Process Heat

Development of a gas-heated energy box for temperature control units

Due to increasing energy prices, the company PGTechnologie has developed an exchangeable heater unit that replaces the electric heating system in temperature control units with a gas-powered system. The aim was to reduce energy costs by 50% and CO2 emissions by more than 60%.

 

Summary

Over recent years, the increase in energy prices in particular has led to energy optimisation in many industry sectors. One energy-intensive system, for example, is temperature control technology, which plays an important role in the plastics industry, in mechanical engineering and in the chemical and pharmaceutical industries. Temperature control units are used, for example, to heat materials such as plastic to a temperature at which they can be processed.

The project's goal was to develop an exchangeable heater unit that replaces the electric heating system in temperature control units with a gas-powered system. 

The aim was to reduce energy costs by 50% and CO2 emissions by more than 60%.

Subsequent to construction of two test systems, referred to as the EnergieBoX, tests with a variety of media and load levels were performed. It was found that the EnergieBoX can be connected to the basic model of the temperature control unit and that the encapsulated design allowed for coaxial air/exhaust routing.

Results:

  • The EnergieBoX can be employed without losses for pressurised water up to 200°C and for heat transfer oil up to 350°C.
  • Use of burner modulation avoids critical film temperatures.
  • High-temperature systems can be used at favourable energy expenditure by integrating an exhaust-gas heat exchanger.
  • The downstream exhaust-gas heat exchanger uses the high exhaust temperature resulting from the high medium temperature of 350°C to heat process water or tools to 95°C.
  • The capacity to heat a variety of media in the EnergieBoX increases the production cycle time of a temperature control unit.
  • The EnergieBox can be fully installed in a temperature control unit and a heating system

Project Participants

Implementing Institution

PGTechnologie GmbH

More Project Informations

Project title:  KMU-innovativ - Klimaschutz: Entwicklung einer gasbeheizten Energiebox für Temperiergeräte

Project number:  01LY0802A

Project region:  Germany (Hesse)

View Publication

Source: German National Library of Science and Technology Hannover (TIB)