Heat Recovery Systems PTG / SWT Series heat via PWT and SWT heat exchanger ... Equipment Heat is not only needed in ... 3,000 3,500 4,000 18 19 19 3,042 3,685 4,208 8,296 10,049

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Heat Recovery Systems PTG / SWT Series

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2 3

Approx. 5 %heat dissipated by

the drive motor

Approx. 76 %of the reusable

heat energy recov-erable through fl uid

cooling

Approx. 2 %of the the heat

energy from the compressor radiates

into the ambient surroundings

Approx. 2 %of the heat energy

remains in the compressed air

Approx. 15 %of reusable heat

energyrecoverable

through compressed air

cooling

Approx 96 %heat energy available for reuse

through heat recovery

100 %Total electrical power

consumption

25 %ambient heat

25 %compressed air energy potential

Heat in the compressor

Almost 100 percent of the electrical energy input to a compressor is converted into heat. The adjacent heat flow diagram (left) shows how this energy is distributed throughout the compressor system and how it can be recovered: 96 percent of the energy can be recovered for reuse, two percent remains in the compressed 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 con-sumption. This energy is only usable however 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 of the pressure and leakage losses within the compressed air system.

Why recover heat?The question should in fact be: Why not recover heat? Amazingly, almost 100 percent of the electrical energy input to a compressor is turned into heat. Up to 96 % of this energy can be recovered and reused for heating purposes.

Saves money and benefits the environment

For plate heat exchanger systems

Compressor size

“Small” “Medium” “Large”

Compressor model SM 15 BSD 83 FSD 471

Rated power 9 kW 45 kW 250 kW

Annual savings potential with fuel oil

€ 982 € 6,326 € 33,916

3,862 kg CO2

24,644 kg CO2

132,126 kg CO2

Gas heating294 up to 56,723 €/year

Heat recovery

Up to 96%

reusable heat

energy

Heat recovery

Electrical power consumption

Oil heating331 up to 63,888 €/year

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

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2 3

Approx. 5 %heat dissipated by

the drive motor

Approx. 76 %of the reusable

heat energy recov-erable through fl uid

cooling

Approx. 2 %of the the heat

energy from the compressor radiates

into the ambient surroundings

Approx. 2 %of the heat energy

remains in the compressed air

Approx. 15 %of reusable heat

energyrecoverable

through compressed air

cooling

Approx 96 %heat energy available for reuse

through heat recovery

100 %Total electrical power

consumption

25 %ambient heat

25 %compressed air energy potential

Heat in the compressor

Almost 100 percent of the electrical energy input to a compressor is converted into heat. The adjacent heat flow diagram (left) shows how this energy is distributed throughout the compressor system and how it can be recovered: 96 percent of the energy can be recovered for reuse, two percent remains in the compressed 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 con-sumption. This energy is only usable however 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 of the pressure and leakage losses within the compressed air system.

Why recover heat?The question should in fact be: Why not recover heat? Amazingly, almost 100 percent of the electrical energy input to a compressor is turned into heat. Up to 96 % of this energy can be recovered and reused for heating purposes.

Saves money and benefits the environment

For plate heat exchanger systems

Compressor size

“Small” “Medium” “Large”

Compressor model SM 15 BSD 83 FSD 471

Rated power 9 kW 45 kW 250 kW

Annual savings potential with fuel oil

€ 982 € 6,326 € 33,916

3,862 kg CO2

24,644 kg CO2

132,126 kg CO2

Gas heating294 up to 56,723 €/year

Heat recovery

Up to 96%

reusable heat

energy

Heat recovery

Electrical power consumption

Oil heating331 up to 63,888 €/year

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

www.kaeser.com

54

Heat recoveryMinimise primary energy consumption for heating

Heat neighbouring rooms

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

Heating with warm air

Warmed 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.

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 enables up to 96 % of the compressor’s total energy requirement to be recov-ered and used for heating purposes. This is the case irrespective of whether fluid-injection cooled compressors or dry-running screw compressors are used.

Heat recovery a win

100 percent of the electrical energy input to a com-pressor is converted into heat. From that, up to 96 percent is available for heat recovery purposes. Use this potential to your advantage!

96%Up to

energy reusable for heating purposes

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6 7

Heat recovery

Plate-type heat exchanger

The cost-effective solution for transferring reusable heat from rotary screw compressors to heating and service water; can also be used for general process heat purposes.

Feed heat energy to a heating system

Up 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.

Process, heating and service water

Hot water up to 70 °C can be produced from reusable compressor heat via PWT and SWT heat exchanger systems. Please contact KAESER regarding higher temperature requirements.

