Features

Efficient heat recovery modules

The finishing and coating of fabrics is among the most energy-intensive
steps in the production of textiles stated Hans-Peter Prinzen, Head of R & D,
A.Monforts Textilmaschinen, in a recent VDMA presentation.
Energy costs account for a considerable portion of the production costs as
significant heating energy is required for
drying, finishing and fixing processes.
Using a heat recovery system, part of
the energy in the exhaust air can be used
in a heat exchanger to preheat the fresh
air. Furthermore, the cooling of the
exhaust air allows finishing agents, oils
and waxes to recondense and be separated; further aiding the environment.

Hans-Peter Prinzen, Head of R & D,

A.Monforts Textilmaschinen.

dyeing ranges and condensation ranges

or retrofitted on existing stenter ranges.
The Eco-Booster is an automated
solution for the production process. The
heat wheel allows computer-controlled
optimisation of the heat exchanger
output relative to the prevailing exhaust
air flow.

Without a heat recovery system, the

hot exhaust air is released unused into the
atmosphere.
Monforts reacted to this situation several years ago and has developed three
variants of heat recovery systems:
 The integrated heat recovery system
for new Monforts ranges,
 The Energy Tower for retrofitting,
 The Eco-Booster with automatic
cleaning for optimised production.
All three variants operate without the
costly intermediate storage of the heat.
The savings effect is achieved by the
direct heating of the fresh air.
Today integrated heat recovery systems form an integral part of the
Monforts standard product range.
Whilst new Monforts ranges generally
have a heat recovery system that is integrated into the existing range, there are
still a large number of older Monforts
ranges in operation worldwide.
It is for these plants that we have
developed the Energy Tower, said HansPeter Prinzen.

Monforts Energy Tower.

Energy Tower is a stand-alone solution that can be can be flexibly deployed

even on third-party machines.
The Eco-Booster is an automated variant. This heat wheel cleans itself fully
automatically during the ongoing finishing process. The system does not become
soiled, so there are no standstill times.
In the integrated heat recovery
system, part of the thermal energy in the
exhaust air is recovered in low-maintenance tubular heat exchangers so that the
fresh air preheated to, for example,
around 90C. It then only has to be
heated to 150C.
As a result, the high drying temperature is reached more quickly and the
energy consumption is reduced. The
energy savings can be as much as 30 %.

Monforts Eco-Booster.

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PAKISTAN TEXTILE JOURNAL - July 2015

The Energy Tower is a

stand-alone solution for retrofitting in machines that do not
have an integrated heat recovery system. Older ranges are
still in operation in many facilities.
The Energy Tower as a
retrofit module with lowmaintenance tubular heat
exchangers can be flexibly
deployed and functions even
on third-party machines. It
can be connected to relaxation dryers, infrared predryers, hotflues, continuous

This optimised efficiency further

reduces the process costs.
The Eco-Booster operates fully automatically so that the operator is relieved
of all other duties. Standstill times for
maintenance are also eliminated, as
cleaning is performed by an integrated
high-pressure cleaner.
Compared with purely static heat
exchanger modules, the new module cleans
itself independently during operation.
We calculate precisely for the customer when the investment in a heat
recovery system has paid for itself, said
Hans Peter, adding, Customers are often
amazed that a payback is achieved within
two years.
But this should not be surprising.
Energy is a major cost factor when it
comes to textile finishing. Two-thirds of
the drying energy is used for evaporation
heat.
Up to 30 % of the heating energy
can be saved with the Energy Tower or
the Eco-Booster.
As the energy costs are a significant
factor in the drying process, that represents a considerable saving.
The Eco-Booster also allows a higher
availability of the range and increases
productivity thanks to its automated
cleaning process. This again saves costs.
Furthermore, a heat recovery system
ensures that no hot exhaust air is released
unused into the atmosphere; reducing the
impact on the environment.