Saving Energy With Ventilex Frac Sand Dryers

VENTILEX
LEADING DRYING SOLUTIONS FOR A BETTER WORLD
FLUID BED DRYING SAND & AGGREGATE
Houston, Texas, USA

February 13, 2024
©2023 – Ventilex – All Rights Reserved. The content of this presentation contains or may contain proprietary, confidential information. It may not be distributed or shared to any other party without prior written consent of Ventilex.
INTRODUCING VENTILEX
OUR VISION: OUR MISSION:
Leading drying solutions for We contribute to a better world by helping our clients reduce the energy, emissions and
a better world! costs of their industrial drying processes. We do this by developing the most process- and
energy efficient drying solutions.
We believe what we do matters: we help sustainably provide for a growing world population.
Food Feed Minerals / Construction
LEADING DRYING SOLUTIONS FOR A BETTER WORLD 2 Z

WE REALISE OUR MISSION THROUGH STRATEGY BUILT ON FOUR KEY PILLARS
Invest in people & technology
Focus to be excellent
Be scalable for result and impact
Build & nurture partnerships

WE DEVELOP THE MOST PROCESS- & ENERGY EFFICIENT DRYING SOLUTIONS
Reduced energy Reduced energy

usage
CLIENT
Reduced Lower More sustainable Higher

carbon footprint total cost of ownership operation profit margins

DEVELOP NEW DRYING
WE REDUCE THE OPTIMIZE DRYING SOLUTIONS
PROCESSES
ENERGY, EMISSIONS
AND COSTS OF THE
INDUSTRIAL DRYING
PROCESSES OF OUR
CLIENTS
LIFE CYCLE MANAGEMENT
HOW?

Foundation of
Fluid bed dryer Ventilex Inc. DryGenic NXT®
1980 2001 2021

DEEP EXPERTISE
BUILT OVER 1965 2000 2004
> 50 YEARS Founded Steam sterilizer DryGenic® Air
dehumidifier & Belt dryer
I N - H O U S E E X P E R T I S E
OVERVIEW:
>100 Employees Product Thermodynamics Mechanical Software /

& Process engineering Automation
Installed • > 1.000 systems

Base • In 80+ countries
International
Partner Network Manufacturing Project Quality Lifecycle
Management Management Management

HQ IN HEERDE, THE NETHERLANDS
Test Warehouse
Center Coating
Carbon
Steel
Stainless
Steel
8.900 m2

VENTILEX DRYING TECHNOLOGY
Fluid Bed DryGenic ®Air Sterilizer /

Belt Dryer Dehumidifier
Dryer pasteurizer
▪ Uniform and gentle drying ▪ Flexible, custom-made design ▪ Kills up to 99% of bacteria ▪ Preservation of characteristics
▪ Abrasive materials ▪ Automatic lubrication ▪ Corrosion-resistant ▪ Fastest method of heating
▪ No excessive wear ▪ Suitable for gelatin production ▪ Reduction in energy costs ▪ Results in healthy product

FLUID BED DRYING
INSTALLATION

FLUID BED DRYING
INSTALLATION

INTRODUCTION
TO FLUIDIZATION
ON YOUTUBE

FLUIDIZATION
Drying by an upward (hot) airflow through the

product and a shaking motion
Each particle gets surrounded by (hot) air
Heat transfer is extremely high and uniform
For thermal processing of powders, granules,

agglomerates and pellets

VENTILEX FLUID BED DRYER WORKING PRINCIPLE

TYPICAL DRYING CURVE
Pre-heating: all the heat

01 provided in the drying air is
used to heat up the product
01 02 03
Constant-rate period:
all the heat from the drying
02 air is used to evaporate
surface moisture
Falling-rate period:
it takes more time for
03 internal moisture to appear
at the surface, and
evaporation of water is no
longer constant in time

FLUID BED DRYER FEATURES
Shaking or Vibrating movement by drive system
Typically operating with lower bed heights

• up to 30 cm with weir in dynamic shaking fluid bed
• a few cm in dynamic vibrating fluid bed (not available at
Ventilex)
For products which are not free flowing in wet condition, so proper fluidization with only air
is not possible
For products with tendency to agglomerate or stick, such as wet salts/sand
Typically for products with wide particle size distribution range
Particles > 100µm can be kept in the fluid bed

DRIVE / SHAKING MECHANISM OF FLUID BED DRYER
Forced movement by crankshaft mechanism
Dynamic movement constant under all process conditions
High amplitude, low frequency: gentle shaking
Low G-forces, below 1G
No breaking of agglomerates / sensitive products
Low maintenance, long lifetime compared to vibrating systems

