Big Dutchman International GmbH Heat Exchanger Earny Type 40.000 Efficiency of heat recovery under practical conditions ANE ut The DLG Focus Test "Efficiency of heat recovery" of the Big Dutchman airair heat exchanger Earny Type 40.000 for use in broiler houses was 09/13 at tnsier) nde conducted as a practical test in accordance with DIN EN 308, delivering (cht conton the following results: Manufacturer/applicant Test result Evaluation* Big Dutchman International GmbH Efficiency of heat recovery Auf der Lage 2 x 5 . Auli Lage 2 ‘Average temperature-transter efficiency: 879% at AT + Germany Heat output Tel: +49 (014447 801-0 ‘Average output under winter conditions: 23.8 KW A Fax: +49 (0)4447 801-237 (see Operating conditions, p. 4) bigbigdutchman.de wwwwbigdutchman.de ‘LG evaluation standard fo ecuperative heat exchangers ‘n praca agricultural use: Assessment +e ° aos Temperature-transter efficiency [%} >50 >401050 >20t40 >201020 <20, —_ ————— DLG ev. Test Center Technology and Farm Inputs uation range: ++ +101 standard) WI = Not Assessed DIG Test Report 6140F Page 1 of 12ET Ce Mec ULE MEU Cd The Big Dutchman heat exchanger Eary Type 40.000 is used to recover heat from the return arin broiler houses. Experience shows thatthe heat exchanger has a postive influence on te bole house's climate and on te liter quality This reduces emissions of mmonia and odours. The Eany Type 40,000 works asa recuperate cross flow heat exchanger (Fg. 2) This heat exchanger therefore fals under Category | This means that warm poultry-house ar ©) and cold ambient ai @ are fed simultaneously through exchanger bundles an thatthe air flows do not come into contact with one another during this process; ony heats exchanged. The clean ambient aris separated from the contaminated pouty hous retum air hygienic manner. Only clean ambient ais fed back int the poultry house G).A iter unit @ ensures that only clean return ar enters the heat ex- changer. The automatic cleaning @ ofthe fier cartridges isa prerequisite for ensuring tat tere iso drop in the heat exchanger's performance during the fattening cycle. Te heat exchange's exhaust iris therfore almost completly cleared of dust and Daricuate-mattr emissions. The exchanger element @ is made of coated aluminium and has aribbed structure order to ensue a high rate of heat transfer. Axia fans convey the inlet and retum a Peed Airflow 20,000 mM for use ina fattening house with approx. 40,000 birds ue) Heat-recovery performance T7OKW (When Visi = 13,100 MM, Tram = 30°C, Pram = 60%, Viner = 18,600 m4, Tie = 10°C, Pier = 60%) Length/width/height?® 5,200 mm/2,300 mm/2;300 mm Figure 2: Functional principle 11 The tem recuparation is generat use in eatin to tecnica processes fr eneray recovery Inrecupeatve eat exchanger oss- and countr-fow), exhaust and ambient a pass alongside one athe without exchange of i andlor mitre 2. Vale for height of eat exchanger without dtusr DIG Test Report 6140F Page 2 of 12ee The tested Big Dutchman heat ‘exchanger Earny Type 40.000 worked reliably throughout the test period Measurement ina broiler house The Big Dutchman heat exchanger Earny Type 40.000 was tested on an existing broiler house with a floor area of 1800 m2. Measure ments were recorded over three fattening periods from 10 Decem- ber 2012 to 29 April 2013. In the tested winter months, the Big Dutchman heat exchanger Earny Type 40.000 achieved an average temperature-transfer effi ciency of 57% (Fig, 4, page 4). This means that 57% of the maxi- ‘mum achievable inlet-air tempera- ture was achieved. The efficiency Of heat recovery is therefore better than the current definition of a standard level of >30% to 40%. In addition, the temperature-transfer efficiency varied only slightly, by +# 3.5%, The heat exchanger raised the temperature of ambient air by 12.6°C on average. However, this temperature increase depends very strongly on the weather conditions: the greater the temperature differ- ence between the poultry-house air and the outside air, the greater the heating effect, and vice versa, Using the heat exchanger also avoids passing on and strongly attenuates the