    0.961.111.381.68

    Internal

    1374716000 1983124113

    37488 43632 5407965756

    8,2489,600

    11,89914,468

    11391 132591643319981

    22782 26518 32866 39962

    8,543 9,944

    12,32514,986

    DSDX 245 DSDX 305 8.5

    132160

    105130

    378468

    3.604.50

    1.642.04 Internal

    2366229296

    6452679890

    14,19717,578

    1960824276

    3921648552

    14,70618,207

    ESD 352 ESD 442 8.5

    200 250

    172 198

    619 713

    5.90 6.80

    2.69 3.10 Internal

    3876144620

    105701 121679

    23,25726,772

    3212036975

    64240 73950

    24,090 27,731

    FSD 471 FSD 571 8

    250 315

    215 266

    774 958

    7.40 9.20

    3.37 4.17 External

    48451 59944

    132126 163467

    29,071 35,966

    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

    39,34743,67447,05450,570

    54342603176498669841

    108684 120634 129972 139682

    40,75745,23848,74052,381

    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 differ for other pressures.

    Savings through hot air heat recovery

    Calculation example for ASD 35For fuel oil

    maximum available heating capacity: 20.2 kW

    Fuel value per litre of fuel oil: 9.861 kWh/l

    Fuel oil heating efficiency: 0.9

    Price per litre of fuel oil: € 0.60/l (1 kW = 1 MJ/h x 3.6)

    Cost savings:20.2 kW x 2000 h

    x € 0.60/l = € 2,731 per year0.9 x 9.861 kWh/l

    For natural gas

    maximum available heating capacity: 20.2 kW

    Fuel value per m³ natural gas: 10.2 kWh/m³

    Natural gas heating efficiency: 1.05

    Price per m³ of natural gas: € 0.75/l (1 kW = 1 MJ/h x 3.6)

    Cost savings:20.2 kW x 2000 h

    x € 0.75/l = € 2,829 per year1.05 x 10.2 kWh/m³

    Technical specifications

    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 differ for other pressures.

    Savings with PTG plate heat exchanger system

    Calculation example for ASD 35For fuel oil

    maximum available heating capacity: 15.2 kW

    Fuel value per litre of fuel oil: 9.861 kWh/l

    Fuel oil heating efficiency: 0.9

    Price per litre of fuel oil: € 0.60/l (1 kW = 1 MJ/h x 3.6)

    Cost savings:15.2 kW x 2000 h

    x € 0.60/l = € 2,055 per year0.9 x 9.861 kWh/l

    For natural gas

    maximum available heating capacity: 15.2 kW

    Fuel value per m³ natural gas: 10.2 kWh/m³

    Natural gas heating efficiency: 1.05

    Price per m³ of natural gas: € 0.75/l (1 kW = 1 MJ/h x 3.6)

    Cost savings:15.2 kW x 2000 h

    x € 0.75/l = € 2,129 per year1.05 x 10.2 kWh/m³

    Type At max. gauge

    pressure

    Motor rated

    capacity

    Maximum available heating capacity

    Amount of reusable hot air

    Amount cooling air is

    heated

    Potential fuel oil savings Potential natural gas savings

    Fuel oil CO2Heating cost

    savings Natural gas CO2Heating cost

    savings

    bar kW kW MJ/h m³/h K (approx.) l kg €/Year m³ kg €/Year

    Savi

    ngs

    pote

    ntia

    l for

    150

    0 hr

    s

    Savi

    ngs

    pote

    ntia

    l for

    150

    0 hr

    s

    Savi

    ngs

    pote

    ntia

    l for

    200

    0 hr

    s

    Savi

    ngs

    pote

    ntia

    l for

    200

    0 hr

    s

    Type At max. gauge

    pressure

    Motor rated

    capacity

    Maximum available heating capacity

    Heated water volumeHeated to 70 °C

    Installation of the PTG

    system

    Potential fuel oil savings Potential natural gas savings

    Fuel oil CO2Heating cost

    savings Natural gas CO2Heating cost

    savings

    bar kW kW MJ/h (ΔT 25 K) m³/h (ΔT 55 K) m³/h Int./ext. l kg €/Year m³ kg €/Year

    Savi

    ngs

    pote

    ntia

    l for

    150

    0 hr

    s

    Savi

    ngs

    pote

    ntia

    l for

    150

    0 hr

    s

    Savi

    ngs

    pote

    ntia

    l for

    200

    0 hr

    s

    Savi

    ngs

    pote

    ntia

    l for

    200

    0 hr

    s

    1110

  • The world is our home As one of the world’s largest compressed air systemsproviders and compressor manufacturers, KAESERKOMPRESSOREN is represented throughout the world by a comprehensive network of branches, subsidiary companies and authorised partners.

    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 every product operates at the peak of its performance at all times and provides maximum availability.

    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 P-6

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    Heat recoveryWhy recover heat?Saves money and benefits the environmentMinimise primary energy consumption for heatingMinimise energy consumption for warming of process, heating and service waterEquipmentTechnical specifications