PTG and SWT heat exchanger systems can provide on-demand heating and service water heated 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, whilst SWT fail-safe heat exchangers are recommended for applications that have no other interconnecting water circuits and where it is essential that the water being warmed remains uncontaminated.

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

+70 °Chot

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98

Jan Mar Apr May Jun Jul Aug Sep Oct Nov DecFeb

100 %

Equipment

Heat is not only needed in winter

It 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 approximately 2000 hours per year.

• Chemical and pharmaceutical industries • Cantines and large scale catering establishments

Tube-type heat exchanger

In water-cooled systems, integrated plate or tube-type heat exchangers are available, depending on the available water quality. Our compressed air specialists can advise you regarding which design is right for your particular application.

Warm air heat recovery

All KAESER-rotary screw compressors can be fitted with exhaust ducting. The ducting is installed on-site. Neigh- bouring rooms and warehouse space, for example, can be heated with the warmed cooling air.

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 externally.

Areas of application • Feed into central heating systems • Laundries • Electroplating • General process heating

SWT fail-safe heat exchanger systems

Rotary screw compressors from the ASD series upwards can also be equipped with SWT fail-safe heat exchanger systems. The SWT heat exchangers are always installed exter-nally from the rotary screw compressor.

Areas of application • Food industry • Tap water heating

Required heating

energy (%)

Required heating energy over the course of a yearSpace heating with warm exhaust air

Heating made easy: Thanks to the high residual thrust radial fan, the reusable (warm) air can be easily ducted away to spaces that require heating.

Image: PTG plate heat exchanger Image: SWT fail-safe heat exchanger Image: Tube-type heat exchanger Image: Internal layout of an ESD compressor – System comprising plate heat exchanger, thermostatic valve and complete pipework

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1110

bei Schrauben-kompressor

bei max. Über-druck

Motor-nenn-

leistung

Maximal verfüg-bare Wärme-

leistung

nutzbare Warmluft-

menge

Kühl-luftauf-heizung

Heizöl-Einsparpotential Erdgas-Einsparpotential

Heizöl

l

CO2

kg

Heizkosten-Einsparung

€/Jahr

Erdgas

m³

CO2

kg


€/JahrTyp bar kW kW MJ/h m³/h K (circa)

