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Heat Recovery with Compressed Air Systems

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Heat Recovery with Compressed Air Systems ( heat-recovery-with-compressed-air-systems )

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compressors and produce hot water. Depending on design, heat exchangers can produce non- potable (gray) or potable water. When hot water is not required, the lubricant is routed to the standard lubricant cooler. Hot water can be used in central heating or boiler systems, industrial cleaning processes, plating operations, heat pumps, laundries, or any other application where hot water is required. Heat exchangers also offer an opportunity to produce hot air and hot water, and allow the operator some ability to vary the hot air/hot water ratio. Heat Recovery with Water-Cooled Compressors Heat recovery for space heating is not as common with water-cooled compressors Heat Recovery with Compressed Air Systems because an extra stage of heat exchange is required and the temperature of the available heat is lower. Since many water-cooled compressors are quite large, however, heat recovery for space heating can be an attractive opportunity. Recovery efficiencies of 50-60% are typical. Calculating Energy Savings When calculating energy savings and payback periods for heat recovery units, it is important to compare heat recovery with the current source of energy for generating thermal energy, which may be a low-price fossil fuel such as natural gas. The equations in the text box below illustrate the annual energy and costs savings available by recovering heat for space heating from an air- cooled rotary screw compressor. Energy Savings Calculations Energy Savings (Btu/yr) = 0.80 x Compressor bhp x 2,545 Btu/bhp-hour x hours of operation Example: Cost Savings ($/yr) Example: A 100 hp compressor running two shifts, 5 days per week (0.80) x (100 bhp) x (2,545 Btu/bhp-hour) x (4,160 hours per year) = 846,976,000 Btu per year where: 0.80 is the recoverable heat as a percentage of the unit’s output 2,545 is a conversion factor = ((Energy Savings in Btu/yr)/(Btu/unit of fuel) x ($/unit fuel))/ Primary Heater Efficiency Waste heat will be displacing heat produced by a natural gas forced-air system with an efficiency of 85% ((846,976,000 Btu per year)/(100,000 Btu/therm)x($0.40/therm))/0.85 = $3,986 per year * Cost of operating an additional fan for duct loading has not been included Improving Compressed Air System Performance A Sourcebook for Industry F10-2

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