Abstract
Energy conservation has become a priority for industry nowadays. Also, the process performance is evaluated according to the overall energy efficiency and the energy recovery potential. Among this work we studied the probability of recovering heat from the exhaust air out of the spray dryer unit by using high-temperature heat pump system and reuse the recovered energy for preheating the inlet air to the dryer instead of exhausting the hot outlet air into the environment. This work is applied by developing a successful model using an Aspen Plus simulation program after data acquisition for the process operating parameters of existing old plant. Then, the dryer’s main dimensions are recalculated by developing a mathematical model numerically and by using Excel software to avoid any missing data and letting the results more clearly and near to the real. The Aspen Plus simulation model was implemented using the following two major steps: (1) Spray dryer unit sizing; mass and energy balance to calculate the desired amount of air and its temperature to dry the slurry to a blown powder to get a valid simulated spray dryer compared to the recorded operating data. (2) The exhaust air from a spray dryer was moved to a heat pump system to exploit its high temperature for preheating the fresh air to the spray dryer. The developed heat pump system succeeded to recover about 17% of the waste energy and applied an economical heat pump of about 4 COP.
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Abbreviations
- PFD:
-
Process Flow Diagram
- Gs:
-
Air mass flowrate (kg/hr)
- Y1:
-
Inlet air humidity (Kg moisture/Kg air)
- Y2:
-
Outlet air himidity (Kg moisture/Kg air)
- Ls:
-
Solids mass flowrate (Kg/hr)
- X1:
-
Moisture in inlet slurry (kg moisture/Kg solids)
- X2:
-
Moisture content in outlet dried powder (Kg moisture/kg solids)
- T1:
-
Hot air inlet temperature
- T2:
-
Air outlet temperature
- H1:
-
Enthalpy of inlet air
- H2:
-
Enthalpy of outlet air
- HL1:
-
Enthalpy of inlet Slurry
- HL2:
-
Enthalpy of outlet dried powder
- t 1:
-
Slurry inlet temperature
- t 2:
-
Dried powder outlet temperature
- GWP:
-
Global Warming Potential
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Nafady, H.H., Mansour, M.S., El-Gayar, D., Morsy, A. (2022). Energy Recovery from Spray Dryer Exhaust Air Using High-Temperature Heat Pump System. In: Rosso, F., Morea, D., Pribadi, D.O. (eds) Innovations in Green Urbanization and Alternative Renewable Energy. Advances in Science, Technology & Innovation. Springer, Cham. https://doi.org/10.1007/978-3-031-07381-6_13
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