? a -' | id y vil rg Ulzale ESTES, ET AND SUPPLIES x 17 gael y Cartridge Heat iGonsiderations Convection ye rss The Path to ayer elvis Piru perature Control ofa Semiconduttor-Process™ECTION DRY THE PATH TO, ENERGY SAVINGS Gerstner ate considered. amining cach ofthese com tht is entering. Thee may be ain Jayco the product. The exact amount ponents individually wll povdea glimpse moisture entering the sytm that is not CON m av o ‘of energy transferred varies for different at energy saving opporcunites, necessary. 1's, you may realize immediate products, but iis usually agin! when energy svings withthe proper removal ot compured co other energy expendiares Heating and prevention of his incoming wae wichin dhe stem In fic this tamsir of Evaporating Water What ate posible sources of incoming ‘energy is offen destable ast may provide Water temoval males p the consumptive moisture? The product may ratve arise desired chemical or physical enhancement “beat” that lines within our drying sys before entering the die. Tisaddsa sueice to the product. cems. Within the belly ofthis beast reside eve of mats that maybe removed eas ‘With ever-increasing energy css, hower- eo components: sensible and latent heat. ly via si knives or additonal conveyance ‘many organizations are searching for ways Sensible heat is the energy required to Perhaps the producti already mechanically to reduce their energy expendinre co main- _clevate the temperature ofthe liquid water dewatered, Cheek the performance of the ‘ain profcabilty. This nitive has led dryer (1.0 BTUMIb-"F [4.2 kW/kg-°C] for wate, dewatering device to ensure it is running manufactures to develop energy-efficient while latent heat is the energy required to optimally, and ask the manufacturer if aay y To identity ways to reduce the amount of energy used by your drying system, you must first understand how that energy is spent — heating and evaporating water, 5 heating fresh airstreams, and making up losses, among others. Evaluating these points in your operation can point to areas where savings may be possible. By Dustin O'Farrell, Aeroglide Corp. technologies that decrease overall consump- change the phase ofthis water from ligul Conveyor-based dryer designs include tion within the equipment. So eerainly, ro vapor (1,000 BTUM (2.326 fg] for single-pass, mult-pass,multrstage, dual ‘ne way to minimize energy consump- atmospheric water, During the drying Plenum and inline airflow, but all have ton pecan engine dyer proces Inet het eauirenens pial ere commen: the potent for design. Aide from echnology advance~ re about 1 ines tha of ese has sens hough tho rsa metodo From this component of ene thre dee we mov options tha allow faker belp reduce opting cos when comes are ewo main obsrtions. Fis me cane mechan dewatering of your ph coding cqupet nat rece the amoune of energy eed” Exe sare may no ents the ‘Whether your stem uilizsconeyor to eraposte the product moire der che prac lone, You may have online bod, rotary; fluid bed or other ype of dry- conventional, convection dryer conditions, cleaning equipment that cleans che dryer ing technology, the techniques co reduce Second, any potential eduction af evzpo- _duting operation. Ths is additional mois- energy usige are similar To identify che rave load on the drying system can resale cure thae will be evaporated duting the potential for energy reduction in a deyer, in large gains in encegy savings. Two ways drying process, Determine the overall you must fic understand its balance of to minimize che evaporative load are 1 necesiy of using this cleaning system energy, which often is spent beating and reduce the moisture level of the incoming during runtime — it may aot be as neces cvaporating, water, and heating fresh air- product and increase che moisture lvl of sary as originally chought It is, consider streams. Loses through radiation, conduc- the exiting proc, the frequency of operation and the vol- sion leaks, component absorprion, and Reduce Incoming Moisture, Look to the ume of water used — perhaps these may applying heat to the product also must be feed end of your deyer and the product be decreased as well 18 | occaber 2007 « Process HeatingIncrease Exit Moisture, Examine the smoisgute of the product fiom the dryers discharge end ac different locations. It is likely cha che overall moisture level of the product is slghily less than the necesary specification. This may be due to many factors, including upstream changes in moisture or poor moisture uniformity Make sure that the dryer settings are such cha the produet is drying o then imum acceptable moisture secting, This ray require some adjustment to ensure {good moisture uniformity. This eedvction in evaporation will noe only save energy but also increase production for weight- based products (abe 1), Heating Fresh (Makeup) Airstreams Tndtag. procs heats Hata Geri eke pea On Pose eee eee cane etic sit oe eet ieee omental ooeee elena at which b belncel eet ti introduced to the dre, The fh as imately heated to the eshaus temperacure ‘efor ic exits the dryer This energy demand 's gpiclly les chan chat of the evapora- tion energy. However ics where the largest potential tes of improvement often exists Optimizing Exhaust Humidity. The more air that is removed from the deyer, the more fresh air needs to be heated. Often, the dryer exhaust may remove too much air ‘overeshausting) in order to ensure proper moisture removal from he product. This may he quite effective for drying, but tan increase energy usage ro heat che frsh ait catering the system. Decreasing this energy usage roquiresthac you oprimize the exhaust humidity level, The Roary dryers often are used forhigh throughput api ‘ations Involving high:mosture, Fable products To maximize ‘energy savings con- ‘See thes Principles Ilustrated sider whether you can detailed graphic tatillustates each, reduce the moisture ofthe areas outined inthis article is level ofthe incoming avaliable as exclusive online content product or increase themoisturelevelof conditions, ie may be posible to incorporate theexiting product. 4g heat recovery sem with your dryer to ideal humidity level vais for differen prod- capitalize on energy remaining inthe exhaust tus and canbe provided by yourdiyer man- steam. One ofthe most common means to fierce Using humidity probesordry- and) accomplish this is hrough a heat exchanger. vwetbulb thermometers the exhasst steams ‘There are many types of eat exchangers humidity level should be checked and adjust- such as altto-airand air-ro-water. Although cel to the design humidity level On simple the principle isthe same forall systems — systems, just reducing the amount that an reeaprure the waste heat in the exhaust cshause damper is open cin increase che steam co provide higher energy makeup hhumiiny level. More advanced systems may air — the proper soluion will depend on require control system adjustments such as your drying environment. Many deyer reducing an inverter signal oslow an exhaust manufacturers can advise which system fan, an aucomatic humidiry-contil system would be best for your application, — intended toads dhe exhaust sytem co Dryer Operation Improper dryer oper ideal conlions — isin place, check it for’ tion sich a8 a short retention time oF ait ‘proper operation and elbration, flaw shore circits will ele in excessively Consider Your Fresh AirSource. Another high operating. temperatures, including ‘omsideration is the source of fresh air exhaust By keeping the exhaust eempera centering thedryer. Air fiom acold, ourdoor tures low; there isles energy leaving the climate may cause signficane demands on dryer, resulting in net savings. the heat energy required co reach the Check the dyer design to ensure that Aesired temperature. Consider whether ic is all exhaust air is coming from the opsimal posible to collect fresh ait from inside the location: afier it has passed shrough the building. IFthis iris warmer duc to equip product. Eliminate any areas where process ‘ment heat loss indoor, i¢ may be a great alemay “short-circuit” the desired path and means of energy recovery and net savings. enter the exhaust steam. Finally, reduce Likewise ifthe produce is cooled afer the operating temperature of the dyer as drying, shin about collecting che spent air much as possible, compensating typically from the eoling process and using this as by incresing retention time and airflow. makeup airfor the deer. lel beat a high- ex emperatue than ambient ir and ie will Other Losses concn very lil adivonal humidity from Losses due to radiation and conduction passing through the product for cooling. losis, component heating and. air leak, Heat Recovery Systems. Given he sight although undesied ate inevitable. Howevet, Pina ee Final ‘Mass Moisture ‘Moisture Evaporation —_Eneray Product (ib) (b) i Out cH) Decrease ‘1900 1302 ar 3 02 —_ 1.000 1.287 25% 5% 267 12% 1,000 1.20 25% 10% 200 38% Table 1 In this example, for every 1,000 lb of product produced, energy use is reduced by 12 percent simply by reducing the amount of water in the product by 2 percent. in total the amount of energy consumed can be reduced by 34 percent (fm the or ral condition) ifthe moisture level ofthe product entering the dryer fs minimized and the final produet moisture evel asitexits the dryers increased, vwmprocesshestingcom * October 2007 | 19Dryers itis imporcane to reduce the magninude of these losses when posible. This opportunity {found primarily in leak reduction. External doors and gaskets should be maintained a¢ regular ineervals, Okler doors may be replaced with betterinslated doors that help reduce hea radiation ro the atmosphere. Furthermore, seals in other areas where product enters or exits should bee properly installed and maincained to leaks So, how much can you really save by implementing some of the suggested change? Actual savings depend on many factors, including the evaporation rate, your currene process sctings, and the production schedule for the dryer. Some "ypical values are shoven in table 2 Thermodynamics tells us that a perfetly cffciont dryer typically asquites, at « mini mum, about 1,200 BTUITb (2,800 kj! of water evaporated. Experi some impropery functioning and inefiient diets can consume up 10 4,000 BTUMb (0,304 fk) of water evaporated, A more LOT Sed Energy Spont, Cost Cost Cost Savings (Tun) Per Hot Per Day ar Year Por Year 4000 S40 $5,760 140.000 2500 S150 $3,600 900,000 $640,000 1.500 $90 2,160 $540,000 sa00.g00 Note: These values assume 2 ay operation, 250 days un rae, and $1. 00therm energy cost Table 2. Actual savings depend on many factors, including the evaporation rate, your current process settings, and the production schedule fr the dryer However, operat- ing costs savings can be substantial in some applications. ‘common situation is to sce an inefficient ideal conditions even when you at alteady dryer using approximately 2,500 BTUill somewhat effi (6.815 kag afer optimization, harsame Follow these simple tpe to achieve energy systems. Enis all of can reach reasonably “good” levee of savings in your dyi 00 BTU (3,489 Keg) the tools as your disposal, inching com Now conser these different energy ev- sult with your dryer manuficeurer, Simple cls fora feed-drying operation producing adjustments such a chese just might prove approximately 15 confhe (13,608 kg/hr) ata lager payback chan you expect. an evaporation sate oF approximately G00 © lor (2,722 gh), Dustin O'Farrell is manager, fl engineering TE your dryers operation is ina sad for Aergia Gor, Bali, N.C, a manta state of ass, chere may be « great deal turer of thermal ro0e8secuigment, including of savings from these enc gy consump- dryers. For more information about Aerogides ‘ion improvements. Because many of che drying systems and enery-anasis services, improvements require simple adjustenerts call (800) 722-748, e-mail sle@aeroglde and low wp-fone costs, why noc push for com ar vst wiraaeregide com, 20 | October 2007 Process Heating + Fluid Process Heating + + Design, Engineer and Manufacture Contact our Engineering Sales Team directly Tel: (800) 647-3165 Fax: (203) 378-3593 sales@hubbellheaters.com Litas ako ue