Drying Installation Air Cooling Heating Energy Recovery
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Solution Overview
Problem
Existing drying systems for bulk materials, such as sewage sludge, face challenges in achieving energy-saving and low-dust drying while managing the recirculation of exhaust air, which is heavily polluted and contaminated with moisture and dust.
Innovation Solution
The system incorporates a multi-stage air cooling and heating process with energy recirculation, utilizing tube heat exchangers and an air scrubber to condense moisture from exhaust air, allowing for its reuse as supply air, and energy recovery from the cooling stages to reheat the air, minimizing environmental discharge and optimizing energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If exhaust air is directly recirculated into the drying area, then energy consumption is reduced, but the air quality deteriorates due to high moisture content and dust contamination
Solution Approach 1:
The air treatment process is segmented into multiple stages: first cooling stage for initial moisture removal, second cooling stage for further condensation, and heating stage for temperature adjustment. This segmentation allows progressive treatment of the exhaust air to achieve both energy recovery and quality improvement
Solution Approach 2:
Heat exchangers are introduced as intermediary devices between the exhaust air and the drying area. These heat exchangers enable heat transfer and moisture condensation without direct mixing, allowing energy recovery while separating harmful moisture and dust from the recirculated air
2Object-affected harmful factors
If exhaust air is cooled to condense moisture, then air quality improves, but energy is lost through cooling
Solution Approach 1:
The system recovers thermal energy from the exhaust air during the cooling process. The first cooling stage condenses moisture while the second cooling stage further cools the air, and the heating stage then reuses this cooled air to preheat fresh air or maintain drying temperature, recovering the energy that would otherwise be lost
Solution Approach 2:
The system utilizes phase transition of water from vapor to liquid during cooling stages to remove moisture. By controlling temperature and pressure conditions in the cooling stages, moisture condenses out of the exhaust air, effectively separating it while the thermal energy is recovered through heat exchangers
3Object-affected harmful factors
If exhaust air is discharged into the environment, then air quality in the drying area improves, but environmental pollution increases
Solution Approach 1:
The system converts the harmful exhaust air containing dust and odors into a beneficial resource by recirculating it through cooling and heating stages. The treated air, now with reduced moisture and temperature appropriate for drying, is fed back into the drying area, eliminating the need for environmental discharge while maintaining drying effectiveness
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 approach significantly reduces the need for external air discharge, minimizes dust and odor pollution, and efficiently recycles energy, resulting in a more energy-saving and environmentally friendly drying process.
Implementation Method 1
the exhaust air is cooled so strongly that the moisture contained in it condenses and can be discharged as condensed water from the two air cooling stages
Implementation Method 2
the exhaust air is heated so strongly that it can be fed back into the drying area as supply air
Implementation Method 3
an energy recirculation device for returning energy from the first air cooling stage to the first Air heating stage is provided
Data Source
AI summary
According to the invention, a drying installation (10) with a drying area (14) is made available for drying bulk material (16) such as pre-granulated sewage sludge, in which an air removal device (32) for removing exhaust air (30) from the drying area (14) and an air delivery device (28) for delivering additional air into the drying area (14) are provided, in which an air cooler (38) with a first air-cooling stage (36) and a second air-cooling stage (44) for cooling the exhaust air (30) and an air heater (62) with a first air-heating stage (64) and a second air-heating stage (72) for heating the additional air (26) are provided, and in which an energy recovery device (70) is provided for returning energy from the first air-cooling stage (36) to the first air-heating stage (64).