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www.kaeser.com
For hot air and hot water applications
Heat recovery
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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
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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
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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
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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
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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
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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
45ED
Su
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t to
alte
ratio
n wi
thou
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.19/
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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