To Achieve Significant Energy Savings by Recovering the Heat Generated from a Multistage Air Compressor

Abstract

newline vi newline newline newlineAbstract newlineThe recovery of waste heat generated by multistage air compressors offers significant potential to newlineenhance energy efficiency, reduce operational costs, and promote sustainability in industrial newlineprocesses. The compression process in these systems generates considerable heat, particularly in newlinethe intercoolers and aftercoolers, which is traditionally discarded to cooling towers or released newlineinto the environment to maintain optimal operating conditions. This research presents a novel newlineapproach to recovering and utilizing this otherwise lost thermal energy before it is released, thus newlineimproving energy efficiency. The study explores the potential of recovering heat from multistage newlineair compressors to optimize industrial operations, with a focus on comparing the performance of newlinePlate Heat Exchangers (PHE) and Shell-and-Tube Heat Exchangers (SandT). The experimental newlinesetup involved integrating PHE and SandT heat exchangers into the multistage air compressor newlinesystem. These exchangers received hot water (Fluid A) from the intercoolers and aftercoolers, newlinetransferring thermal energy to a secondary stream of water (Fluid B) for industrial heating newlineprocesses such as preheating water and space heating.The primary objective was to evaluate the newlineenergy recovery efficiency of both heat exchangers, comparing their performance to identify the newlineoptimal heat recovery option. The results show that PHEs outperformed SandT heat exchangers, newlineachieving an efficiency of 92.67%, compared to 68.72% for SandT. In the first observation, PHE newlinerecovered 4233.5 kJ/min, while SandT recovered 3139.39 kJ/min. Subsequent observations newlineconfirmed PHE s superior performance, with energy savings of 4279.92 kJ/min and 4256.82 newlinekJ/min, compared to 3173.80 kJ/min and 3156.67 kJ/min for SandT, respectively.While PHEs newlineexcel in heat transfer efficiency, compact design, outlet water temperature, and total energy newlinesavings, SandT heat exchangers offer advantages in handling higher pressures and providing a newlinelonger operational life. In beverage