As much as 80-93% of the electrical energy used by an industrial 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.
The air entering the compressor at atmospheric pressure has a base level of energy content. After the compression process increases the air pressure and raises its temperature, energy is available for transfer. Heat must be removed to maintain the compressor tolerances and clearances, and the compressed air cooled to make it suitable for the intended use.
The heat energy is usually released to the atmosphere or the cooling water. One of the better methods for improving the overall efficiency of any compressed air system is to recover the released heat.
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.
Using Imagination
In one case, a manufacturer used natural gas to heat wax used in its end product. In other case, in a food processing plant, the jacket water from an engine driven compressor liquefied chocolate and sugar. The opportunities are excellent. Use your imagination to recover air compressor heat and reap the benefits of reduced energy consumption and lower operating costs.
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