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XXXXX Munters DH Systems for Spray Drying Applications Presented by: XXXX XXXXX
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Founder Munters AB Carl Munters (1899 – 1989) Swedish Inventor
Considered "Thomas Edison" of Sweden Earned over 1,000 Patents Invented: First Home Refrigerator Styrofoam® Desiccant Dehumidifiers
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Brief History Cargocaire (CEC) was founded in 1939 by Commander Colvin to protect cargo aboard merchant and naval vessels. Munters Corporation was founded by Carl Munters in The two companies merged to create Munters Cargocaire. Nick Des Champs develops air-to-air counter flow heat exchanger in 1973 for cooling jet fighter cockpits. Des Champs Laboratories incorporated in 1974. Munters acquires Des Champs Technologies in 2007.
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Munters Today OMX Nordic Exchange "MTRS“ Headquartered in Stockholm
Three Divisions: MCS, HumiCool, and DH Operations in 30 Countries 4,000 Employees Sales of US $1 Billion
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Humicool Division Evaporative cooling and humidification Aghort
Gas compressor stations Industrial humidification Residential cooling Gas turbines Allow enclosed bird houses to operate efficiently and let birds mature in a consistent time. Side benefit: Gets birds inside – reduces risk of spreading bird flu. Turbine inlet cooling: Higher air density increased kW output. Prevents new plant construction, lowers CO2 emissions, etc. HVAC pre-coolers can make condensers more efficient 5
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DH Division Controlling Humidity Ventilation Systems Low Dewpoint
Frost prevention Condensation control Ventilation Systems Indoor Air Quality Improvement Energy Recovery Indirect Evap Cooling Low Dewpoint Corrosion prevention Preservation / Storage
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DH Basic Product Areas Air Treatment Technologies
Dehumidification Energy Recovery Indirect Evaporative Cooling Indirect Heating VOC Abatement Standard or custom configurations Three USA manufacturing facilities Dehumidification Energy Recovery Heating & Cooling VOC Abatement
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Amesbury Manufacturing Facility
130,000 sq ft
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Texas Manufacturing Facility
134,000 sq ft
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Virginia Manufacturing Facility
250,000 sq ft
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Markets We Serve
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Some of our customers: Some of our other national and global customers….
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Applications Food Pharmaceutical School and Universities Chemical
Plastics Casinos Archival Storage Biotechnology Investment Casting Swimming Pools Ventilation & Environmental Control Military Semiconductors Optical Steel Storage Paper & Printing Confectionery Specialty Metals
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Humidity and Dew Point Control
Spray Drying No clogs in product collectors (increases throughput) Allows smaller spray towers, fluid beds and heaters Improves product quality
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Spray Drying Process
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Spray Tower Problems Production rate varies by season
Drying time too long Inconsistent quality of the powder Production stops Product scrap Lack of flexibility
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Typical Production Losses Related to Moisture in the Air
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Munters Approach Using desiccant technology to dry the outside air required for the process (GTR). Provide a consistent low dew point (winter time conditions year round). Desiccant wheel removes moisture while also heating the process air (energy savings).
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Direct Fired Gas Heater Manual Balancing Damper DH React Fan D E F
(GTR3) Process Fan 30% Filters C B A Balancing Damper 25 gr/lb = 30 F DP Munters Cargocaire Prelim Layout Drawing IDS-I0-8DG-0 9/9/09
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Cooling-Based Dehumidification
Air is circulated across a cold coil and cooled to saturation Further cooling condenses moisture from the air stream Dewpoint reduction is limited by minimum practical coil temperatures Air is delivered at saturated conditions
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Cool / Reheat Spray Dryer Applications Ambient 90°F / 130 gr/lb
140 120 Psychrometric Plot Cool / Reheat Spray Dryer Applications Ambient 90°F / 130 gr/lb 100 80 Humidity Ratio Grains of Moisture per Pound of Dry Air (gr/lb) 60 40 20 -10 -10 10 20 30 40 50 60 70 90 150 200 350 Dry Bulb Temperature °F
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GTR Rotor Spray Dryer Applications Ambient 90°F / 130 gr/lb
