US20180149386A1 - Process and equipment capable to achieve zero-energy heating, ventilation, air conditioning operation - Google Patents

Process and equipment capable to achieve zero-energy heating, ventilation, air conditioning operation Download PDF

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Publication number
US20180149386A1
US20180149386A1 US15/881,578 US201815881578A US2018149386A1 US 20180149386 A1 US20180149386 A1 US 20180149386A1 US 201815881578 A US201815881578 A US 201815881578A US 2018149386 A1 US2018149386 A1 US 2018149386A1
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Prior art keywords
air
manufacturing
factory
manufacturing equipment
systems
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US15/881,578
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English (en)
Inventor
Martin Scaife
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Mobiair PteLtd
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Mobiair PteLtd
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
    • F24F13/30—Arrangement or mounting of heat-exchangers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F1/00—Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
    • F24F1/0007—Indoor units, e.g. fan coil units
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F1/00—Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
    • F24F1/0007—Indoor units, e.g. fan coil units
    • F24F1/00075—Indoor units, e.g. fan coil units receiving air from a central station
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F1/00—Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
    • F24F1/0007—Indoor units, e.g. fan coil units
    • F24F1/0071—Indoor units, e.g. fan coil units with means for purifying supplied air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F3/00—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems
    • F24F3/044—Systems in which all treatment is given in the central station, i.e. all-air systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F3/00—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems
    • F24F3/12—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems characterised by the treatment of the air otherwise than by heating and cooling
    • F24F3/14—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems characterised by the treatment of the air otherwise than by heating and cooling by humidification; by dehumidification
    • F24F3/1603—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F8/00—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying
    • F24F8/10—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering
    • F24F8/108—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering using dry filter elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
    • F28D9/0037—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the conduits for the other heat-exchange medium also being formed by paired plates touching each other
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
    • Y02B30/54—Free-cooling systems

Definitions

  • the present invention outlines new air property management related systems such as HVAC (Heating, Ventilation, Air Conditioning) systems that can be used to remove heat from air exiting a room or factory or production process having an elevated temperature without the need for the typical energy requirements associated with existing HVAC technology where significant amounts of energy are required to chill within the HVAC cooling and de-humidification process.
  • HVAC Heating, Ventilation, Air Conditioning
  • the process dwell time time the air spends in the coil area
  • the coils must be chilled to a low temperature in order for the coil process to function adequately.
  • the coils also control the air humidity by reducing their temperature to below the dew point of the air passing through the coil.
  • the present inventions are directed towards a new process using heat exchanger technology with the process having an extended dwell time as well as having large contact areas for the air within the heat exchanger, as well as the respective equipment.
  • the present invention allows full air recycling independent of external air climate (humidity and temperature) and also allows factories to expel air outside of the factory if desired without comprising final filter stages and also reducing main system fan energy requirements.
  • Production sites such as hygiene factories producing hygiene products, such as diapers, feminine pads, bed pads, tampons, tissue, wipes, and the like, as well as materials useful for such products like tissue and non-wovens factories, as well as textile, carpet and garment factories typically extract air from their production processes and production areas. This extracted air is typically used for production processes such as core-forming, fibre making, holding materials, products and/or assemblies onto conveyor systems as well as removing dust from the production area.
  • the temperature of air being removed from the production process and/or factory typically increases as a result of many factors such as ancillary production systems such as (i) hot-melt gluing systems and non-woven extruder heads, (ii) the passing of air through vacuum conveyors which run at an elevated temperature, (iii) passing the air through ducts at high speed and (iv) passing the air through process fan and main fan systems operating at an elevated temperature.
  • ancillary production systems such as (i) hot-melt gluing systems and non-woven extruder heads, (ii) the passing of air through vacuum conveyors which run at an elevated temperature, (iii) passing the air through ducts at high speed and (iv) passing the air through process fan and main fan systems operating at an elevated temperature.
  • ambient factory air can be at a temperature of about 25° C.
  • air exiting a baby diaper convertor process typically increases to about 45° C. and in some instances has been recorded as high as about 88° C. or even more.
  • HVAC or air property management systems typically calculate the cheapest option for the factory and automatically balance the amount of recycled air, the actual amount depending on process air temperature, external air temperature and external air humidity and energy prices.
  • air exiting the filter and expelled externally to the factory typically passes through all filtration stages.
  • Adiabatic cooling processes are used in many air systems and essentially have the capability to chill air to a defined point (referred to as the wet-bulb air temperature). This process is very similar to the human body's cooling system where sweat evaporates causing a cooling effect and is essentially an energy free cooling process in that no external energy is required and works on the evaporation cooling process.
  • adiabatic cooling process in a factory is possible and, in, many locations around the globe, adiabatic cooling process are used, however, these processes have by default undesirable effects in that the air humidity significantly increases, both the relative humidity (RH) as the absolute water content.
  • RH relative humidity
  • Increasing air humidity is in almost all instances not desirable, as this increases the “feel” temperature of the air due to the higher humidity levels and reduces the quality of the work environment for factory workers.
  • increased humidity is also not desired particularly in the hygiene sector where SAP (super absorbent polymer) is used.
  • the present invention is an air property management system ( 200 ) in the manufacturing of hygiene products in a manufacturing set up ( 210 ), such as of baby and adult incontinence absorbent articles, feminine hygiene articles, and materials adapted to be used in such articles, preferably selected from the group consisting of nonwoven, films, or composites thereof.
  • the manufacturing set up ( 210 ) comprises: a) A production area ( 215 ) comprising walls ( 217 ), which are adapted to separate the production area ( 215 ) from the external ambient environment ( 205 ).
  • the manufacturing room comprises space for the manufacturing equipment ( 230 ) of the articles, preferably a multiplicity of the manufacturing equipment, and for operators ( 236 ).
  • the manufacturing room further comprising aerial environment ( 220 ).
  • the housing is integral with sound retarding housing.
  • the manufacturing equipment further comprises article forming elements ( 245 ) inside the housing, which are adapted to change at least one of the properties of the process air of from said manufacturing equipment aerial environment properties ( 250 ), these properties being selected from the group consisting of temperature, moisture content, dust content, and pressure.
  • the article forming elements ( 245 ) are preferably selected from the group consisting of hot melt application systems, ultrasonic systems, separation systems, defiberization systems, separation systems, web handling drive system, web handling friction systems.
  • Duct work ( 270 ) adapted to connect the manufacturing equipment housing ( 235 ), the production room environment ( 220 ) and the external ambient environment ( 205 ) to the air treatment system ( 260 ).
  • the air treatment system ( 260 ) comprises an indirect heat exchange system adapted to transfer energy from the external ambient air ( 205 ) to the aerial manufacturing environment ( 220 ) or the process air ( 240 ), most preferably without mixing of the energy transferring air streams.
  • the indirect heat exchange system is an adiabatic heat exchange system.
  • the air property management system further comprises one more elements selected from the group consisting of one or more temperature adjustment element(s) ( 282 ) preferably indirect heat exchange elements, preferably selected from the group consisting of:
  • Closing valves ( 288 ) in the duct work preferably adapted to be closed, more preferably automatically, in case of an opening of the housing.
  • a fan element ( 280 );
  • an air humidity adjustment element ( 286 ) adapted to allow increase or decrease of the absolute humidity (water content) of the air;
  • a dust reduction system ( 284 ), preferably filter, more preferably HEPA filter;
  • an air flow distribution system comprises valves ( 288 ), side ducts and optionally further air treatment systems so as to provide predetermined air flows to various parts of the system, preferably to different article forming elements.
  • the indirect heat exchange system is a multi-way heat exchanger, preferably comprising multiple layers consisting of a 3D surface structure of materials separating airflows within the heat exchanger, and more preferably of the high-surface area honeycomb type.
  • the indirect heat exchange system is adapted to match dimensions of a standard ISO 668 container, whereby preferably the housing serves multiple purposes of providing structural integrity to achieve ISO 668 standards and to support the material layers of the heat exchanger.
  • the present invention is a process for the management of air properties in the manufacturing of products in a manufacturing set up, whereby the products are preferably selected from the group consisting of baby and adult incontinence absorbent articles, feminine hygiene articles, and materials adapted to be used in such articles, preferably selected from the group consisting of nonwoven, films, composites thereof.
  • the process for the management of air properties comprises the following steps:
  • the treated process air and room air may further be submitted to one or more of the steps selected from the group consisting of: further heating or cooling; adjusting water content by adding or removing moisture; reducing dust level; creating further pressure differential; interrupting the air flow of the processing and the treated air by stop valves upon opening the walls of the manufacturing equipment; collecting air from more than one manufacturing equipment; directing more than one air flow to the indirect heat exchange system, preferably by operating a multi-way heat exchanger; diverting the air flow of treated air towards two or more endpoints in the manufacturing room environment or within the equipment environment.
  • the present invention is a heat exchanger where at least one incoming airflow stream is connected to process-air exiting a production process, which may be a hygienic, non-wovens or air-laid process or fibre or food, which may be with elevated air temperature.
  • the heat exchanger may be at least a two-way heat exchanger.
  • One incoming airflow stream may be connected to ambient air, wherein optionally the heat exchanger may be at least a two-way heat exchanger.
  • the ambient air may be treated with an adiabatic cooling process.
  • the ambient air is exited back to ambient.
  • the heat exchanger may be connected to a production process for the making of hygienic products or materials therefore, such as non-woven or air-laying processes or fibre making processes.
  • An incoming airflow stream may be connected to both ambient air and factory air.