SX 3SX 4SX 6SX 8

8

2.234

5.5

2.83.54.56.1

10131622

1,0001,0001,0001,300

8111414

473592761

1,031

1,2901,6142,0752,812

331414533722

392490630854

784980

1,2601,708

294368473641

SM 9SM 12SM 15

85.57.59

6.89.0

11.8

253243

2,100101317

1,1491,5211,994

3,1334,1485,438

8041,0651,396

9521,2611,653

1,9042,5223,306

714946

1,240

SK 22SK 25 8 11

1513.216.5

4859

2,5003,000

1617

2,2312,789

6,0847,606

1,5621,952

1,8492,311

3,6984,622

1,3871,733

ASK 27ASK 32ASK 35

815

18.522

18.021.824.9

657890

3,0003,5004,000

181919

3,0423,6854,208

8,29610,04911,475

2,1292,5802,946

2,5213,0533,487

5,0426,1066,974

1,8912,2902,615

ASD 32ASD 37ASD 47ASD 57

8

18.5222530

20.424.629.735.6

7389

107128

3,8003,8004,5005,400

16192020

4,5975,5446,6938,023

12,53615,11818,25221,879

3,2183,8814,6855,616

3,8104,5945,5466,648

7,6209,18811,09213,296

2,8583,4464,1604,986

BSD 62BSD 72BSD 81

8.5303745

35.243.452.0

127156187

6,5008,0008,000

161620

7,9329,78011,718

21,63126,67031,955

5,5526,8468,203

6,5738,1059,711

13,14616,21019,422

4,9306,0797,283

CSD 85CSD 105CSD 125

8.5455575

506376

180227274

9,4009,400

10,700

162021

11,26814,19717,127

30,72838,71546,705

7,8889,93811,989

9,33711,76514,192

18,67423,53028,384

7,0038,824

10,644

CSDX 140CSDX 165 8.5 75

9085

102306367

11,00013,000

2324

19,15522,986

52,23662,683

13,40916,090

15,87319,048

31,74638,096

11,90514,286

DSD 142DSD 172DSD 202DSD 238

98.58.58.5

7590

110132

8498

124150

302353446540

9,00014,00014,00021,000

28212721

18,93022,08527,94433,803

51,62260,22676,20392,181

13,25115,46019,56123,662

15,68618,30123,15628,011

31,37236,60246,31256,022

11,76513,72617,36721,008

DSDX 243DSDX 302 8.5 132

160148180

533648 21,000 21

2633,35240,564

90,951110,618

23,34628,395

27,63833,613

55,27667,226

20,72925,210

ESD 352ESD 442 8.5 200

250221254

796914 34,000 20

2249,80357,240

135,813156,093

34,86240,068

41,27047,432

82,54094,864

30,95335,574

FSD 471FSD 571 8 250

315278341

10011228 4,0000 21

2662,64976,846

170,844209,559

43,85453,792

51,91463,679

103,828127,358

38,93647,759

HSD 651HSD 711HSD 761HSD 831

8.5

360400450500

35384246

127138151164

10,000

11111314

7,9328,6099,46510,276

21,63123,47725,81128,023

5,5526,0266,6267,193

6,5737,1347,8438,515

13,14614,26815,68617,030

4,9305,3515,8826,386



Motor-nenn-

leistung

Maximal verfügbare

Wärmeleistung

WarmwassermengeAufheizung auf 70 °C

Platzierung des PTG-Systems


Heizöl

l

CO2-Einsparung

kg


€/Jahr

Erdgas

m³

CO2-Einsparung

kg


€/JahrTyp bar kW kW MJ/h(ΔT 25 K)

m³/h(ΔT 55 K)

m³/h int./ext.

SM 9SM 12SM 15

85.57.59

4.66.28.3

172230

0.160.210.29

0.070.100.13

External777

1,0481,403

2,1192,8583,826

544734982

644868

1,162

1,2881,7362,324

483651872

SK 22SK 25 8 11

159.4

12.03443

0.320.41

0.150.19 External 1,589

2,0284,3335,530

1,1121,420

1,3171,681

2,6343,362

9881,261

ASK 27ASK 32ASK 35

815

18.522

13.015.817.9

475764

0.450.540.62

0.200.250.28

External2,1972,6703,025

5,9917,2818,249

1,5381,8692,118

1,8212,2132,507

3,6424,4265,014

1,3661,6601,880



Motor-nenn-

leistung

Maximalverfügbare

Wärmeleistung

WarmwassermengeAufheizung auf 70 °C

Platzierung des PTG-Systems

Platzierung des SWT-Systems


Heizöl

l

CO2-

kg


€/Jahr

Erdgas

m³

CO2-

kg


€/JahrTyp bar kW kW MJ/h(ΔT 25 K)

m³/h(ΔT 55 K)

m³/h int./ext. int./ext.


