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Maximizing Efficiency: Understanding the Core Components of Energy Recovery Systems
An energy recovery system can be installed as part of a new plant or added as an upgrade to an existing facility. The primary core components of these systems include advanced calculation software, an overall system design tailored to the project, and heat exchangers. The software enables precise calculations, ensuring accurate sizing and optimal component selection.
With a deep understanding of dryer energy systems, we strategically place each component to maximize efficiency, customizing every system to fit the specific needs of the installation.
![maximizing efficiency [image depicts an energy recovery system and its components]](https://caloris.com/wp-content/uploads/2024/08/ERS1.jpg)
A standard energy recovery system includes components such as an inlet recuperator (liquid-to-air) for process air, an outlet recuperator (air-to-liquid) for exhaust air, and a pump station. Depending on the design of the dryer installation, the system may also incorporate a flue gas recuperator if the plant uses an indirect gas/oil burner, or flash steam/condensate recovery if available from the steam heater.
Typically, the inlet recuperator is installed either for pre-conditioning process air or within the regeneration section of a sorption dehumidifier. The outlet recuperator is positioned in the exhaust stack of the spray dryer, downstream components like cyclones, wet scrubbers, or bag filters.
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In installations with no recuperation system on the flue gas from the indirect gas/oil main air heater, there is significant potential to recover additional energy, greatly enhancing overall energy efficiency. For dryer installations utilizing steam as the heating medium, the system can be upgraded to include a flash steam/condensate stage to boost energy recovery further if this feature is not already part of the heater.
The pump station is crucial in circulating the heated liquid, facilitating energy transfer. This heated liquid can be repurposed for various uses beyond heating dryer process air, optimizing overall factory energy utilization.
Our heat exchangers are a key component of these systems, allowing us to optimize fin spacing and length to suit specific needs. We can adjust fin pitches during the design phase, ensuring both effective Clean-In-Place (CIP) capability and minimal system pressure drops. Fins are designed to provide smooth, uninterrupted CIP liquid flow through the unit, ensuring long-term efficiency and ease of maintenance.
Optimizing Energy Recovery in Industrial Processes
Single- or multi-stack energy recovery systems can be installed on the dryer exhaust, with multi-stack systems offering the highest level of energy recovery. A multi-stack design is advantageous because it allows for utilizing multiple energy sources at different temperatures, enhancing energy distribution throughout the factory.
This system also enables the cooling of process exhaust air below the dew point, making it possible to recover latent heat through moisture condensation. As a result, heat transfer efficiency is significantly improved, reducing the thermal load and energy required for further air processing, leading to enhanced system efficiency.
![maximizing efficiency [image depicts a single-stack unit next to a multi-stack energy recovery system]](https://caloris.com/wp-content/uploads/2024/08/singlemulti-1024x473.png)
The outlet recuperator, installed in the dryer’s exhaust air, which is typically powder-loaded, is equipped with an automatic CIP system that cleans the unit during the dryer’s CIP process. This CIP system features dedicated nozzles that cover the entire coil surface, ensuring effective cleaning. The coils are made to withstand pressure washing without damage.
For ease of inspection, the unit is accessible through a manway, and the heater section can be extracted if additional inspection or cleaning is required. This design ensures the system remains efficient and easy to maintain over time.
Please proceed to the next blog in this series, “Unlocking Savings: How to Achieve Rapid ROI with Advanced Energy Recovery Technologies.” Contact Caloris if you are interested in discussing an energy recovery system by calling 410-822-6900 or send email to problem.solved@caloris.com.