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To avoid degradation of PET during processing, PET must be dried at 150-177°C for 4-6 hours so that the residual moisture content is less than 0.005%. In general, this drying process consumes a lot of energy. According to Conair's assessment, the energy consumption of traditional dryers has accounted for 12% of the total energy consumption of the blow-molding plant and 25% of the total energy consumption of the preform molding process. Based on this, Conair launched a new dehumidifying drying system, Energysmart, for PET processing that reduces energy consumption through heat recovery.
The Energysmart Drying System recycles hot dry air to warm the polymer entering the hopper. According to Conair, the system can reduce energy consumption by 1/3 in bulk PET production compared to conventional dehumidification dryers. After trials, if the US PET bottle manufacturers use the system, it is expected to save $400000 per year by reducing energy consumption.
Conair said that for conventional PET dryers, air left the drying hopper still hot and the temperature could reach 90°C. Because the desiccant does not have a significant effect on dehumidification at high temperatures, the air will pass through the heat exchanger and will reduce the temperature to 50°C, wasting energy.
The Energysmart dryer is a two-station system that combines the hot air circuit and the dehumidified air circuit so that previously wasted energy can be reused. The process is that some air from the top of the hopper is introduced into a filter, which is then reheated to 175°C and then reintroduced into the drying hopper. Conair explained that the system can save energy because there is no heat exchange in the return air heat exchanger and the return air does not have to add more heat when it is added to the hopper again.
The air to be recovered does not need to be air-dried normally. The dew point is generally between -30°C and -20°C, and the dew point of commonly used dry air is -40°C. The main function of the reclaimed air is to preheat the polymer in the upper half of the hopper to achieve its desired drying temperature, while allowing the polymer to meet the required moisture content, which is accomplished in the dehumidification loop of the system.
In order to reduce the energy consumption of PET processing and improve the efficiency of dehumidifying dryers, Conair has introduced Energysmart, a new desiccant drying system that uses heat recycling technology. It is said that compared with the traditional dehumidifying dryer, this system can reduce 1/3 energy consumption in the production of bulk PET.