Global label manufacturer heat recovery project.

Introduction:

Our client, renowned for their expertise in label and packaging materials, faced the challenge of optimising their silicone dryer and reducing the operating costs associated with natural gas consumption. Operational (UK) Limited was tasked with assessing the feasibility of recovering energy from the exhaust stack of the coater dryer and reusing that otherwise wasted energy within the upstream coater dryer process.

The first step in this process was for Operational (UK) Limited to conduct a comprehensive dryer and energy survey of the coater. The data collected enabled the development of a heat recovery and reuse system that met the client’s energy reduction targets while maintaining quality requirements.

Solution:

Operational (UK) Limited proposed an air-to-water heat recovery system combined with water-to-air reuse units. This system would increase the intake fresh air temperature of the gas burner-based dryer systems from an average of 21°C to 83°C. The heat recovery and reuse systems were supplied with hot water via a pressurised hot water recirculation system, equipped with all the necessary safety components to ensure reliable and secure operation.

To maintain precise control and ensure that the dryer setpoints and temperature profiles remained unaffected, the temperature setpoint control system was modified to ensure stable temperature profiles were achievable.

Implementation:

The project implementation included:

• Dryer and Energy Survey – Conducting a detailed assessment to evaluate the feasibility of the heat recovery project.
• Heat Recovery and Recirculation System – Designing, manufacturing, installing, and commissioning a bespoke heat recovery system, including a pressurised hot water recirculation and reuse system.
• Temperature Control System – Designing, manufacturing, installing, and commissioning a precision temperature control system to ensure accurate temperature regulation.
• Structural Platform Construction – Designing and constructing a bespoke structural platform, complete with maintenance access for safe and efficient operation.

Results: