Highly-efficient technologies, designed for industry
Targeted investments are needed to optimise industrial systems by reducing environmental impact and constantly improving production capacity. The aim is to ensure both a rapid return on investment and minimise operating and maintenance costs.
CAREL offers two innovative technologies for saving energy in industrial processes: high-efficiency heat recovery for process air flows, and high-pressure adiabatic atomisation for humidity control and evaporative cooling of industrial environments.
Heat recovery for industry
Klingenburg thermal wheels stand out for their high efficiency and reliability in industrial and heavy-duty applications, where constant performance is required over time, even with air flows that contain dust, solvents, abrasive and flammable substances.
Benefits of the proposal include:
Solutions for recovering moisture and latent heat, as well as sensible heat;
Heat recovery from exhaust air with high efficiency - up to 90% - and reduced maintenance;
Automatic cleaning system combining high-pressure water and compressed air, depending on the type of dirt in the air flow;
Layout and surface coating of the fins designed to optimise efficiency, pressure drop, corrosion resistance and cleaning;
Resistance to high temperatures, up to 600°C, for heat recovery from drying and combustion processes;
Tailored solutions and components for potentially flammable and explosive air flows;
Consultancy, commissioning, installation and retrofit services in the field.
The painting and surface technology sector is one of the main targets of this heat recovery solution. Indeed, the urgent need to develop industrial processes with a low environmental impact has led the industry to reduce energy consumption and polluting emissions. Find out how:
Heat exchangers in coating processes are used to recover heat from the solvent-laden exhaust air, reducing by up to 80% the production of heat due to gas burners.
The CAREL Group offers a wide range of rotary and plate heat exchangers with specific features and accessories for the surface treatment industry, such as silicone-free certification, ATEX components, fin surface treatments and built-in cleaning systems.
Klingenburg website Recuperator website
Increasingly often, the air handling units that serve painting and surface treatment processes use high-efficiency technologies, such as fan speed controllers, heat recovery units, control and bypass dampers, direct expansion systems, humidifiers and adiabatic coolers. CAREL supplies control, local monitoring and remote supervision systems for air handling units, to ensure the highest efficiency and lowest energy consumption of the spray booth.
The CAREL offering includes steam humidifiers and adiabatic humidifiers, with a wide range of flow-rates. Adiabatic humidifiers not only feature very low energy consumption, but also guarantee significant energy savings in the summer, due to evaporative cooling, brought about by the spontaneous evaporation of very fine droplets of water in the air flow.
Choosing CAREL products for spray booths and coating systems means:
Silicone-free guaranteed humidifiers, heat exchangers and dampers, to avoid coating defects;
ATEX certified components for humidification, evaporative cooling and heat recovery in flammable or explosive air streams;
Components able to withstand high temperatures;
Heat recovery units with specific surface finishes and automatic cleaning systems to ensure high efficiency, service continuity and reduced maintenance;
HVAC controllers with built-in temperature and humidity management logic, programmed to manage highly-efficient components.
Direct in-room humidification for green manufacturing
Designed to exploit the enthalpy from the vaporisation of water, humiFog Multizone Touch combines an intelligent pumping station with a modular distribution system, equipped with special nozzles capable of maximising the atomisation of the water so as to ensure complete absorption in the air in short distances.
The strengths of the humiFog in-room solution are:
- High flexibility in controlling the humidification load, with stepped modulation;
- Precise control of demand, measured by multiple probes and a safety limit probe;
- Multi-zone system capable of managing up to 12 zones with independent set points;
- Wide range of distributors, with simple manifolds and single-side and double-side blowers;
- Extended maintenance intervals, up to 8000 operating hours for models with oil-free pump.
In addition to all this are the company’s extensive know-how made available to customers in the form of dedicated services and turnkey solutions:
- Thermodynamic consulting during design and planning;
- Humidification system installation;
- Commissioning and in-field technical training;
- Remote monitoring and control;
- Planned and predictive maintenance with warranty extension plans;
- Unscheduled maintenance.
One application that has historically relied on ambient humidity control solutions is printing.
In the printing industry, precise control of air humidity guarantees greater efficiency of the process, a reduction in equipment downtime and wasted materials, and better quality of the final product.
Paper and textiles are in fact hygroscopic materials, and are extremely sensitive to variations in humidity.
Controlling air humidity in the printing industry is needed to:
Limit the deformation of paper, which may shrink, lose flatness, curl and cause printing defects such as misalignment of subsequent colour layers;
Reduce the accumulation of electrostatic charges that make the sheets of paper stick together, causing the machinery to jam and stopping production;
Guarantee correct operation of the machinery, enhancing lubrication of moving parts, reducing the formation of suspended dust, limiting product waste due to inaccuracies;
Ensure better quality of the finished product and repeatable standards in all production facilities with controlled operating conditions.
