{"id":3088,"date":"2021-12-09T14:48:27","date_gmt":"2021-12-09T13:48:27","guid":{"rendered":"https:\/\/www.altairnative.de\/cost-reduction-and-energy-efficiency-in-epp-processing"},"modified":"2022-04-05T11:15:49","modified_gmt":"2022-04-05T09:15:49","slug":"cost-reduction-and-energy-efficiency-in-epp-processing","status":"publish","type":"page","link":"https:\/\/www.altairnative.de\/en\/cost-reduction-and-energy-efficiency-in-epp-processing\/","title":{"rendered":"Cost reduction and energy efficiency in EPP processing"},"content":{"rendered":"

[et_pb_section fb_built=”1″ fullwidth=”on” _builder_version=”3.22″ global_colors_info=”{}”][et_pb_fullwidth_image src=”https:\/\/www.altairnative.de\/wp-content\/uploads\/altairnative_Header1.jpg” _builder_version=”3.0.106″ global_colors_info=”{}”][\/et_pb_fullwidth_image][\/et_pb_section][et_pb_section fb_built=”1″ specialty=”on” background_position_1=”top_left” background_position_2=”top_left” background_repeat_1=”no-repeat” background_repeat_2=”no-repeat” padding_right_1=”2%” custom_css_main_1=” border-right: 1px solid #0071b5;” _builder_version=”3.22″ global_colors_info=”{}”][et_pb_column type=”3_4″ specialty_columns=”3″ _builder_version=”3.25″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_row_inner admin_label=”Zeile” _builder_version=”3.25″ global_colors_info=”{}”][et_pb_column_inner saved_specialty_column_type=”3_4″ _builder_version=”3.25″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_post_title meta=”off” featured_image=”off” _builder_version=”3.0.90″ title_text_color=”#0071b5″ title_font_size=”30px” global_colors_info=”{}”][\/et_pb_post_title][\/et_pb_column_inner][\/et_pb_row_inner][et_pb_row_inner admin_label=”Zeile” _builder_version=”3.25″ global_colors_info=”{}”][et_pb_column_inner saved_specialty_column_type=”3_4″ _builder_version=”3.25″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_text _builder_version=”3.27.4″ global_colors_info=”{}”]<\/p>\n

The processing of EPP (expanded polypropylene) is an energy-intensive process in plastics processing. Due to the process-specific use of steam, compressed air and cooling water, which are often not further utilised for energy purposes after the end of the process, i.e. are simply lost unused, the energy costs significantly influence the total costs for the end product.<\/span> <\/b> <\/b>The steam required for production is often generated from treated fresh water. Thus, the water must be heated from room temperature to approx. 180-190 \u00b0C steam temperature via the steam generator. At the same time, the generation of compressed air generates a lot of waste heat potential that is only partially used or not used at all.<\/span> By using a compressed air heating system (CAHS) with e.g. 300 kW shaft power, 2,900 m\u00b3\/h of compressed air can be generated at 8.5 bar and at the same time 11 m\u00b3 of water can be heated from 30 \u00b0C to 95 \u00b0C. This requires 776 kWh of natural gas. In comparison, 325 kWh of electricity must be used for the same amount of compressed air.<\/span> To heat the 11 m\u00b3 of feed water by 65 \u00b0C, 973 kWh of natural gas must be used at a boiler efficiency of 90 %.<\/span> Table 1 shows an example of the energy costs incurred for the provision of the media described. The conventional generation of steam and compressed air without heat recovery from compressors, the conventional generation with heat recovery from compressors and the use of a CAHS are considered.<\/span><\/p>\n

