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SunChemical
 

AIR/AIR HEAT RECOVERY

PRODUCT:  PIGMENT

  PROCESS:  SPRAY DRYING SYSTEM

  EXHAUST AIR:  21,000 SCFM

  TEMPERATURE:  203 ºF

 Sun Chemical Heat Recovery case study
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ORIGINAL SYSTEM SCHEMATIC
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SYSTEM TESTING

 

OCTOBER 2006

Supply Air Flow

Exhaust Air Flow

System Temperatures

Systems Pressure

  
THERMAL RECOVERY POTENTIAL
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ORIGINAL FEASIBILITY REPORT
 

  ØPredicted Heat Recovery Savings Of $140,000 To $200,000 Per Year
  ØPredicted Equipment Payback Period Of 1.5 Years
 

 

  
SCOPE OF WORK
 
ØHeat Recovery Wheel
ØSupply Ductwork
ØExhaust Ductwork
ØExhaust Air Filter Box
ØStructural Steel & Structural Platform
ØElectrical Panel, Local Devices, VFD
ØElectrical Installation
ØMechanical Installation (By Customer)

 

  
DESIGN HEAT RECOVERY
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SYSTEM ISOMETRIC VIEW
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ACTUAL HEAT RECOVERY
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HEAT RECOVERED
 Flow Rate = 21,000 SCFM
ΔT=(189.6-89.9)=99.7
Heat Recovery=21,000x99.7x1.1=2.3 Million BTU/Hr

  
HEAT AVAILABLE FROM GAS
 		 
GAS SAVINGS
 
ØBest Case Of 90% Available Heat
ØGross Heating Value Of 1,000 BTU/CF
ØUse Current Price of $10.00/1,000 CF

ØGAS SAVINGS:

 

Ø  2,300,000     x  $10.00  =  $25.56 per Hour

  1,000 x 0.90        1,000

 

  
CONSUMPTION
 
ØAdded System Pressure Drop Due to Wheel Of
2 Inches W.C.
ØAdditional Exhaust Fan HP Required of 11 BHP (8.2 Kw)
ØWheel Drive Motor HP Of 2 HP (1.5 Kw)
ØIncluding Control Panel, Increase of 10 Kw Power Requirement

Ø10 Kw @ $0.075/Hour = $0.75/Hour Cost

  
ELECTRICAL
ANNUAL SAVINGS
 

Equipment Operating Hours:

Ø345 Days x 24 Hrs/Day   =   8,280 Hrs/Year
ØNatural Gas Savings:  $25.56 per Hr
ØExtra Electrical Cost:  $  0.75 per Hr
ØNet Hourly Savings:  $24.81 per Hr
ØANNUAL SAVINGS:= $24.81 X 8,280=$205,427
  
EQUIPMENT PAYBACK
 
ØEquipment Cost:  $ 215,000
ØInstallation Cost:  $   85,000 (Mechanical/Electrical)
 

ØTotal Cost:  $ 300,000
 

Ø  PAYBACK:
Ø$300K/$200K per Yr =  1.5 Years
  

10 YEAR OUTLOOK

Ø10 Year Gas Savings:  $2,000,000
ØSystem Initial Cost:  $   300,000
ØBottom Line: $1,700,000

 

  

INSTALLATION PICTURES

  
ENERGY CONSERVATION WHEEL
THE COMPONENTS
THE ROOF
THE LIFT
THE JUNGLE