Cooling with Heat from Air Compressors

Using the Energetic Potential of Compressed Air
Almost all manufacturing companies use compressed air. At the same time, the need for cooling, both for production and for buildings, is constantly increasing, driving energy demand. Adsorption cooling offers an ideal approach for generating cold and reducing energy costs through heat recovery.

More than three quarters of the electrical energy consumed by air compressors can be recovered as hot water. This hot water happens to have just the right temperature for driving an adsorption chillers. This makes combining both an ideal way to increase energy efficiency whenever cooling is needed, whether for process cooling or room air conditioning.

Increasing Energy Efficiency in Manufacturing

Combined heat and power not only reduces electricity costs significantly, it also relieves the power plants and supports the decentralized energy supply approach.

The combination of compressed air and adsorption cooling works with practically all makes and models of air compressors. The adsorption chiller cools the compressor and simultaneously generates cold, e.g. for cooling production processes, or for room air conditioning.

Alupress

Process cooling with compressor waste heat: Alupress manufacturing of aluminium die-cast components

2018

Alupress GmbH is a leading manufacturer of innovative aluminium die-cast components and systems. The company has become a key supplier for the automotive industry through continuous further development in the areas of technology and quality. Here, the environment and the economical use of resources is always viewed as a main concern.

For this reason, in 2018 Alupress chose to use the energy-saving adsorption technology from FAHRENHEIT on their site.
In collaboration with the innovative system engineers GALEK And KOWALD from Mühlhausen (Thuringia), a highly-efficient eCoo 20 X adsorption cooling system was installed. The adsorption chiller unit in this system is powered by the heat from the air compressors. A large part of the cooling capacity, approx. 41 kW, is used all year round to predry the compressed air immediately after it has left the air compressor. As such, the eCoo 20 X saves over 60 MWhe per year and pays for itself in less than 3 years.

Drive power
76 kW
Drive temperature
75°C
Cooling capacity
41 kW
Chilled water temperature
16°C
Recooler
dry
Operating hours
Approx. 8000/a
Commissioning date
2018
Payback
3 years

ERKO CNC

PROCESS COOLING USING COMPRESSOR HEAT: ERKO PRÄZISIONS- UND STEUERUNGSTECHNIK

2016

More than three quarters of the heat produced by compressed air generators can be recovered for hot water systems.

The ERKO Präzisions- und Steuerungstechnik GmbH (also “ERKO CNC”) is u.a. specializing in the production of high-precision components in CNC milling and turning technology. In order to use the thermal energy of its compressors more efficiently, in 2016 it commissioned five adsorption chiller units.

The cold produced in this way is now used for cooling tools. The company has a solution that is as economical as it is ecological – especially against the background of multi-shift operation and thus an almost constant need for compressed air and cooling.

Drive source
Heat from air compressors
Drive temperature
75°C
Cooling capacity (nominal)
63 kW
Refrigeration temperature
20°C
Recooling
dry
Commissioning date
2015
Operating hours per year
approx. 6,000
Avoided CO2 emissions
76.8t p.a
Payback
3.3 years

ZWL LEIPZIG

COMPRESSED AIR HEAT: NEUES ZAHNRADWERK LEIPZIG GMBH

2016

The NZWL Group is an international manufacturer of engine and transmission parts (gears, synchronizers, shafts), gearbox assemblies and fully assembled gearboxes for the automotive industry. In order to utilize the thermal energy of its compressors more efficiently, in 2016 it commissioned two eCoo 2.0 I 10 IPS adsorption chiller units.

The cold produced in this way is used to cool tools. The company has a solution that is as economical as it is ecological - especially against the background of multi-shift operation, which requires almost constant demand for compressed air and cooling.

Drive heat source
Waste heat from air compressors
Cooling application
Cooling machine tools
Drive power
46 kW
Drive temperature
70°C
Cooling capacity
24 kW
Cold water temperature
12°C
Recooler
dry
Operating hours
approx. 6,000 p.a
Commissioning date
2016
Avoided CO2 emissions
76.8t p.a
Payback
3.3 years