sometimes very large variations in the ambient-air temperature, which varies with the outside temperature, Ifthe poultry-house ventilation system is operated in combination with a heat exchanger, the thermal energy gained from heat recovery is offset by an increased demand for electrical energy on the part of the fans. This arises due to the addi- tional pressure losses in the heat exchanger that must be overcome, This increased consumption of electrical energy is many times lower than the recovered thermal energy. The ratio is approximately 1:20. This means that for one kilo- watt-hour of electrical energy (electricity), approx. 20 kilowatt- hours of thermal energy (heat) can be recovered. The temperature-transfer efficiency represents a key quality parameter for evaluating a heat-recovery system. Efficiency of heat recovery Figure 5 (page 7) and Figure 6 (page 8) show the variations in temperature-transfer efficiency, Overview 2 (page 5) provides inlet-air temperature increase, an explanation of correlations ambient-air temperature, heat out- and calculations for heat put and inletair volume flow rate. exchangers. Because of the large volume of eater eater data, not all data points are visual- exclusively to operating ised. Occasionally, measurements Conditions ‘were taken that exceed the scale. 30 1B December 25. 18 ° | Temperature [°C] Ambient air/ Inlet air Exhaust air outside alr Figure 3: Bar chart of temperatures showing measured range (standard deviation) Table of supplementary data for Figure 3: fei e ‘Ambient air/outside air Inlet air Exhaust air December 61 209 170 January 4a 181 2 February 28 160 95 ‘March 22 193, 103 pail 65 139) 80 December January February = March April a a DIG Test Report 6140F Page 3 of 1220: TH Gacomber . Bimen” | =” 1 February sue <2 oo. mar HE oo B53 $22 282 Ll S25 30. ad ee oy 1 é to o ‘Temperature air (AT) due to of heat exchanger Figure 4: Bar chast of performance parameters (standard deviation) increase of ambient transfer efficiency heat exchanger ‘Temperature- ' Heat output of heat exchanger showing measured range Table of supplementary data for Figure 4*: ely air (AT) due to heat exchan: December 148 #55 January 1.0218 February 13.2234 March 17155 pail 70218 Mean, 126236 Overview 1: Operating states during the measurement period Cree i) eae December 123243 January 155 = 52 Febuary a4etd March 116 = 42 Mean 120238 a the heat exchanger over the entire Operating mode (according to manufacturer's information) ‘The heat exchanger was controlled by the AMACS climate-control ‘computer during the testing phase The air volume flow rate passing through the heat exchanger was regulated by the minimum ventila- tion. Starting with a minimum ventilation or with the additional humidity control, the heat exchanger's venti- lation requirement increased as the number of days of fattening increased (Gee Fig, 6) After 14 to 18 days of fattening, in order to achieve energy-optimised opera- tion, the heat exchanger is automat- ically switched to a stand-by mode in which the exchanger operated at a reduced level of ventilation. achieved by cao} B71 32.4299 131272 23889 Seed Cee Ly measurement period Inet aif 5,008 + 2,375 Roturnair(m‘/n] 5,025 + 2,036 * Belanaton of umerical values: mean = standard doviton DIG Test Report 6140F eee 262 +52 Page 4 of 12Overview 2: Heat exchanger ~ alagram and calculations Exhaust air (t12) Ambient air (toi) => => Inlet air (to2) Return air (t11) ‘or wit regard tothe “pouttry-house ventilation” application: pa tzcts g_ _beneftofthe recovered heat __achieved temperature increas ofthe ambient air (7) inetd Potential ofthe recovered heat ‘theoretically possible temperature increase of the ambient air Sa mm © Temperature-transfr efficiency — indicates the thermal efficiency of heat transfer % Other terms used to mean the same in technical contexts: heat-ecovery efficiency, thermal-transfer efficiency ty Temperature of return air °c te Temperature of exhaust air a) tay Temperature of ambient air Gi te Temperature of inlet air Ea at. Temperature ciference = inlet air (22) - ambient air (21) kK v Inletreturn-air volume flow