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Heat recovery multiplies the energy efficiency of compressed air

There are only upsides to heat recovery – energy is the single largest cost item in a compressed air system.

Who would want to waste the heat energy of their compressed air system? Wherever compressed air is used, there is often an opportunity to use waste heat as well.

There are only upsides to heat recovery – energy is the single largest cost item in a compressed air system. By recovering and reusing the heat energy generated by your compressors in your own processes, you can save on costs and carbon dioxide emissions.

It is a smart move to consider heat recovery during the purchase of compressed air equipment, but heat recovery systems can be installed at practically any time.

But what is the best heat recovery method and what are the pitfalls to avoid? Read this article to find out.

Waste heat exists in almost all compressed air applications

In Finland, there remains vast unexplored potential for exploiting waste heat that is generated in industry and large buildings in particular, such as hospitals and commercial properties. Large facilities also consume large amounts of compressed air, leading to greater energy consumption.

The considerable amount of heat generated by compressors during production is typically removed to prevent overheating and optimise the temperature of the compressed air produced.  This is often done by venting the waste heat into the air, but a more efficient way is to recover the heat and use it elsewhere in the facility.

Waste heat has the advantage of being highly versatile – it is useful for many industrial processes. The heat generated during compressed air production can be used to heat process water or other liquids on the property, for example. Waste heat can be used for pre-heating or primary heating, depending on the temperature required.

The recovery of waste heat is especially useful if a clear use for the heat exists or the site has or is about to install heat pumps that can better distribute heat and exploit it efficiently.

Waste heat is also useful for heating buildings such as production halls. Furthermore, water-cooled compressors produce hot water or even steam that can be used for cleaning, sterilisation and pasteurisation processes.

There are practically as many uses as there are processes that need heat, as long as recovery is effective!

There are many reasons for recovering heat:

  • Helps reduce the electricity and other energy costs of the largest consumers. Compressed air production consumes a lot of energy, which waste heat recovery can help compensate.
  • Helps improve your facility’s self-sufficiency and flexible energy use. Waste heat recovery systems can be integrated with existing processes such as heat pumps.
  • Helps reduce your carbon footprint. Waste heat recovery means less wasted energy, which makes your production processes more environmentally friendly.

If waste heat can be used to replace fossil fuels, this can reduce carbon dioxide emissions significantly.

What you should consider for maximum heat recovery efficiency

Heat recovery is becoming more commonplace, and equipment manufacturers are offering more recovery solutions.  More important than any single technology is the whole of the compressed air system and choosing the most compatible solutions.

The number of devices and technologies is endless, so making the right choices avoids unnecessary investments. For example, compressors are not great “heat generators” in themselves and must be dimensioned correctly.

Heat recovery is facilitated by a heat exchanger – a heat pump, for example – that can transfer the waste heat from the compressor to a water circulation system for use.

One of the most common mistakes is to choose an oversize compressor with the hope of extracting more heat. Oversize compressors will produce more waste heat, but also consume more energy, which eats away the total efficiency. Likewise, it is common to overlook the effects of waste heat recovery on downstream processing and drying, which may reduce the quality of the compressed air.

Again, it is crucial to understand the compressed air system as a whole – heat recovery should be designed and dimensioned to fit your use case and needs. The compressed air system is the sum of its parts, its efficiency affected by individual devices as well as their dimensioning and optimisation.

Looking to use waste heat and improve the energy efficiency of your compressed air system?

Contact us and our experts will review the best solutions for your business. We operate independently of equipment manufacturers to provide optimal technology solutions, expert consultation, and life cycle and maintenance services.

We deliver complete solutions that allow you to make smarter use of compressed air – save energy and costs while improving quality.

Learn more about our compressed air solutions!

Contact us

Our experts are happy to help you with any questions.
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Mika Kiuttu

Key Account Manager, Compressed air

010 550 4582
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Jesse Suokas

Key Account Manager, Compressed air

010 550 4758