CMM Show Features Process Energy Solutions

Industry shows are an excellent window on the latest technology approaches needed to solve the problems that confront us. The CMM show in Chicago in June was no exception when the question of environmental responsibility and energy consumption was addressed by the four exhibitors producing dryers or air emission control equipment.

The need to reduce the amount of energy required to fuel the drying systems and the control systems was at the top of the priority list. With energy going into and extremely hot air exiting the process, the challenge has been to minimize the energy required up front and maximize the use of the hot air afterward. The four companies were MEGTEC, Anguil Environmental Systems Inc., Catalytic Products Int’l, and Tann Corp./L&E America.

Why is energy conservation a hot topic? A third of all energy is consumed by the industrial sector. A printing plant’s energy consumption is used to either heat or cool products. With the fluctuation of prices for energy in recent years and the extremely high energy costs as compared to the past, companies are seeking solutions to reduce their energy consumption. A competitive marketing position requires control of the costs of manufacturing. Coupled with this is the moral effort to reduce greenhouse gases and a company’s carbon footprint.

Both factors have placed a new face on the potential for the obvious use of the hot air exiting the process. In the early years of air emission control equipment, ROI for heat recovery was negative. With typical ROI of two to three years for equipment, and earlier financial analysis indicated periods as long as twenty years to recover the cost of the closed loop systems, it was difficult to justify the investment. With the escalated cost of energy and innovation in the technology of air handling, however, the pay back period has been considerably reduced and is more affordable for many printing and converting operations.

Drying systems offer an opportunity for heat recovery. Using air to air heat exchangers enable the waste heat from a dryer to be recovered and returned to the system, or diverted to pre-heat building air. Air to liquid exchangers can be used to process liquids or generate steam. What will work best can be determined by a thorough energy evaluation of the process and the facility.

It is possible that the design of the dryer, while adequate for the initial application, is no longer valid for the current materials and inks or coatings. This can also be addressed in the evaluation. With the advent of water borne formulations, the equations for the drying systems has changed to allow for greater air flow. On the other hand, solvent based inks and coatings require more effective systems for monitoring concentrations in the air to avoid potential explosive percentages. Preventive maintenance plays a key role in assuring the proper performance of the dryers.

Oxidation control systems pose a different set of problems. The earlier use of randomly packed catalytic materials of heat exchange media has been replaced by structured media with improved air flow resistance and higher thermal efficiency. Lowering the pressure drop across the oxidizer enables exhaust fans to operate at lower brake horsepower minimizing electrical consumption.

With many air control systems aging, the four firms offer services to conduct energy audits, as well as evaluations of the current condition of the system and its components. Preventive maintenance programs are available, as well as replacement and upgrading projects to bring the systems into a more modern and effective mode.

Looking ahead as we plan to purchase new equipment, the impact of energy usage will be a major factor both in terms of the environment and effective cost. It is best be informed and up to date on the technology that will perform best for your company. Return on investment computations must now include that evasive issue —energy. Be one up and make sure what you do is in the best interests of your firm and the community.