rate mh Indices Fest number: Second number, 1 = telore the het exchanger 2 aftr the et exchanger The temperature-transfer efficiency can take values between 0 and 100%. For example, in the field of air conditioning for buildings*, heat-recovery systems are classified with regard to temperature-transfer efficiency into six heat-recovery classes over the range of = 37% to 75%. Because of the different mass flow rates (inlet and return air), the following interrelation was used in accordance with DIN EN 13053, page 29: (Grto\* ® =O rearran a (Gia) roraneedios Som Fea Git Where &, = temperature-transfe efficiency without taking account of mass low rates 8) py = temperaturestansiereficeney, mase-specifie nue =inlet ai mass flow rate ths) Gen = relurrait mass flowrate ag) “DIN EN 13053 "Vonlation for bung Ar handing units Rating and pecormance for units, components and sect 112007 DIG Test Report 6140F Page 5 of 12Table Operating conditions 4. Operating condition: Housing techniques Poultry fattening Prolonged fattening with earty removal from housing = Housing on iter Poultry-house building (manufacturer and operator information) = Approved places for 41,800 birds — Poultry-house flor space 20 m x 90 m, constructed in 2008 = Solid construction with thermally insulated gable root — Heated with gas heaters with flue-gas extraction Ambient-ir supply via infet-air valves inthe poultry house's side wall, retum air via gable fans (forced ventilation) Heat exchanger Erected on a metal platform on the side ofthe poultry house Ventilation system = Inet air Inlet aris sucked in from the outside and through the heat exchanger by the ilt-ar fan and fd into the poutry-house area Adjustable nozzles allow the inet air tobe dosed and directed (see Fig 2, page 2). The aris stributed inside the poulty house withthe agjustabe nozle and by te arow within the poultry house thats produced by gas heaters and circulation fans. = Return air The retum air is extracted by a retur-air fan and discharged to the outdoors via the heat exchanger. Inthe process, the return air from the poultry houseis cleared of dus by ar-fiter cartridges. The fiers are cleaned regulary with compressed i. Climate computer AMACS climate and production computer from Big Dutchman rs ‘The temperatures were recorded in accordance with DIN EN 308, ‘Temperature sensors = TypeT thermocouples Heat exchangers: 21 units in total, distributed over the inlet- and return-air sides = Outside temperature/ambient-air temperature: 2 units Humidity sensors, = Dol 114, = 4 units in total, 1 unit before and after the heat exchanger on both the inlt- and retum-air sides Measuring fans — LMU-820 forthe inet-air volume flow rate (diameter = 820 mm) = LMU-710 forthe return-air volume flow rate (diameter = 710 mm) Data acquisition Recording and storage of all sensor measurements ata sampling interval of 1 minute Sooo Total observation period: 10 December 2012 to 29 April 2013 = Calibration: temperature and humidity sensors at start and end of measurement DIG Test Report 6140F Page 6 of 12Fattening period 1 Fattening period 2 Fattening period 3 100 Temperature-transfer efficiency [%] Inlet-air temperature increase [K] 20 5 § 8 a 5 os i 2 iE & 18 104 10 11.42.2012 31.12.2012 20.01.2013 09.02.2013 01.03.2013 21.03.2013 10.04.2013 Figure 5: Temperature-transfer efficiency, inlet-air temperature increase and ambient-air temperature over time DIG Test Report 6140F Page 7 of 12Fattening period 1 Fattening period 2 Fattening period 3 70 60 50 7] . : 40 s+r9 ia Heat output [kW] 204 = 10 20000 18000 16000 14000 = 12000 10000 000 6000 4000 2000 Inlet-air volume flow rate [m°/h] 1142.2012 31.42.2012 20.01.2013 09.02.2013 01.03.2013 21.03.2013 10.04.2013 FATTENING Ist fattening cyclo 2nd fattening cycle ‘3rd fattening cycle OATA Placed in poultry house on Placed in poultry house on Placed in poultry house on 10 Dec 2012 28 Jan 2013 16 Mar 2013 Early harvest on 29th day of Early harvest on 29th day of Early harvest on 30th day of fattening (9 Jan 2013) fattening (27 Feb 2013) fattening (16 Apr 2013) Removed from poultry house Removed from poultry house Early harvest on 38th day of ‘on 42nd day of fattening on 4st day of fattening fattening (24 Apr 2013) (22 Jan 2013) (11 Mar 2013) Peart erred tates ‘on 43rd day of fattening (28 Apr 2013) Figure 6: ‘Heat output and inlet-air volume flow rate over time DIG Test Report 6140F Page 8 of 12‘Temperature-transfer efficiency Figure 7: 2 a é a 10 2 4 Outside temperature [°C] Dependence of temperature-transfer efficiency on ambient-air/outsidle temperature Characterisation of the heat exchanger Earny Type 40.000 according to DIN EN 308, Determination of the ‘nominal air mass flow rate Inletair fan at 100% output = 18,639 mh 2 6.26 kg/s Return-air fan at 100% output = 13,058 mh 2 4.39 kg/s Analysis of leak tightness ~ external leakage External leakage is leakage be- tween the air flowing through the heat exchanger and the environ- ‘ment. In accordance with DIN EN 308, the airtightness of external leakage is determined at 400 Pa of excess and negative pressure. For systems with static pressures of up to 250 Pa, DIN EN 308 allows test- ing of the system to be performed at 250 Pa instead of 400 Pa. The heat exchanger from Big Dutchman was tested at both pressure options (Table 2). Analysis of leak tightness - internal leakage or internal air leakage Internal leakage is leakage of air between primary and secondary air flows of a heat-recovery system. ‘According to DIN EN 308, internal return-air leakage is defined as leak- age from the return-air side to the inletair side (Table 3) The internal leakage is measured at an excess pressure of 250 Pa on the Table 2: Analysis of leak tightness ~ external leakage Leakage volume Leakage mass. Pressure [Pa] fow rate (m°/h] flow rate [kg/s] Excess pressure 250 131 0.044 400 7 0.057 Negative pressure 250 125 0.082 400 165 0.056 Calculation for leak tightness of external leakage: ‘Geran 100% = 0.70% at 250 Pa excess pressure ‘rena 100 % 0,67 % at 250 Pa negative pressure ‘Average air density over the entire measurement period = 1.21 kgm? an --- Measured nominal air mass flow rate for inlet air [kg], . extermal-leakage mass flow rate at excess pressure [kg-S"] ‘en --- extemal-leakage mass flow rate at negative pressure [kg -S"] Table 3: Analysis of leak tightness ~ internal leakage easy ec ra flow rate [m*/h] flow rate [kg/s] Excess pressure on return-air side: 100 Pa; inet-air sie: 0 Pa VJ ee Calculation for leak tightness for internal air leakage: eu" 100% = 0.83% at 100 Pa pressure dtlerence Gna... internal-leakage mass flow rate [kg - s"'] return-air side and 0 Pa on the inlet- system to be performed at 100 Pa, air side in accordance with DIN EN instead of 250 Pa, on the retur- 308. For systems that are only de- air side. The measurements were signed for pressures of up to 250 Pa, conducted at an excess pressure of DIN EN 308 allows testing of the 100 Pa on the returnair side. DIG Test Report 6140F Page 9 of 12Heat balance The change in enthalpy flow between the two flowing media ‘was calculated as follows (for one "measurement point as an example): Pit = Cyn" Geu’ tray = 1,006 [KJ kg"-K'}- 178 kg-s"1- 14,4 1K] (6) 25,741KI-5"I Pen = Gps" Ata = 1,007 Ik} kg? +) 1,60 tkg5"-15 41K (7 = 24,731K}-s' Pram Oe G_~- Spe. heat capacity of air Uh) kg? toy. ambientair temperature IK] ty. exhaustaie temperature {K] ta. inletair temperature IK] thy. retur-aie temperature [K] Gin --inlet-air mass flow rate [kg/s} Grew feturn-air mass flow rate [kgs Table 4 Drop in pressure The total drop in pressure is determined from the measurements in front of and behind the fan (Gee Tables 4 and 5). The drop in pressure isthe pressure difference along the length of a pipeline section. Other results Power consumption The heat exchanger's average power consumption over the entire ‘measurement period was 34.45 kWh per day. This figure also includes the DLG's measurement technology and the heating for the condensate tank. Humidity The relative humidity of the am- bient air varied between 30 and Drop in pressure on the inletair side as a function of the percentage of nominal air mass flow rate Ceo Gear) 100%" 18,639 80% sagt 60% 11,183 40% 455 20% 3,728 Table 5: > 240 2.25 