Performance, Precision, Partnership

Save energy sustainably with heat recovery

When using screw compressors, boosters and blowers, a considerable amount of the energy generated is lost in the form of heat. This is a no-go in times of dwindling resources and high energy prices. But this does not have to be the case: thanks to innovative heat recovery systems, this heat can be recovered and put to good use. 

 

Waste Heat Utilization – The Right Decision

Screw compressors, boosters and blowers convert almost 100% of the electrical drive energy supplied into heat energy. The heat flow diagram uses the example of a fluid-injected screw compressor to show how this energy is distributed in the compressor and how much of it can be used. A good 96% is available for heat recovery, 2% remains as heat in the compressed air and a further 2% is emitted as radiant heat. 

 

 

* approximate information
 
(1) |  100%  |  total electrical power consumption
(2) | about 5 %  |  waste heat from the drive motor
(3) | approximately 15 %  |  heat output recoverable by cooling the compressed air
(4) | approximately 76 %  |  heat output recoverable by cooling the fluid
(5) | approximately 96 %  |  usable heat
(6) | approximately 2 %  |  heat dissipation of the compressor system to the environment
(7) | approximately 2 %  |  heat output remaining in the compressed air
(8) | about 4 %  |  unusable heat

 

How is the energy in the compressed air created? The answer is simple: During compression in the compressor, the electrical drive energy is converted into compressed air and heat. The compressor charges the air it sucks in with an energy potential. This corresponds to around 25% of the electrical power consumption of the system. The resulting heat energy is available in the form of warm air or warm water, depending on the compressor design.

 

When can the energy of the compressed air be used? The energy can be used as soon as the compressed air relaxes again at the point of consumption and extracts heat energy from the environment. Depending on the pressure and leakage losses in the compressed air system, more or less of this energy can be used.

 

 

Heat recovery systems – flexible for every need

In order to fully exploit the potential of the thermal energy generated, screw compressors, booster compressors and blowers can be equipped with modern heat recovery systems. These significantly reduce primary energy consumption for heating or hot water production. 

 

KAESER offers the optimal solution for every requirement.

 

Heating air for room heating:  Air-cooled screw compressors, booster compressors and blowers from KAESER are ideal as a complete system for heat recovery for heating rooms or for other warm air applications. The direct use of waste heat via an exhaust air duct system opens up the high recycling potential of 96% of the energy used.

 

 

Hot water generation: For applications requiring hot water, KAESER offers heat recovery systems with special heat exchangers. Depending on the model, this enables fluid-injected screw compressors to generate process, service and drinking water at temperatures of up to 85 °C. The indirect use of waste heat via heat exchanger systems uses up to 76% of the electrical power supplied by the compressed air supply.

 

 

With our energy saving system KESS it is possible to calculate exactly the heat that can be recovered using hot water depending on the operating behavior of the compressors. Your advantage: After a measurement, you receive your individual potential for heat recovery - stated in kWh and euros. This means you have your savings in black and white.

 

This is where heat recovery comes into play:

  • feeding into central heating systems
  • hot water for sanitary facilities
  • drying and sterilization processes
  • industrial water for the food and beverage industry
  • process water for the textile industry
  • process water for the manufacturing industry
Heat recovery systems can be used in a variety of areas to improve energy efficiency and reduce costs. A common application is the use of waste heat from compressors to heat buildings or to heat water in industrial processes. These systems can also be used in the food and beverage industry to generate process heat or to preheat air in drying plants. 

 

In addition, heat recovery systems can be used in the chemical, mining, textile and many other industries to increase energy efficiency and reduce environmental impact.

 

 

 

Advantages at a glance

To give you a better overview, we have summarised the many advantages that KAESER heat recovery systems offer.
  • Energy efficiency: By recovering waste heat, you can significantly reduce your energy costs. The heat recovered can be used to heat rooms, prepare hot water or support industrial processes. This way, you use your energy twice and save money at the same time.
  • Sustainability: By using the waste heat from the compressed air supply, you can significantly reduce CO2 emissions. Heat recovery actively contributes to climate protection and helps your company to operate more sustainably. 
  •  According to needs: Depending on your specific requirements, you can choose from different temperature levels and water quantities. This means you can be optimally prepared for your individual needs.  
  •  Flexibility: KAESER heat recovery systems can be adapted to almost any compressor. Whether you already have an existing system or want to install a new one, our innovative technology can be easily integrated. 
  •  Funding opportunities: There are government funding programs for energy-efficient measures. Find out about possible financial support and benefit today.