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It is a thermodynamic fact that around 94 % of the energy needed to run a compressor gets converted to heat. Without heat recovery, this heat is directly blown into the atmosphere.
The heat generated during compression is paid for as part of the process, then it creates additional costs as this heat needs to be removed by cooling fans. At the same time, most companies consume a lot of energy and money to generate hot process water, space heating or preheat water for steam generation.
Given that compressed air systems account for 10% of all electricity used in industry, and energy is the largest single lifecycle cost of a compressor, it makes sense to recover this heat, save energy and reduce costs.
With heat recovery system from CompAir, the heat generated by the compressor can be re-used, providing the following BENEFITS:
The basic principle lies in the transfer of the heat to a medium and then transporting it to where the heat can be utilised.
Instead of simply removing the heat from the airend, it can be used to generate free hot process water or supplement hot water heating systems by utilising a high-efficiency oil-water heat exchanger – factory fitted, retro fitted or as a CompAir energy recovery box.
By re-directing the hot cooling oil to a high efficiency oil to water heat exchanger, the heat can be transferred to water, raising the temperature to a required level for a multitude of applications - heating, process, production or washing:
Heat recovery systems are perfect for augmenting your facility’s heating system. By utilising the heat energy from your compressor(s) that would otherwise go to waste, you can keep your premises warm, reduce your heating bill and cut back on your company’s carbon emissions.
Heat recovery systems can provide up to 72% of the energy required to heat your hot water system. By utilising the heat energy that would otherwise go to waste, you can have running hot water and cut back on your company's carbon emissions.
Heat recovery systems can also be used to pre-heat the water supplying your process application requirements, for example, steam generation. Anywhere hot water is required, supplying pre-heated water makes the process more cost efficient.
An enclosed, air cooled compressor with defined air outlet can transfer the total amount of heat of the cooling air for ambient air heating:
The compressor’s heated cooling air can be utilised to increase the ambient temperature of rooms instead of being dissipated into the atmosphere. By ducting the air to somewhere where it would be more useful, you can increase the ambient temperatures of those rooms and save on their heating costs.
Best case scenario: Based on 8.760 hours a year 15℃ IN 75℃ OUT Temperature Increase 60℃
1)For illustration purposes only. Depending on electricity cost, water input heat and required temperature rise, the savings and pay back time will vary.