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<\/th>Conventional generation <\/th>Conventional generation with heat recovery compressed air generation <\/th>CAHS 08\/2900 <\/th><\/tr><\/thead>
Operating hours \/ year <\/td>6500 <\/td>6500 <\/td>6500 <\/td><\/tr>
Compressed air [m\u00b3\/h] <\/td>2900 <\/td>2900 <\/td>2900 <\/td><\/tr>
Electricity [kW] <\/td>325 <\/td>325 <\/td>10 <\/td><\/tr>
Total supply volume [m\u00b3\/a] <\/td>18850000 <\/td>18850000 <\/td>18850000 <\/td><\/tr>
Total electricity demand [kWh\/a] <\/td>2112500 <\/td>2112500 <\/td>65000 <\/td><\/tr>
Electricity costs [\u20ac\/kWh] <\/td> 0,15 \u20ac <\/td> 0,15 \u20ac <\/td> 0,15 \u20ac <\/td><\/tr>
Total electricity costs \u20ac\/a] <\/td> 316.875 \u20ac <\/td> 316.875 \u20ac <\/td> 9.750 \u20ac <\/td><\/tr>
Heat recovery of compressor [kW] <\/td><\/td>210 <\/td>876 <\/td><\/tr>
Feed water prewarming [m\u00b3\/h] (30-95\u00b0C) <\/td>11 <\/td>11 <\/td>11 <\/td><\/tr>
Energy demand [kWh\/h] <\/td>876 <\/td>666 <\/td>0 <\/td><\/tr>
Boiler efficiency <\/td>90% <\/td>90% <\/td>90% <\/td><\/tr>
Fuel demand [kWh\/h] <\/td>973 <\/td>740 <\/td>776 <\/td><\/tr>
Total fuel demand [MWh\/a] <\/td>6326667 <\/td>4810000 <\/td>5044000 <\/td><\/tr>
Fuel costs [\u20ac\/kWh] <\/td>0,03 <\/td>0,03 <\/td>0,03 <\/td><\/tr>
Total fuel costs [\u20ac\/a] <\/td> 189.800 \u20ac <\/td> 144.300 \u20ac <\/td> 151.320 \u20ac <\/td><\/tr>
Energy costs [\u20ac\/a] <\/td> 506.675 \u20ac <\/td> 461.175 \u20ac <\/td> 161.070 \u20ac <\/td><\/tr><\/tbody><\/table><\/div>WordPress Data Table<\/a>\n

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Table 1: Comparison of energy costs for the provision of compressed air and heat<\/b><\/p>\n

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Figure 1: Energy costs for the provision of compressed air and feedwater heating<\/b><\/p>\n

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The bar charts in Figure 1 illustrate the possibilities that the technology generates in terms of cost savings. Compared to conventional provision, there is an energy cost reduction of 345,000 \u20ac\/a; if conventional compressors are equipped with heat recovery, the saving is still 300,000 \u20ac.<\/span> Thermal efficiencies of over 100% can be achieved through the heat pump effect that occurs during the compression and subsequent expansion of air. The prerequisite for this is that the condensation heat from the condensing heat exchanger as well as that from the compressed air cooling can be used. Due to the low temperatures (< 30 \u00b0C) at which the fresh water is available, this process represents one of the ideal applications.<\/span><\/p>\n

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Download<\/h4>\n

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The processing of EPP (expanded polypropylene) is an energy-intensive process in plastics processing. Due to the process-specific use of steam, compressed air and cooling water, which are often not further utilised for energy purposes after the end of the process, i.e. are simply lost unused, the energy costs significantly influence the total costs for the […]<\/p>\n","protected":false},"author":4,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_et_pb_use_builder":"on","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":""},"class_list":["post-3088","page","type-page","status-publish","hentry"],"yoast_head":"\nCost reduction and energy efficiency in EPP processing — altAirnative<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.altairnative.de\/kostenreduzierung-und-energieeffizienz-in-der-epp-verarbeitung\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Cost reduction and energy efficiency in EPP processing — altAirnative\" \/>\n<meta property=\"og:description\" content=\"The processing of EPP (expanded polypropylene) is an energy-intensive process in plastics processing. 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