  • the heat exchanger may be at least a two-way heat exchanger.
  • the ambient air may be treated with an adiabatic cooling process.
  • the ambient air is exited back to ambient.
  • the heat exchanger may be connected to a production process that is a hygienic, non-wovens, air-laid process, fibre making process.
  • the present invention is a singular production process or multitude of production processes, enclosed with a housing to separate air of differing properties like temperature, humidity, pressures, or dust levels for the manufacturing process as compared to the manufacturing room environment.
  • the housing may serve as a sound reducing or retarding means.
  • a dedicated humidity control process may be used to control air humidity levels within this housing.
  • the conditioned air within this housing can be controlled by secondary humidity control process to boost capacity until pre-set moisture levels have been reached, e.g. during start-up periods.
  • the booster humidity capability may come from humidity control processes that process the factory air that is external from the air enclosed with a housing.
  • valves may close on the ducting working connected to the housing to prevent air of the manufacturing room environment from entering the ducting.
  • the present invention is a singular production process or multitude of production processes, that utilises air within this production process, where the air exiting the process is filtered and sent back to the production process in a form that the returning air re-enters the production process.
  • the returning air may re-enter the production process wherein the returning air volumes are similar to air process volumes within +/ ⁇ 90% variance.
  • the returning air may re-enter the production process within multiple points within the process to reduce cross air flow currents within the multitude of production processes.
  • the present invention is a singular production process or multitude of production processes that utilises air within this production process, where the air exiting the process is filtered and sent back to the production process via a heat exchanger.
  • the present invention relates to a heat exchanger comprising multiple layers of materials separating air flows within the heat exchanger where the layers are contained within a shipping container confirming to ISO 668 shipping container standards with little or no modification.
  • the multiple layers may exhibit a 3D surface structure of materials separating airflows within the heat exchanger where the layers are contained within a shipping container confirming to ISO 668 shipping container standards with little or no modification.
  • the shipping container housing may serve multiple purposes, such as providing both structural integrity to achieve ISO 668 standards and to support the material layers of the heat exchanger.
  • FIG. 1 A to H outline exemplarily and schematically various production factory set ups
  • FIG. 2 A to D depict schematically various air management systems according to the present invention
  • FIG. 3 A to C depict various more detailed views of the filtration and heat exchanger system, as may be suitable for the present invention
  • FIG. 4 A to G depict further detailed views of the heat exchanger system suitable for the present invention.
  • FIG. 5 A to D depict further details of an exemplary a diaper convertor platform.
  • the present invention relates to manufacturing set-ups or factories, which require for a good operation active management of the air properties. Whilst there are many types of manufacturing operations that have such requirements, a particular manufacturing set ups for producing hygiene products are particular sensitive to uncontrolled air properties, among others for hygienic reasons but in particular since the introduction of superabsorbent polymers also to allow smooth operation. Whilst such facilities used to operate without any HVAC capability, developments covered the introduction of HVAC capability, air recycling capability, optionally with valve systems to control the amount of recycled air entering the factory, and also heat exchanger technology. The present invention builds on such developments.
  • Further embodiments of this invention are to return the recycled air back to the convertor process and not back into the factory air that is common today. With more and more production systems having higher sound emission criteria and with this trend most likely to continue, most production equipment are fully enclosed with sound retarding housing. This sound retarding housing can also be used to adequately separate the factory and process air. In the scenario where filter exhaust air is being returned to the production system, process air remains separated from factory air, and as such both air streams can operate at different temperature levels and moisture levels. Being able to run both air streams at separate temperature and moisture levels has distinct advantages for the end-user that is described herein below.
  • a diaper factory located close to the equator is considered that is recirculating air at ten air changes per hour whilst adding 10% of newly conditioned fresh air from the HVAC system back into this air stream, whereby this additional air being pumped into the factory is exiting the factor via doors, windows, air vents etc.
  • external air temperature at 32° C. with 65% relative humidity with air pressure at 1011 millibar
  • the wet-bulb temperature is at 26.2° C.
  • the dew point is at 24.1° C. Taking this external factory air at 32° C.
  • this air stream originally at 32° C. can be chilled down to 28.3° C. prior to entering the heat exchanger. This allows the air that was previously exiting the heat exchanger at 34.4° C. to be reduced to 28.3° C.
  • this air stream can operate at a higher temperature without increasing the factory room environment, e.g. for the operators.
  • the heat exchanger can be further split, in that internal factory air can also be passed through the heat exchanger and exit back into the factory. Further improvements to this would be to divert all external air-flows (vertical flow in cross flow heat exchanger and parallel flow in parallel flow heat exchanger and counter flow in counter flow heat exchanger) from the overfeed adiabatic cooling process into this zone of the heat exchanger to further enhance performance.
