Flexible heat recovery module also for older ranges
The "Energy Tower" and "ECO Booster" retrofit modules increase energy efficiency
The challenge in the context of sustainability:
In new Monforts ranges, the principle of heat recovery is offered as standard. But what about older ranges that many customers still have in operation? Particularly in the field of textile finishing, ranges are extremely durable and therefore in use for many years, despite the high demands made on them. An investment in new ranges is very costly and not always feasible. Retrofit modules could be an alternative because they are less expensive and can nevertheless offer energy-efficient solutions.
The status quo:
In the field of textile finishing, energy is a major cost factor. The vast majority of the energy is required to achieve a high drying temperature so that water can evaporate. Two-thirds of the drying energy are used for the evaporation heat. If there is no heat recovery system, the hot waste air is simply discharged into the atmosphere unused. Stenters require a high temperature level of between 130°C and 240°C. Energy can be saved during the drying process if
- a machine produces continuously and standstill times can be avoided.
- the ingoing temperature is already high so that the required operating temperature can be reached more quickly.
- the necessary fresh air volume can be controlled by means of process parameters, and leakage losses via inlet and outlet openings can be reduced.
- the pass speed is high in order to ensure energy-efficient utilisation of the range.
The "Energy Tower" from A. Monforts Textilmaschinen is a stand-alone air/air heat exchanger for heat recovery. Thanks to its design it is a versatile and flexible retrofit module that enables even older ranges to benefit from the principle of heat recovery. The module draws in the exhaust air from the drying process and returns it via heat exchangers to the range so that the air is preheated to around 90°C and only has to be heated to 150°C. The high drying temperature is thus reached more quickly and the energy costs are reduced.
The Eco Booster HRC can also help to minimise the energy costs when using stenters. By contrast with purely static heat exchanger modules, the new module actually cleans the stenter during operation, thus eliminating standstill times for maintenance. Only 100 litres of water are used for cleaning. The Eco Booster permits a computer-controlled adaptation of the heat exchanger performance to the prevailing waste air stream. This optimised efficiency further reduces the process costs. The Eco Booster runs fully automatically so that the operator has no additional duties to carry out.
The sustainable strengths:
The Monforts Energy Tower 7000 can be connected to infrared dryers, hotflues, relaxation dryers, continuous dyeing ranges and condensation ranges, and can also be retrofitted in existing stenter ranges. Depending on the process, up to 30 per cent of the heating energy costs can be saved by using the hot waste air – a significant added value in view of the high energy requirements for the drying process.
An Eco Booster HRC on an eight-field stenter, nominal width 200 cm, 150 g/m² woven fabric, fixing process and 6000 operating hours per year even enables 35 per cent of the energy costs to be saved. The new module permits a higher availability of the range and increases the effectiveness of the cleaning process thanks to the automation.