Problem/Goal
To reduce gas usage on air recycling plants (ARP) in automotive paint plant by optimised use of the CHP waste heat coils on each ARP.
Approach
Industratech carried out an analysis of the current ARP control strategy over a 3-week period. The analysis involved detailed monitoring of the ambient air enthalpy delivered to the paint booths via the ARP burner and humidifier in corelation with the CHP/PAG skid control system. Several areas were identified to improve the performance.
Action
The CHP/PAG controls were modified to improve the CHP start-up sequence to facilitate a smooth transition from min load to maximum load. This also prevented spurious shut down of the CHP due to excessive temperature cycling.
Additionally the CHP/PAG controls were synchronised to the ARP controls to a much tighter tolerance to maximise the waste heat available which in turn minimised the gas usage.
Results
The result is, under nominal conditions the CHP/PAG units can provide all the necessary heat energy required to maintain optimal paint application conditions within the booths, resulting in significant energy savings within the paint shop.
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