Download Air purification in industrial plants producing automotive

Open Eng. 2017; 7:106–114
Research Article
Open Access
Andrzej Grzebielec*, Artur Rusowicz, and Adam Szelągowski
Air purification in industrial plants producing
automotive rubber components in terms of energy
eflciency
DOI 10.1515/eng-2017-0015
Received May 31, 2016; accepted March 23, 2017
Abstract: In automotive industry plants, which use injection molding machines for rubber processing, tar contaminates air to such an extent that air fails to enter standard
heat recovery systems. Accumulated tar clogs ventilation
heat recovery exchangers in just a few days. In the plant
in which the research was conducted, tar contamination
causes blockage of ventilation ducts. The effect of this phenomenon was that every half year channels had to be replaced with new ones, since the economic analysis has
shown that cleaning them is not cost-efficient. Air temperature inside such plants is often, even in winter, higher
than 30°C. The air, without any means of heat recovery, is
discharged outside the buildings. The analyzed plant uses
three types of media for production: hot water, cold water at 14°C (produced in a water chiller), and compressed
air, generated in a unit with a rated power consumption of
180 kW. The aim of the study is to determine the energy efficiency improvement of this type of manufacturing plant.
The main problem to solve is to provide an air purification process so that air can be used in heat recovery devices. The next problem to solve is to recover heat at such
a temperature level that it would be possible to produce
cold for technological purposes without air purification.
Experimental studies have shown that air purification is
feasible. By using one microjet head, a total of 75% of tar
particles was removed from the air; by using 4 heads, a
purification efficiency of 93% was obtained. This method
of air purification causes air temperature to decrease from
35°C to 20°C, which significantly reduces the potential for
heat recovery. The next step of the research was designing
a cassette-plate heat exchanger to exchange heat without
air purification. The economic analysis of such a solution
revealed that replacing the heat exchanger with a new one
even once a year was not cost-efficient. Another issue examined in the context of energy efficiency was the use of
waste heat from the air compressor. Before any changes,
the heat was picked up by a chilled water system. The idea
was to use the heat for cold generation. Temperature of
oil and air in the compressor exceeds 65°C, which makes
it a perfect heat source for an adsorption refrigeration device. This solution reduced the cooling demand by 147 kW,
thus reducing power consumption by 36.75 kW. This study
shows that even in factories where air is heavily polluted
with tar, there are huge potentials for energy recovery using existing technical solutions. It is important to note that
problems of this kind should always be approached individually.
1 Introduction
Most production plants struggle with a heat overproduction problem, especially with regard to lowtemperature heat [1]. Such heat is generated mainly
in technological processes performed in production
plants [2]. The largest amount of heat comes from plastic
processing machinery, machine tools, welding processes,
soldering, or air compression. Although in winter this effect can be used for space heating, in summer it is a serious
problem and makes the temperature in production halls
too high. Also, it often happens that even in winter the
heat production exceeds the demand. The result is that
machinery has to be cooled for the whole year, which is
associated with high operating costs and increasing CO2
emissions. In many cases, the main problem of low energy
*Corresponding Author: Andrzej Grzebielec: Warsaw University of Technology, Faculty of Power and Aeronautical Engineering, Nowowiejska 24, 00-665 Warsaw, Poland, E-mail: [email protected]
Artur Rusowicz: Warsaw University of Technology, Faculty of
Power and Aeronautical Engineering, Nowowiejska 24, 00-665 Warsaw, Poland
and Ośrodek Badawczo Rozwojowy Aparatury Badawczej i Dydaktycznej, Jagiellońska 55, 03-301 Warsaw, Poland, E-mail: [email protected]
Adam Szelągowski: Warsaw University of Technology, Faculty
of Power and Aeronautical Engineering, Nowowiejska 24, 00-665
Warsaw, Poland, E-mail: [email protected]
© 2017 Andrzej Grzebielec et al., published by De Gruyter Open.
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivs 3.0 License.
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Air purification in industrial plants producing automotive rubber components |
efficiency is the lack of connection between heat, cold, or
other media generation [3].
In most cases, this problem can be solved using standard recuperation [4], but there are industries in which air
pollution on the shop floor is large enough to make recuperative heat exchangers block the air flow in just a few
days. One of such industries is rubber parts production for
automotive branches. As a consequence of rubber injection molding, large amounts of tar enter into the air. Tar
clogs heat exchangers quite quickly and effectively builds
up in exhaust ducts. These types of plants are usually characterized by low energy efficiency. According to the latest EU regulations, it is worth considering whether such
plants can manage to boost their energy efficiency [5, 6].
