How compressed air is turned into heat

Integrated heat recovery

An important component is the usage of Kaeser compressors with integrated heat recovery. These compressors are used for production of sterilised air, which is inavluable for food production, as well as working air, e.g. used for conveyor belts.

The previous compressors used prepared domestic water for cooling. The used domestic water was disposed right into the drain, which caused an average use of 30 m³ per day - an unnecessary waste of resources. The new compressors boast with an electric output of 55 kW. During the compression process, air heats up, which naturally generates waste heat. With the switchable heat recovery system, this valuable waste heat can be put to use - up to 48 kW.

The flow temperature lies between 85 and 90 °C (at an air delivery rate of 11 m³/min and finaly pressure of 8 bar). This energy is charged into a 12,000 liter buffer tank and used for DHW preparation.

The company Carl Nolte Technik GmbH values security, which is why the system was conceptualised and installed as per security requirements of safety class 1. Wiring was reduced to a minimum through usage of bus systems. Valves and pumps are monitored and controlled using Modbus. Extension modules like 4-20 mA pressure sensors communicate with the controllers using TA's own field bus system CORA.

Conclusion

The integration of Kaeser compressors with heat recory into the production processes of Froneri marks an important step towards sustainability and energy efficiency. The gradual replacement of old compressors and the targeted use of bus systems lower operating costs and reduce the ecological footprint.

This project was realized by:

Carl Nolte Technik GmbH
Mergenthalerstraße 11-17
48268 Greven
Germany
https://www.carlnolte.de/