Objective
Reduction of energy costs in drying of packing varnishes through a recovery of process heat from the combustion of recovered solvents and its utilization for heating the drier plant.
The calculated energy savings are assumed to amount to approx. 4,500,000 kW/year.
The technical and chemical feasibility of the project described in the applicaion could be demonstrated with the conclusion of the design phase.
A number of aspects have arisen, however, which may turn the project into a financial failure on the current level of information.
One of these facors is the draft of the Accident Prevention Rules for Lacquer Driers (VBG 24) of March 1988, which calls for a considerable reduction in admissible solvent concentrations compared to the older version of these Accident Prevention Rules. With these new, reduced solvent concentrations, the recovery of solvents through condensation is no longer an economically viable proposal.
Moreover, the Ministry of the Environment expects the packaging industry to make increasing use of low-solvent lacquers.
Renowned packaging manufacturers are already using low-solvent or water soluble varnishes. Plants designed for such applications have already been supplied; others are soon to follow.
In view of the aforementioned items it makes no sense to continue with the further realization of this concept, as industry no longer exhibits any interest in this approach.
The innovative technology consists of a combination of individual technological solutions. These include the condensation of solvents, the drying of packing varnish, thermal post-combustion of the exhaust air from the plant (which is rich in carbohydrates), heating of this port-combustion system by using the solvent condensate as fuel, and the utilization of the resulting energy (i.e. pure exhaust air exhibiting a very high temperature) as process heat for drying of packing varnish. Overall plant structure :
Evaporation section with heat exchanger and vacuum extraction system;
Measuring device for monitoring the solvent concentration;
Condensation system for recovery of incoming solvents;
Preheating zone with heat exchanger and extraction system;
Daking section with heat exchanger and extraction system;
Post-combustion system for generating process heat through combustion of the recovered solvents; Cooling section;
Air recirculation system between the different sections.
This combination of system components causes the exhaust air volume (and hence, the total carbohydrate release rate) to be drastically reduced.
The investment cost of this combine plant is about twice as high as that of a conventional system. On the other hand, the total annual energy generating cost for a conventional plant exceeds that of the combined plant by a factor of 1.5. This means that the combined system achieves cost savings between DM 150000 and DM 180000 per year.
Assuming that the proceeds from a conventional systems and the combination plant are the same, the capital recovery from a plant of the type envisaged in the project is markedly higher (due to the lower total cost), which considerably shortens the period of amortization.
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Programme(s)
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Funding Scheme
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Coordinator
4930 DETMOLD
Germany
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.