DRIVE / SHAKING MECHANISM OF FLUID BED DRYER

FLEXIBLE CONNECTIONS

ADVANTAGES OF THE VENTILEX FLUID BED TECHNOLOGY
Highest possible thermal processing efficiency
High efficiency also means relative short drying time,

so best possible solution for thermo sensitive
products
Uniform drying: no Hot Spots in fluidized beds due

to excellent mixing of product
Fully automated operation systems

EFFECTIVE DRYING

EFFECTIVE DRYING
Capacity
• Volume
• Speed
Product quality
• Within specs Productivity
• Consistency
System quality
• Reliability
• Predictability
• User-friendliness
• Serviceability Quality
Energy efficiency
Energy efficiency
• Costs
• Sustainability
• Social Responsibility
FLUID BED DRYING
INSTALLATION FOR
SAND

UNIQUE FEATURES
Energy-efficient: significantly reduces energy

costs
An exclusive “shaking” motion that allows first-in,

first-out drying of products with low G-forces
Fluidization or sub-fluidization of the product (when

longer times in the dryer are needed) allowing for
precise control of process-required plug flow
characteristics
Heavy duty, robust product transport that assures

low-maintenance, dependability, and long lifetime

KEY BENEFITS
Plug Flow: uniform and gentle drying
Accurate product temperature control
Also, for fragile products -> not damaging the product
Also, for abrasive materials -> no excessive wear of M/C
Long life-time, reliable dryers
Low maintenance
High energy savings – up to 40%

SAVING ENERGY
WITH VENTILEX
SANDDRYERS

TYPICAL SPECIFICATIONS FOR SAND
Particle size 0 – 6 mm Operating temperatures
Drying air 475 - 550 °C
Specific heat of the product 0.84 kJ/kg°C
Cooling air Ambient
Bulk density 1.4 – 1.6 T/m3
Product capacity at inlet 42.3 T/h Product temperatures

Inlet dryer 15 °C
Product capacity at outlet 40.0 T/h Outlet dryer ± 80 °C
Outlet cooler ≤ 40 °C at
Evaporation capacity 2.3 T/h
20 °C ambient
Moisture content at inlet max. 6 %
Moisture content at outlet ≤ 0,3 %

FLUID BED DRYING
INSTALLATION FOR
SAND

FLUID BED DRYING
INSTALLATION FOR
SAND

DRYER/COOLER/FILTER (STANDARD)
Filter
Product IN
Product OUT
Burner

DRYER/COOLER/FILTER WITH RECIRCULATION
9%
energy saving
vs standard

DRYER/COOLER/FILTER WITH TWIN COIL SYSTEM
9%
energy saving
vs standard

DRYER/FILTER + RECIRCULATION AND EVAPORATIVE COOLING
22%
energy saving
vs standard

VENTILEX VENTURA
Up to 35%
energy saving
vs standard

COMPARISON VARIOUS SOLUTIONS
Modernized Standard fluid bed Fluid bed dryer/cooler Fluid bed dryer Fluid bed dryer/cooler
Classic drum Ventura
drum without recirculation with recirculation with twin coil with evaporative cooling
Thermal energy
325 240 230 210 210 180 150
usage MJ/ton
Savings compared to
-41% -5% 0% +9% +9% +22% +35%
standard fluid bed
Note: based on sand with 5% moisture and 15°C infeed condition, dried to 0,2% moisture content and <45°C exit temperature

VENTILEX SOLUTION OFFERING
FILL IN YOUR SPECIFIC PROJECT DESIGN VALUES (yellow boxes)
Moisture content input 6 % w/w

Max ambient temp. 20 dgr C
Desired temperature cooler output 60 dgr C
Desired througput / output 45 T/h
GENERATED PROJECT OUTPUT PARAMETERS
max. througput capacity overdesign % CAPEX

VTX standard T/h % EURO
Model A 30 -33
Model B 50 11
Model C 75 66
Model D 120 166
Capacity Charts Standard VTX sand dryers

Type A Type B Type C Type D Project Case
SHOW GRAPH A
170
160
150
140 SHOW GRAPH B
130
Easy to handle performance calculation 120

110
SHOW GRAPH C
Throughput [T/h]
100
tool available for agents \ 90

80
SHOW GRAPH D
representatives to select the solution 70

60
50
needed for end-user 40

30
20
10
0
3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 9,5 10
Moisture content input [% w/w]
VTX standard Thermal energy consumption @ Project design conditions

