Additional Heat Source for Thermal Post-Combustion Efficiency
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Solution Overview
Problem
The existing drying process in vehicle painting plants is inefficient due to rising primary energy prices, as the projected clean gas temperature does not match the real temperature, leading to suboptimal operation of the thermal post-combustion system at part load instead of full load.
Innovation Solution
An additional heat source, such as an additional burner, is introduced to further heat the clean gas, allowing for controlled temperature and volumetric flow rate adjustments, ensuring adequate oxidative conversion and energy efficiency by retaining heat within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermal post-combustion system operates at part load to match the projected clean gas temperature of 160°C-180°C, then the system can maintain stable operation, but the actual primary energy consumption increases and efficiency decreases
Solution Approach 1:
The invention changes the temperature parameter of the clean gas by introducing an additional heat source that raises the clean gas temperature from the projected 160°C-180°C to a higher actual temperature of 280°C-320°C. This parameter change allows the thermal post-combustion system to operate at full load with improved energy efficiency while maintaining stable operation
Solution Approach 2:
The invention introduces an additional heat source as an intermediary element between the thermal post-combustion system and the circulating air recuperators. This intermediary provides the necessary thermal energy to raise the clean gas temperature, enabling the system to operate at full load rather than part load, thereby reducing primary energy consumption
2Productivity
If the clean gas temperature is increased to 280°C-320°C using an additional heat source, then the thermal post-combustion system can operate at full load with improved efficiency, but the system complexity increases
Solution Approach 1:
The additional heat source is designed to integrate with the existing thermal post-combustion system and circulating air recuperators, serving multiple functions: heating the clean gas to the required temperature, enabling full load operation, and maintaining system stability. This multi-functionality approach minimizes the need for entirely separate systems, thereby limiting the increase in overall system complexity
3Loss of energy
If the clean gas temperature is raised above the projected temperature, then less heat energy is needed from the thermal post-combustion system, but additional heating equipment is required
Solution Approach 1:
The additional heat source operates continuously in conjunction with the thermal post-combustion system to maintain the clean gas temperature at the higher level of 280°C-320°C throughout the drying process. This continuous heating action ensures that the clean gas consistently carries sufficient thermal energy to the circulating air recuperators, reducing the overall heat energy requirement from the primary combustion system while maintaining process continuity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables full load operation of the thermal post-combustion system, simplifies temperature control, and increases the efficiency of the drying process by providing only the necessary heat energy, thereby optimizing energy usage and reducing energy consumption.
Implementation Method 1
the clean gas is subjected to at least one additional heat source
Implementation Method 2
the clean gas is conducted as through circulating air recuperators, in which the circulating air extracted from the dryer is heated up
Implementation Method 3
the waste air from the dryer is heated in a thermal post-combustion system and as clean gas is conducted... for the oxidative conversion of the organic substances into the non-toxic compounds carbon dioxide and steam
Data Source
AI summary
A method for efficient utilization of hot air flows in a dryer system for goods to be dried is provided, in particular for a vehicle painting plant. Waste air from the dryer is heated in a thermal post-combustion plant and, as clean gas is conducted through circulating air recuperators, the circulating air extracted from the dryer is heated up and returned into the dryer. A device for efficient utilization of the hot air flows in a dryer system for goods to be dried is also provided, in particular for a vehicle painting system. The device includes a dryer, the waste air of which is heated in a thermal post-combustion plant. Clean gas is fed to circulating air recuperators and at least one fresh air recuperator. At least one additional heat source for the clean gas is also provided.