Improving energy efficiency is not only a direction of industrial development but even a requirement [7, 8]. As
such, it supports developing technologies that have not yet
been successfully implemented in industrial applications.
These include solutions for fuel cells [9], thermoelectric
generators [10], ejector devices [11], or adsorption refrigeration devices [12, 13]. Nevertheless, the solutions have
faced many barriers during implementation [14].
The research in the manufacturing plant was divided
into several stages. In the first one, the flow of air in the
production hall, the way the fresh air flows in, and the
way the polluted air flows out were determined. The next
step was to establish potential energy that could be used
in heat recovery processes. Velocity and temperature of air
in two production halls were measured at 2, 4, and 6 m
above the floor. In the next stage of the research, the exhaust air temperature was examined using a bypass provided in the ventilation system directly behind a working
machine. The bypass line was used not only for temperature measurement but also for an air purification experiment. Since standard methods of air purification using
filters have proved inefficient, it was decided to examine
the use of water micro-jets to precipitate solid tar particles
from the air stream. The next step was an experimental test
of possibilities of recovering heat from an air compressor
for the production of cold. For this purpose, an adsorption refrigeration unit, which can convert low-temperature
heat (of up to 55°C) into cold, was used.
2 Description of the production
plant
The analyzed manufacturing facility is located in northern
Poland and consists of two production halls, a warehouse
and an office area. It produces components for the auto-
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motive industry and, for production purposes, it requires
heat, cold, and pressurized air. In the factory, there are oil
boilers with a total capacity of 3 MW to produce heat for
rubber injection molding and to provide space heating of
the halls in winter. The plant operates more than 80 rubber injection molding machines. In the factory, there is an
air compressor with a rated power consumption of 180 kW.
The compressor is lubricated and cooled with oil. Oil and
compressed air are cooled in heat exchangers with chilled
water fed from a chiller. The oil temperature at the inlet
of the heat exchanger can reach a maximum of 85°C. The
average temperature is 75°C. Compressed air is used for
technological purposes. “Cold” is produced by a vapour
compressor chiller with a cooling capacity of 515 kW. The
working fluid in the unit is R134a. Chilled water temperatures are 14°C and 20°C respectively. The cold is used for
cooling the air compressor, for technological purposes in
injection molding machines, and, in summer, for cooling
the air in supply ducts. Air removed from the production
hall has a temperature of 35°C. The reason for such a high
temperature of the extracted air is that the exhaust ducts
are connected directly to the injection molding machines.
First, the air removed from the halls cools the injection
molding machines and then is expelled outside. Since the
air is heavily polluted withtar, no heat recovery system is
mounted. Such attempts were made in the past, but standard heat exchangers become totally clogged in just a few
days.
2.1 Distribution of air in the production halls
In the first stage of the research, the flow of air in the production hall No. 1 was examined. For this purpose, velocities and temperatures were measured in the plant. Figures 1 to 6 show velocities and temperatures of air at 2, 4,
and 6 m above the floor.
According to the measurements, the highest air velocity was at the gates connecting the production hall with the
warehouse. Exhaust fans in one production hall have total
capacity of 60,000 m3 /h, while the total capacity of supply
fans is only 50,000 m3 /h. The result is that the production
hall is under a vacuum. For this reason, the air is sucked
out of the warehouse. This advantage of the solution is
that pollutants from the production halls do not get into
the warehouse. The experimental studies show that the
air temperature rises as the place of measurement moves
away from the inlet of air, with temperatures of 21°C to 26°C
on the opposite end of the hall. Near the supply air duct,
no high velocity of air was observed, which resulted from
the duct design as a perforated steel sheet; hence, the air
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108 | Andrzej Grzebielec, Artur Rusowicz, and Adam Szelągowski
Figure 1: Air velocity in Hall1 at a height of 2 m, m/s.
Figure 4: Air temperature in Hall1 at a height of 4 m, °C.
Figure 2: Air temperature in Hall1 at a height of 2 m, °C.
Figure 5: Air velocity in Hall1 at a height of 6 m, m/s.
Figure 3: Air velocity in Hall1 at a height of 4 m, m/s.
