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Heat Recovery with Compressed Air Systems As much as 80-93% of the electrical energy used by an industrial air compressor is converted into heat. In many cases, a properly designed heat recovery unit can recover anywhere from 50- 90% of this available thermal energy and put it to useful work heating air or water. Typical uses for recovered heat include supplemental space heating, industrial process heating, water heating, makeup air heating, and boiler makeup water preheating. Recoverable heat from a compressed air system is not, however, normally hot enough to be used to produce steam directly. Heat recovery systems are available for both air- and water-cooled compressors. Heat Recovery with Air-Cooled Rotary Screw Compressors Heating Air. Air-cooled packaged rotary screw compressors are very amenable to heat recovery for space heating or other hot air uses. Ambient atmospheric air is heated by passing it across the system’s aftercooler and lubricant cooler, where it extracts heat from both the compressed air and the lubricant that is used to lubricate and cool the compressor. Since packaged compressors are typically enclosed in cabinets and already include heat exchangers and fans, the only system modifications needed are the addition of ducting Improving Compressed Air System Performance A Sourcebook for Industry and another fan to handle the duct loading and to eliminate any back pressure on the compressor cooling fan. These heat recovery systems can be modulated with a simple thermostatically- controlled hinged vent. When heating is not required -- such as in the summer months -- the hot air can be ducted outside the building. The vent can also be thermostatically regulated to provide a constant temperature for a heated area. Hot air can be used for space heating, industrial drying, preheating aspirated air for oil burners, or any other application requiring warm air. As a rule of thumb, approximately 50,000 Btu/hour of energy is available for each 100 cfm of capacity (at full-load). Air temperatures of 30 to 40oF above the cooling air inlet temperature can be obtained. Recovery efficiencies of 80-90% are common. Caution should be applied because if the supply air for the compressor is not from outside, and the recovered heat is used in another space, you can decrease the static pressure in the cabinet and reduce the efficiency of the compressor. If outside air is used, some return air may be required to avoid damaging the compressor with below freezing air. Heating Water. Using a heat exchanger, it is also possible to extract waste heat from the lubricant coolers found in packaged water- cooled reciprocating or rotary screw F10-1 Compressed Air Systems Fact Sheet #10PDF Image | Heat Recovery with Compressed Air Systems
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