181 083 036 ‘Drop in pressure on the returtair side as a function of the percentage of nominal air mass flow rate Ceo Gotan) 100%" 13,058 > 240 80% 10,446 229 60% 7,835 1.60 40% 5,223 90 20% 2612 031 Table 6: Results of the dust measurements P ‘st fattening period 11 Dec 2012 to 24 Jan 2013 4d fattening period 17 Mar 2013 to 13 Apr 2013 * For technical reasons he measurement range was exceeded, the drop n pressure could only be reliably measured for upto approximately 80% ofthe nominal ai mass flow rate, ardent f 1005 bu-1a'-K"}-1.78h0"-8")- 144K 11007 Pu g*-K"]- 160-87 15.409 DIG Test Report 6140F 100% over the measurement period. The inlet air fed into the poultry house had a humidity value of between 10 and 80%, and the value for the return air from the poultry house rose from approxi- mately 50% to 80% during a fat- tening period. It was not possible to reliably measure the humidity in the vent stack (exhaust ait) until March (due to condensation effects and icing up). From April onwards, the ‘exhaustair humidity predominantly measured just over 90%. Dust The amount of dust arising in the heat exchanger per fattening period vas also investigated. For this pur- pose, the first and third fattening periods were analysed (Table 6). The dust samples had an average moisture content of approximately 18% after the respective fattening period. Cleaning (operator information) To allow safe and functional opera- tion of the heat exchanger Earny Type 40.000, the appliance is to be cleaned after each fattening period, For this purpose, the filter compart- ment is frst to be opened and the dust in the base area dispersed in water; after approx. 1 hour, the dust is to be scrubbed off, and the walls are also to be scrubbed. The filters ‘can be rinsed with a conventional garden hose. The stopper in the fil- ter compartment's outlet is to be removed, allowing the rinsed-off dust to escape from the area of the heat exchanger. Care must be taken to ensure that the stopper is rein- serted after cleaning. The side of the heat exchanger behind the filters is also to be checked and cleaned if necessary. Twice a year, the entire heat ex- changer should be rinsed. Clean tap water is to be used to clean the heat exchanger and the compo- nents. Page 10 of 12In conclusion, the heat exchanger and 13,058 m¥h for the return-air Earny Type 40.000 from Big Dutch- flow. Furthermore, the heat man operated reliably over the exchanger was tested according to measurement period. DIN EN 308 during the measure- . xd. The heat exchanger ‘Three full fattening periods were Tent Perio« measured. The measurement ( period ran from December 2012. The Big Dutchman heat exchanger {o April 2013. In this period, an Earny Type 40.000 is suitable for average temperature-transfer effi- heat recovery in prolonged broiler ciency of 57% was achieved. production with litter for up to The nominal volume flow rate was approx. 40,000 birds. 18,639 m°/h for the inletair flow DIG Test Report 6140F Page 11 of 12i This test report was prepared Test Execution based on DIN EN 308, which is the basis for testing heat systems for HVAC (Heating, Ventilation and Air Condi appliances. DiGev,, Test Center Technology and Farm Inputs, Max-Eyth-Weg 1, D-64823 Gro®-Umstadt recovery tioning) The test was conducted at a broiler house in Emsland. No survey was conducte Technology a Dipl-Ing.T. Pfeifer Other criteria were not tested. atte ENTAM: Tegistered «y+ 2012-00735 March 2014 epic Project Manager Dipl-Ing, J. Drmi¢ ENTAM — European Network for Testing of Agricultural Machines, is the association of European test centres, ENTAM's objective is the Europe-wide distribution of test results ‘or farmers, agricultural equipment dealers, and producers. More information about the Network is available at www.entam.com or by writing to ENTAM at the email address: info@entam.com DIG eV. ~ Test Center Technology and Farm Inputs Max-Eyth-Weg 1, D-64823 Grof-Umstadt, Tel.: 069 24788-600, Fax: 069 24788-690 E-Mail: tech@dg.org, Internet: www.dlg-test.de Download all DLG test reports free of charge at: www.dlg-test.de! DIG Test Report 6140F Page 12 of 12