Figure 6: Air temperature in Hall1 at a height of 6 m.
flows into the hall with the same velocity along the entire
length of the channel.
of heat recovery before and after purification. The second
experiment focused on the use of an adsorption refrigeration unit.
3 Experimental research
In order to determine the heat recovery potential, two experiments were performed. The first one involved the purification of air and consisted in determining the potential
3.1 Air purification
Exhaust air from the production hall is extracted via the
channel mounted directly on the rubber injection mold-
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Air purification in industrial plants producing automotive rubber components |
ing machine. This way the air can be used for additional
cooling of the injection molding machine. In order to determine the temperature of the air downstream of the machine, a ventilation passage was made, which directs the
air first into a measuring system. Figures 7 and 8 present
the temperature and relative humidity, respectively, of the
air immediately downstream from the injection molding
machine. The temperature was measured with type K thermocouples, while relative humidity with Honeywell HIH4000 series humidity sensors.
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three, or four microjet batteries. Tests of filtration effectiveness were carried out in accordance with EN 779:2012.
Figure 9: Microjet air purification unit used for the experiment.
Figure 7: Air temperature in the exhaust duct.
Figure 10: Air parameters during the air purification process.
Figure 8: Relative humidity of the air in the exhaust duct.
The results of the experiment presented in Figures 7
and 8 show that the variations in air temperature and relative humidity during operation are low. Injection cycles
are visible, but they do not cause a significant change in
temperature and humidity. A temperature change was observed in the range of 2 K and a relative humidity change
in the range of 2%.
The next stage of the research was determining the
possibility of air purification by the use of water microjets. For this purpose, an experimental apparatus (Fig. 9)
was built to show the effect of cleaning the air by one, two,
Figure 10 (Mollier I,x diagram for moist air) presents
the results of changes in the exhaust air parameters during
the cleaning process for one, two, three, and four microjet
heads, respectively.
The results show that the process is not purely isenthalpic, which follows from the theory of humidification.
In addition, as a consequence of air humidification, the air
temperature felt down. This phenomenon is a result of water evaporation. Another issue considered was recuperation of heat from the exhaust air. In this case it was important that the filtering process does not decrease the air temperature. As shown in Figure 10, with one microjet head
applied the air temperature decreases by 7 K, while with 4
microjet heads the air temperature decreases by 15 K.
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110 | Andrzej Grzebielec, Artur Rusowicz, and Adam Szelągowski
Table 1: Filtration eflciency.
Working microjet
heads
Filtration eflciency
[%]
1 head
2 heads
3 heads
4 heads
75
81
87
93
3.2 The use of an adsorption refrigeration
unit
In order to reduce energy consumption, it was decided
to check how much energy can be saved using a sorption refrigeration unit. There are two types of sorption
refrigeration devices [15, 16]:absorption and adsorption
units [13, 17] More devices are used for the absorption process and they are more widely known, but in this case it is
only possible to use an adsorption refrigerating appliance,
because only this type can work with heat at a temperature
lower than 75°C [12]. The adsorption refrigeration unit will
be driven by heat obtained from the air compressor cooling
system. The heat transfer fluid will be water at a temperature of 60 to 75°C. The adsorption refrigeration unit works
with three circuits (Fig. 11). In this case, the heat source
circuit will be a cooling system for the air compressor; the
second one is the chilled water circuit for the production
of cold; and the third one is the outside heat sink in the
form of a dry cooler.
As part of the experimental work, an adsorption refrigeration unit with a nominal capacity of 10 kW was installed
and the effects of its operation were examined. During the
test, temperatures were measured at the points shown in
Figure 11. In each of the three circuits, the flow of water
was continuously measured. A five-sectioned heater with
a total heating power of 25 kW was used as a heat source.
The dry cooler as well as the cold receiver were finned coil
heat exchangers with variable fan speed control.
The results were compared with those of a standard
vapour compressor refrigeration unit with the same nominal capacity. The results of the comparison of these two
systems are presented in Figures 12 and 13. In both graphs
the results are shown as a function of the ambient air temperature, because it turned out to be most important parameter affecting the operation of the adsorption refrigeration device. The coefficient of performance COP was determined according to the equation
COP = Q́ E / Q́ HS
(1)
The cooling capacity Q́ E was determined from the equation
Q́ E = ḿ E c p (T E,outlet − T E,inlet )
(2)
where ḿ E is the mass flow of water through the condenser,
and c p is the isobaric mass heat capacity of water. The capacity of heat source Q́ HS was determined according to the
equation
Q́ HS = ḿ HS c p (T HS,outlet − T HS,inlet )
(3)
where ḿ HS is the mass flow of water through the heat
source, and c p is the isobaric mass heat capacity of water.