8

18.5222530

15.418.622.627.1

55678198

0.530.640.780.93

0.240.290.350.42

Internal External

3,4704,1925,0936,107

9,46311,43213,88916,654

2,4292,9343,5654,275

2,8763,4734,2205,061

5,7526,9468,44010,122

2,1572,6053,1653,796

BSD 62BSD 72BSD 81

8.5303745

27.133.540.1

98121144

0.931.151.38

0.420.520.63

Internal External6,1077,5499,037

16,65420,58624,644

4,2755,2846,326

5,0616,2567,488

10,12212,51214,976

3,7964,6925,616


8.5455575

38.648.459.0

139174212

1.331.672.03

0.600.760.92

Internal External8,699

10,90713,296

23,72229,74336,258

6,0897,6359,307

7,2089,03811,018

14,41618,07622,036

5,4066,7798,264

CSDX 140CSDX 165 8.5 75

906679

238284

2.302.70

1.031.24 Internal External

14,87317,803

40,55948,549

10,41112,462

12,32514,753

24,65029,506

9,24411,065


98.58.58.5

7590

110132

667697

118

238274349425

2.302.603.304.10

1.031.191.521.85

Internal External

14,87317,12721,85926,592

40,55946,70559,60972,516

10,41111,98915,30118,614

12,32514,19218,11422,035

24,65028,38436,22844,070

9,24410,64413,58616,526

DSDX 243DSDX 302 8.5 132

160116142

418511

4.004.90


26,14132,000

71,28787,264

18,29922,400

21,66226,517

43,32453,034

16,24719,888

ESD 352ESD 442 8.5 200

250172198

619713

5.906.80


38,76144,620

105,701121,679

27,13331,234

32,12036,975

64,24073,950

24,09027,731

FSD 471FSD 571 8 250

315215266

774958

7.409.20


48,45159,944

132,126163,467

33,91641,961

40,14949,673

80,29899,346

30,11237,255


8.5

360400450500

313339372405

1127122013391458

10.8011.7012.8014.00

4.905.315.836.34

Internal External

70,53676,39583,83291,269

192,352208,329228,610248,891

49,37553,47758,68263,888

58,45063,30569,46875,630

116,900126,610138,936151,260

43,83847,47952,10156,723

For rotary screw compressor

at max. operating pressure

Rated motor power

Maximum available

heat capacity

Heated water volumeHeated to 70 °C

Installation of the PTG

system

Potential fuel oil saving Potential natural gas saving

Heating oil l

CO2Saving

kg

Heating cost saving€/Year

Natural gasm³

CO2Saving

kg

Heating cost saving€/YearModel bar kW kW MJ/h

(ΔT 25 K)m³/h

(ΔT 55 K)m³/h Int./ext.

SM 9SM 12SM 15

SK 22SK 25

ASK 27ASK 32ASK 35

Savings with PTG plate heat exchanger system


at max. operating pressure

Rated motor power

Maximum available

heat capacity

Heated water volumeHeated to 70 °C

Installation of the PTG

system

Installation of the SWT

system


Heating oil l

CO2 kg


Natural gasm³

CO2 kg

Heating cost saving€/YearModel bar kW kW MJ/h

(ΔT 25 K)m³/h

(ΔT 55 K)m³/h Int./ext. Int./ext.


BSD 65BSD 75BSD 83


CSDX 140CSDX 165


DSDX 243DSDX 302

ESD 352ESD 442

FSD 471FSD 571


Savings with PTG and SWT heat exchanger systems

Technical specifications


At max. operating pressure

Rated motor power

Maximum available heating capacity

Usable volume of heating air

Amount cooling air is

heated


Heating oil

l

CO2 kg


Natural gas

m³

CO2

kg

Heating cost saving€/YearModel bar kW kW MJ/h m³/h K (approx.)

SX 3SX 4SX 6SX 8

SM 9SM 12SM 15

SK 22SK 25

ASK 27ASK 32ASK 35


BSD 65BSD 75BSD 83


CSDX 140CSDX 165


DSDX 243DSDX 302

ESD 352ESD 442

FSD 471FSD 571


Savings through warm air heat recovery

Calculation example for ASD 32

For fuel oil

Maximum available heat capacity: 15.4 kWFuel value per litre of heating oil: 9.861 kWh/lFuel oil heating efficiency: 0.9Price per litre of heating oil: 0.70 €/l 1 kW = 1 MJ/h x 3.6 Cost saving: x 0.70 €/l = € 2,429 annually15.4 kW x 2000 h

0.9 x 9.861 kWh/l

For natural gas

Maximum available heat capacity: 15.4 kWFuel value per m³ natural gas: 10.2 kWh/m³Natural gas heating efficiency: 1.05Price per m³ of natural gas: 0.75 €/m³ 1 kW = 1 MJ/h x 3.6 Cost saving: x 0.75 €/m³ = € 2,157 annually15.4 kW x 2000 h

1.05 x 10.2 kWh/m³

Calculation example for ASD 32

For fuel oil

Maximum available heat capacity: 20.4 kWFuel value per litre of heating oil: 9.861 kWh/lFuel oil heating efficiency: 0.9Price per litre of heating oil: 0.70 €/l 1 kW = 1 MJ/h x 3.6 Cost saving: x 0.70 €/l = € 3,218 annually20.4 kW x 2000 h

0.9 x 9.861 kWh/l

For natural gas

Maximum available heat capacity: 20.4 kWFuel value per m³ natural gas: 10.2 kWh/m³Natural gas heating efficiency: 1.05Price per m³ of natural gas: 0.75 €/m³ 1 kW = 1 MJ/h x 3.6 Cost saving: x 0.75 €/m³ = € 2,858 annually20.4 kW x 2000 h

1.05 x 10.2 kWh/m³

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.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.

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As one of the world’s largest manufacturers of rotary screw compressors, KAESER KOMPRESSOREN is represented throughout the world by a comprehensive network of branches, subsidiary companies and authorised partners in over 100 countries.

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 all products operate at the peak of their performance at all times and provide maximum availability.

KAESER – The world is our home

www.kaeser.com

KAESER KOMPRESSOREN AG P.O. Box 2143 – 96410 Coburg – GERMANY – Tel +49 9561 640-0 – Fax +49 9561 640130www.kaeser.com – e-mail: [email protected] P-

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D.15

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Documents

Heat Recovery Systems PTG / SWT Series heat via PWT and SWT heat exchanger ... Equipment Heat is not only needed in ... 3,000 3,500 4,000 18 19 19 3,042 3,685 4,208 8,296 10,049