MJ / Ton dry product output
Model A n.a.
Model B 201
Model C 196
Model D 194

FLUID BED DRYING
INSTALLATION FOR
SAND

37

FLUID BED DRYING
INSTALLATION FOR
SAND

OUR PROMISE
LOWEST COST PER TON

MOISTURE LEVELS IN STOCKPILE

OPTIMAL SOLUTION FOR STOCKPILING

CAPEX BASED ON INTAKE MOISTURE, TOUTPUT AND CAPACITY
€ 950,000
€ 900,000
€ 850,000
€ 800,000
€ 750,000
CAPEX
€ 700,000
€ 650,000
€ 600,000
€ 550,000
€ 500,000
8% 7% 6% 5%
Intake Moisture
50 t/h - 45°C 50 t/h - 40°C 40 t/h - 45°C 40 t/h - 40°C

OPEX BASED ON INTAKE MOISTURE
Energy consumption per ton DRY sand

at 50 t/h & T output = 40°C
300
263
250
233
204
200 175
Energy in MJ
150
100
50
8% 7% Intake moisture 6% 5%

FLUID BED DRYING
INSTALLATION FOR
SAND

VENTILEX DEVELOPMENTS
Ventilex MAPSTM
improving uptime and performance by:
Continues measuring all available data
Data Logging
Data Analyses - Diagnostics
KPI’s in clear visuals
Generating valuable information for

operations and management

VENTILEX DEVELOPMENTS
… and more!
In-line real-time moisture measuring
Advanced heat pump and heat recovery technologies
100% Electrical heating (green energy)
100% Hydrogen

COST AND ENERGY ASSESSMENT TOOL

FLUID BED DRYER
/ HEATER FOR
ROCK POWDER

VENTILEX
TEST CENTRE

VENTILEX TEST CENTRE - SERVICES
Demonstrations
Customer testing
Internal Research & Development
Joint R&D with partners
Rental installation for testing on site

VENTILEX TEST CENTRE - PILOT SYSTEMS
Continues fluid bed dryers
Batch fluid bed dryers
Batch sterilizer
Belt dryer simulators and bread mill
DryGenic® dehumidifier

TEST CENTRE

VENTILEX
THANK YOU FOR YOUR ATTENTION

Saving Energy With Ventilex Frac Sand Dryers

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VENTILEX

LEADING DRYING SOLUTIONS FOR A BETTER WORLD

FLUID BED DRYING SAND & AGGREGATE

Houston, Texas, USA

OUR VISION: OUR MISSION:

Food Feed Minerals / Construction

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 2 Z

Invest in people & technology

Be scalable for result and impact

Build & nurture partnerships

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 3 Z

Reduced energy Reduced energy

Reduced Lower More sustainable Higher

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 4 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 5 Z

1980 2001 2021

>100 Employees Product Thermodynamics Mechanical Software /

Installed • > 1.000 systems

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 6 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 7 Z

Fluid Bed DryGenic ®Air Sterilizer /

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 8 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 9 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 10 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 11 Z

Drying by an upward (hot) airflow through the

Each particle gets surrounded by (hot) air

Heat transfer is extremely high and uniform

For thermal processing of powders, granules,

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 12 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 13 Z

Pre-heating: all the heat

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 14 Z

Typically operating with lower bed heights

For products with tendency to agglomerate or stick, such as wet salts/sand

Typically for products with wide particle size distribution range

Particles > 100µm can be kept in the fluid bed

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 15 Z

Forced movement by crankshaft mechanism

Dynamic movement constant under all process conditions

High amplitude, low frequency: gentle shaking

Low G-forces, below 1G

No breaking of agglomerates / sensitive products

Low maintenance, long lifetime compared to vibrating systems

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 16 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 17 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 18 Z

Highest possible thermal processing efficiency

High efficiency also means relative short drying time,

Uniform drying: no Hot Spots in fluidized beds due

Fully automated operation systems

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 19 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 20 Z

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 22 Z

Energy-efficient: significantly reduces energy

An exclusive “shaking” motion that allows first-in,

Fluidization or sub-fluidization of the product (when

Heavy duty, robust product transport that assures

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 23 Z

Accurate product temperature control

Also, for fragile products -> not damaging the product

Also, for abrasive materials -> no excessive wear of M/C

Long life-time, reliable dryers

High energy savings – up to 40%

LEADING DRYING SOLUTIONS FOR A BETTER WORLD 24 Z