According to Figure 12, no cooling power is generated
when the ambient temperature exceeds 30°C. The coefficient of performance COP drastically drops from 0.4 at
15°C to 0.0 at 30°C. The results indicate that the use of the
adsorption refrigeration equipment is limited to a certain
part of the year. To expand the scope of application of adsorption refrigeration appliances, an evaporative heat exchanger should be used instead of the dry cooler.
4 Proposed improvements in the
factory
Figure 11: The adsorption refrigeration unit and cooperating circuits.
Some proposals for improvements in the manufacturing
plant are given in this section. It should be noted that they
are to be considered separately, since in combination they
affect each other.
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Air purification in industrial plants producing automotive rubber components
Figure 12: Influence of the outdoor air temperature on the cooling
capacity of the refrigeration equipment.
| 111
Figure 14: Cassette-type heat exchanger.
heat transfer coefficient k according to the equation:
k=
Figure 13: Influence of the outdoor air temperature on the coeflcient of performance COP.
4.1 Regenerative heat exchangers without
air purification
As far as refrigeration and air conditioning systems are
concerned, heat exchangers designed with microchannels [18, 19] have gained popularity. In the case of the
plant considered, the approach to be taken is exactly opposite. The use of the other type of heat exchangers was
suggested. The proposed heat exchanger is temporarily insensitive to dirt. The structure of the heat exchanger, being a cassette-type heat exchanger, is shown in Figure 14.
A shell-and-tube construction was also considered, but its
effectiveness with regard to air proved to be highly inadequate [20].
Table 2 lists the results of calculations for the proposed
heat exchanger for one exhaust fan (15,000 m3 /h) using
the finite difference method and the dependence of the
1
1
α out (∆T out )
+
δ sheet
λ sheet
+
1
α(∆T)
+ R deposit (t)
(4)
where α out (∆T out ) is the heat transfer coefficient between
the sheet and the exhaust air from the hall as a function
of the temperature difference between the wall and the air
∆T out . α(∆T) is the coefficient of heat transfer between the
sheet and the fresh air as a function of the temperature
difference between the wall and the air ∆T. δ sheet is the
thickness of the sheet, λ sheet the thermal conductivity of
the sheet material, and R deposit (t) the thermal resistance
of the tar sludge building up as a function of time t.
As the technology of heat exchanger construction advances, new materials have been developed in addition to
titanium and grapheme [21]. However, in the case of the
proposed heat exchanger, the membrane material is of secondary importance. The reason is that the resistance to
heat transfer is associated mainly with the heat transfer
coefficient between air and the membrane.
4.2 Cassette-type heat exchangers with
microjet air purification
According to the measurements described in Section 3, the
application with two heads can remove particulates from
the air with the efficiency of 81% and this leads to a temperature decrease of only 8 K. Therefore, the second solution proposed is a combination of this method of air purification and the use of a cassette-type heat exchanger. Table 3 presents the results for the exhaust air temperature
reduced to 27°C and a smaller distance between the sheets
inside the heat exchangers. The distance can be smaller
because the amount of sludge in the heat exchanger will
be smaller. At a distance of 1 cm, a larger heat flux was
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Table 2: The calculation results for the plate heat exchanger.
The distance
between plates
[cm]
The coeflcient of heat transfer
from the exhaust air side
[W/m2 /K]
Heat transfer coeflcient
from the air supply side
[W/m2 /K]
The heat
transfer coeflcient - k
[W/m2 /K]
Heat exchanger
capacity Q
[kW]
The eflciency of the
heat exchanger heat
[%]
5
4
3
2
11.95
12.51
13.38
14.92
12.60
13.16
14.02
15.53
6.13
6.41
6.85
7.61
28.60
35.13
46.02
64.33
15.4
19.1
24.9
34.9
achieved in the recovery unit than in the case of an untreated air and the distance of 2 cm between the plates.
4.3 The use of superheat from the
refrigeration unit
The water chiller is operated through the whole year and
at this stage, superheat is not used (Fig. 15). The superheat is the heat ata temperature higher than it is in the
condenser. For this reason, it may become economically
attractive [18].