140 120 Psychrometric Plot GTR Rotor Spray Dryer Applications Ambient 90°F / 130 gr/lb 100 80 Humidity Ratio Grains of Moisture per Pound of Dry Air (gr/lb) 60 40 20 -10 -10 10 20 30 40 50 60 70 90 150 200 350 Dry Bulb Temperature °F
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Reactivation Usage (summer): Process Savings (summer):
Direct Fired Gas Heater Manual Balancing Damper HCE-15,000 React Fan D E F 30% Filters (GTR3) Process Fan C B A Balancing Damper Reactivation Usage (summer): Process Savings (summer): BTUH = ((6390) * (1.08) * (325-84)) / .92 BTUH = ((10,000) * (1.08) * (200-89)) / .8 BTHU = 1,807,800 btuh input BTUH = 1,498,500 btuh input Net Gas Used For Dehumidification = (1,807,800 – 1,498,500) = 309,300 Input Therefore (Net): 309,300 btuh / lb water removed = 433 btu / lb water removed
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Reactivation Usage (fall / spring): Process Savings (fall / spring):
Direct Fired Gas Heater Manual Balancing Damper HCE-15,000 React Fan D E F 30% Filters (GTR3) Process Fan C B A Balancing Damper Reactivation Usage (fall / spring): Process Savings (fall / spring): BTUH = ((6390) * (1.08) * ( )) / .92 BTUH = ((10,000) * (1.08) * ( )) / .8 BTHU = 1,612,800 btuh input BTUH = 1,093,500 btuh input Net Gas Used For Dehumidification = (1,612,800 – 1,093,500) = 519,300 Input Therefore (Net): 519,300 btuh / lb water removed = 973 btu / lb water removed
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Cooling Usage (summer):
Process Fan B 30% Filters A C Balancing Damper Cooling Coil Indirect Heater D Cooling Usage (summer): BTUH = ((10,000) * (4.5) * (42.76 – 11.22)) BTHU = 1,419,300 BTUH = 118 Tons Actual Gas Used For Re-Heat = ((10,000) * (1.08) * (200 – 30)) / .8 = 2,295,000 btuh Therefore: Gas Usage = 2,295,000 btuh Cooling Usage = 118 Tons (NOTE: Does not account for cooling inefficiencies (COP and defrost) for cooling below the freezing point of water)
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Cooling Usage (fall / spring):
Process Fan B 30% Filters A C Balancing Damper Cooling Coil Indirect Heater D Cooling Usage (fall / spring): BTUH = ((10,000) * (4.5) * (32.08 – 11.22)) BTHU = 938,700 BTUH = 78 Tons Actual Gas Used For Re-Heat = ((10,000) * (1.08) * (154 – 30)) / .8 = 1,339,200 btuh Therefore: Gas Usage = 1,339,000 btuh Cooling Usage = 78 Tons (NOTE: Does not account for cooling inefficiencies (COP and defrost) for cooling below the freezing point of water)
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Energy Comparison Dehumidification (84°F / 136 gr/lb) Cooling Only Net
Net Gas Usage 309,300 BUTH 2,295,000 BTUH -1,985,700 BTUH Net Cooling Usage 118 Tons -118 Tons Dehumidification (70°F / 90 gr/lb) Cooling Only Net Net Gas Usage 519,300 BUTH 1,339,000 BTUH -1,029,700 BTUH Net Cooling Usage 78 Tons -78 Tons
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Energy Analysis (Cont.)
For New Jersey: Target = 40°F DP, constant outlet gr/lb, 10,000 CFM of outside air $127,035 Cool / Reheat $76,081 Desiccant Dehumidification $50,954 Savings for DH vs. Cool / Reheat
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What Products Can This Apply To:
End users of the following industries: Dairy (powdered milk) Fragrance Companies Flavor Companies Gelatin Whey and other proteins Any powdered product that is spray dried (meats, fats, broth powders, etc.)
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Europe's Customer Base Whey Lactalis 4 units Milk CPS New Zealand
Celia (for baby) 2 units Sevres 1 unit Starch Roquette 6 units Yeast Lesaffre 5 units Kerry 1 unit Scotland Baby foods Kerry 3 units Malaysia Kerry Penang Food Colorant Roche Vitamines 1 unit Coffee Nestlé 3 units Soup Leibig 1 unit Aroma Aromes de Bretagne 1 unit Seaweed Sea Oil 1 unit Mix Bionov 1 unit
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What Do We Sell? Fully Welded Construction: GTR Wheel Basic Controls
Better gr/lb depression with raw outside air. Basic Controls Reactivation Control High Temperature Reactivation Utility Direct Fired Gas High Pressure Steam (min 150 PSIG)
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What Do We Need to Know What is the total CFM that you need for the process (making sure they include wall sweeps, etc.)? What do you have for reactivation energy? Do you want to maintain a constant DP, or is drier better? What are your AHU requirements.
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Summary If the customer currently has no humidity control:
Desiccant Dehumidification will supply winter time humidity conditions year round. If the customer already uses cooling for humidity control Desiccant Dehumidification will provide better humidity control for less energy. If the customer already uses a competitors desiccant system: Munters GTR wheel will provide better performance for less energy
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Questions???
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