BRUCKNER presents solutions for efficient energy saving in finishing processes
One of the biggest challenges worldwide faced by the textile industry, too, is the increasing energy shortage with raising prices. In the field of textile finishing, the stenter is the line with the highest energy consumption. Therefore BRUCKNER's technologists checked all parts of the stenter on potential energy savings and developed intelligent solutions to save energy.
Main processes of the stenter
There are three main processes on a stenter:
1. Drying
2. Drying & heat-setting (fabric is presented in wet form)
3. Heat-setting (fabric is presented in dry form)
The main energy consumption results from the mere drying process since a lot of water has to be evaporated using energy (please refer to illustration 1).
Ilustration 1
The diagram (Ilustration 1) makes clear that 92 % of the thermal energy is used to heat the fresh air and to evaporate the water. A relatively low portion of about 8 % gets lost due to radiation losses of the fabric, the chain and the insulation. Therefore BRUCKNER concentrated their development activities mainly on the optimization of the drying process.
Main possibilities to save energy
Padder with efficient squeezing unit
The most simple way to save energy is with the padder placed before each stenter. A padder provided with an efficient squeezing unit is able to squeeze out up to 50 % of the applied water and to save thus up to 50 % of the energy required for the evaporation of water. BRUCKNER offers the corresponding types of rollers.
Patented BRUCKNER split-flow air circulation system
With a new process technology for air circulation around the fabric, BRUCKNER improved its split-flow air circulation technology further and increased the productivity and energy efficiency of its POWER-FRAME stenters.
Good insulation and intelligent control systems
Even an optimized insulation allows to realize energy saving potentials by consistently avoiding thermal bridges. With a heat loss portion of only 2 - 3 %, however, the saving potential is clearly limited in this field. In addition, intelligent control systems for exhaust air, residual moisture and frequency-controlled circulating air fans allow by far higher energy savings. Such effects have been particularly considered by BRUCKNER in the development of the new POWER-FRAME generation.
Innovative BRUCKNER heat recovery systems
Retrofittable air-to-air heat recovery system
The hot stenter exhaust air is supplied to the heat recovery system via a collector line. In the air/air system about 70 % of the exhaust air heat is transferred by platen-type heat exchangers in cross flow to the fresh air. This heated fresh air is then supplied directly to the individual zones of the stenter. BRUCKNER shows that merely the use of this system reduces the process heat demand of a stenter for the drying process by 12 - 15 %, for the heat-setting process even by 33 - 36 %.
Retrofittable air-to-water heat recovery system
The air/water heat recovery system is another possibility to use the thermal energy of exhaust air, which is often and with success used in practise. In these units, heat is transferred to water in the heat exchanger units in crossed counterflow. The advantage compared to co-current systems is that water can be heated to more than 90 ¢XC. This offers excellent saving possibilities in the overall company energy balance for textile finishers having for example wet or dyeing ranges.
Integrated ECO-HEAT back-pack heat recovery system
ECO-HEAT back-pack is the optimum choice for those who want to invest in a new line and in an energy-saving heat-recovery system. This system, which can be ordered additionally to the main machine, is integrated into the stenter roof structure and saves thus space.
Previous< 1 2 3 4 5 6 7 8 9 >Next
|