4.4 The use of an adsorption refrigeration
apparatus
Experimental studies show that when dry coolers are used
in combination with an adsorption refrigeration device,
the adsorption units fail to produce cold during warm summer periods. A much better solution is to use evaporative
coolers. They are able to decrease the temperature of cooling water to a lower level than the air temperature. In principle, evaporative cooling operation tends to obtain dew
point temperature. This solution will enable the adsorption refrigeration unit to work even in the days when the
air temperature exceeds 30°C.
5 Final proposal of changes
Figure 15: Superheat in the refrigeration cycle.
For refrigerant R134a, the highest temperature of fluid
in a pipe downstream the compressor can be 62°C, which
makes it a good heat source for hot water or space heating production. If the chiller operates throughout the year
with a nominal cooling capacity of 515 kW, the super heater
could achieve the heating capacity of 85 kW.
The selected proposals for changes are the result of the
economic analysis based on the analysis of simple payback times. It turned out that the best solution is, first,
to use cassette-type heat exchangers without air purification. The investment cost for a single heat exchanger is
50,500.00 PLN net and savings for one exchanger amount
to 51,700.00 PLN/year. The payback period is less than one
year. The operating costs include the replacement of the
exchanger once a year.
The second improvement in the plant is a combination
of processes according to Figure 16. This solution can be
called a kind of poly generation [22].
Table 4 lists investment costs of the proposed solution.
The main item (and the most expensive one) is the adsorption refrigerating equipment.
Due to the fact that the refrigeration chiller will not
operate at full capacity, since the adsorption device can
partly replace it, and no cooling will be required for the
air compressor, the water chiller capacity will decrease by
147 kW. This will give profits at a level of 160,965.00 PLN
per year. The capacity of the super heater will be proportionally smaller and decrease to 60.74 kW (first calculated
as 85 kW). The use of the super heater will result in saving
a total of 32,534 l of oil, i.e. 71,249 PLN/year.
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Air purification in industrial plants producing automotive rubber components | 113
Table 3: The calculation results for the plate heat exchanger.
The distance
between plates
[cm]
The coeflcient of heat transfer
from the exhaust air side
[W/m2 /K]
Heat transfer coeflcient
from the air supply side
[W/m2 /K]
The heat
transfer coeflcient - k
[W/m2 /K]
Heat exchanger
capacity Q
[kW]
The eflciency of the
heat exchanger heat
[%]
2.0
1.0
0.5
15.08
18.16
22.45
15.57
18.57
22.74
7.61
9.18
11.29
50.21
78.43
103.80
34.8
55.2
73.3
Figure 16: Diagram of the proposed improvements.
Table 4: Summary of investment costs.
Name
Price
Adsorption refrigeration unit (160 kW)
Evaporative recooler
Plate heat exchanger in chilled water circuits
Heat exchanger HX1
Water pump for HX1 loop
Materials and installation
Total
799,590 PLN
45,000 PLN
10,000 PLN
12,000 PLN
1,000 PLN
15,000 PLN
882,590 PLN
The annual profits are:
WRK = 160, 965PLN/year + 71, 249PLN/year
= 232, 214PLN/year
The total profit is 232,214.00 PLN/year, which gives a simple payback time
SPBP =
882, 590PLN
= 3.8years
232, 214PLN/year
exchanger efficiency of 34.9%. Twelve such heat exchangers will be placed in the production halls, which will make
the total consumption of heat produced by oil boilers in
winter fall by 772 kW, while the cost of improvements is
PLN 606,000.00. That will give the simple payback time of
less than one year. Another aspect of the improvement is
connecting the processes of cold, heat, and compressed air
production. This solution causes the generation of cooling
capacity in the chiller to fall by about 147 kW, and provides
an extra heat generation of 60.74 kW from the super heater.
The solution offers the profit of 232,214.00 PLN/year and a
simple payback time of 3.8 years. The study found that in
industrial plants where the air is contaminated with tar,
cleaning is not cost-efficient, but improving energy efficiency is unquestionably feasible.
Acknowledgement: This contribution is the result of the
project ’Studies to evaluate the possibility of temperature
stabilization of the production process of vulcanization
and its surroundings while reducing energy consumption’
under the Regional Operational Programme for KujawskoPomorskie Voivodeship, implemented within the framework of Measure 5.4 Strengthening the Regional Capacity
for Research and Technological Development of the Regional Operational Programme for Kujawsko-Pomorskie
Voivodeship 2014-2020.
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