Our clients are basically into making of colored mylar and artificial glitter. The raw material is aluminized mylar and this needs to be coated in different colors as per client requirements, and for this it needs to be dipped into a dye and then baked in 4 zones of varying temperature upto 280C. To save on conventional fuel costs, we recommended them to go in for pre-heating of air using solar upto 90-95C, and then use conventional air-heaters such as diesel fired. The solar air heating system was designed in such a way so that it met the pre-heat that was needed at the baking chamber. The big challenge was to optimize the flow through the collectors in order to achieve higher efficiencies and at the same time providing air flow rate only at the required capacities to the baking chamber.
The flow rate through the collectors and flow rate required at the baking chamber obviously didn’t match up, thus an elaborate design change had to be worked in and a re-circulation system designed so as to balance both these parameters in order to achieve both higher efficiencies and maintaining the feed-in flow rates. A 100 sq meter collector area (copper selectively coated absorbers, with proprietary turbulence promoters for enhanced efficiencies) were used for this as space was a constraint) along with a suitably designed blower and ducting with aluminum cladding with glasswool insulation. The results achieved were amazing and despite the high initial cost of the solar air heating system developed by NRG Technologists Pvt Ltd, the client recovered this cost in less than 2 years and is now looking to install a larger capacity plant to meet their expansion plans.
Advantages of Preheating of Air using Solar for industrial application
Savings in time
Increased production possible
Less space requirement for drying
More hygenic than drying outside in the sun
Negligible maintenance costs
Free and Clean energy
Just one time investment, after that the energy is Free!
Quick Return on Investment (ROI) – just 3 years
- Renewable – Save on gas/electricity bill
- Convenience – 24 X 7 Hot Water
- ISI mark, GEDA, MNRE Approved
- Tax benefit – 80% depreciation
- Branded Quality Product
- Service – Prompt & reliable
Did You Know?
Solar energy can be integrated with existing energy methods, such as Coal or gas fired boilers, to produce 100% of the required thermal loads.