  • the heat exchanger would then essentially cool the hot production air circuit from 46.5° C. to 34.4° C. And as part of the heat exchanger would be used to chill internal factory air, the hot production air circuit cannot reach 34.4° C. but can reach 36.5° C.
  • honeycomb profiles within the heat exchanger rather than conventional fin/plate technology.
  • a heat exchanger made from honeycomb profiles has a high strength profile thereby allowing a thinner metal profile to be used.
  • automatic honeycomb production methods allow a combine structure to be made that require little or no assembly effort hereby allowing the heat-exchanger to be produced at a more attractive cost for the end-user.
  • Further embodiments of the present invention are to combine channels within the heat exchanger to allow water flows such as water that has been chilled or heated using geo-thermal energy.
  • using geo-thermal energy to change the heat exchanger plates allows air temperatures to be modified further without the pressure drops that are associated with incumbent HVAC coil technology.
  • This technology is of particular benefit in sandy regions such as Saudi Arabia where drilling costs are very low and as such the installation of geo-thermal ground pipes is also very low.
  • further embodiments to this invention are to combine channels within the heat exchanger to allow water flows such as water that has been chilled or heated using solar energy.
  • the two-way heat exchanger having a high surface area and being an efficient means to change air temperature with low pressure drop
  • using geo-thermal energy to change the heat exchanger plates allows air temperatures to be modified further without the pressure drops that are associated with incumbent coil technology.
  • Further embodiments of the present invention are to use the elevated air temperature of the closed circuit system in secondary drying processes.
  • This higher air temperature combined with low humidity levels make this an ideal drying medium. This can for instance be used for the making curly fibers on-line where a significant drying load and heat is required.
  • FIG. 1 For purposes of this specification, many filter processes consist of multiple filtration stages. In these processes, air exits the filter after the HEPA stage, however, if the air is exiting the factory to an external environment, then, it is not preferred to pass this air through a HEPA air filter as this requires further energy in the main system fan to pull the air through the HEPA filter media, and, the HEPA filter media has a reduced life span, also adding costs to the end-user on top of the higher energy costs. Installing a valve prior to the HEPA filter media allows factory exhaust air to exit the external environment prior to entering HEPA filter media, whilst, air being recycling back into the factory passes through the HEPA filter media prior to entering the factory.
  • a well-designed HVAC system typically exchanges/replaces the air about 10 times per hour, and this air which is continuously being re-circulated has new fresh conditioned air from outside injected into this air stream at values of around ten percent.
  • air within the factory is typically vented to the environment and the energy invested to de-humidity this air is lost.
  • Further embodiments of this invention are to reduce the percentage of air exiting the factory, and to divert this air back into the adiabatic cooling processes thereby reducing the wet-bulb temperature further.
  • a diaper factory located close to the equator, that is recirculating air at ten air changes per hour whilst adding 10% of newly conditioned fresh air from the HVAC system back into this air stream, whereby this additional air being pumped into the factory is exiting the factor via doors, windows, air vents etc.
  • FIG. 1A outlines a production factory ( 100 ) with no HVAC capability with the factory production area ( 101 ) and several of a production system ( 105 ) within the factory production area ( 101 ).
  • An air filter system ( 110 ) is shown to be connected to the production system ( 105 ) and duct work ( 115 ) is connecting the outlet of the filter to the exterior ambient environment of the factory to where the air is expelled.
  • FIG. 1B A typical example of this is in FIG. 1B where a factory is depicted where a standard HVAC system is used.
  • FIG. 1B depicts the same elements as FIG.
  • this factory configuration has HVAC capability with chillers ( 120 ) and with AHUs (air handling units, 125 ), from where air re-enters the factory via the duct work ( 130 ) connecting the AHUs to the interior of the factory respectively the factory production area.
  • chillers 120
  • AHUs air handling units, 125
  • FIG. 1C in addition to the elements of the previous figures, a factory configuration is depicted with air filters ( 135 ) specified to clean the air to HEPA standards and as such, the air exiting the air filters can be sent back into the factory production area.
  • valve configuration 140
  • valve configuration 140
  • These valve systems are typically adjusted to achieve either full venting of filter air outside (say in hot climates where exhaust air is hot) or the full venting of the filter air inside the factory (say in cooler climates where exhaust air is hot). In many instances such valves are controlled by computer systems that constantly measure outside environments, air temperatures, power costs and adjust the values accordingly to ensure the most efficient settings are achieved.
  • FIG. 1E outlines the addition of a heat exchanger ( 145 ) to the filter system as depicted FIG. 1C .
  • the additional heat exchanger cools the air exiting the air filter prior to this air entering the factory production area
  • production air is taken from the production process via fans and passed into the filter to remove all contaminants, thereafter exiting the filter process and entering the heat exchanger where typically at this stage, the air would be at 65° C.
  • the air is cooled by the external ambient air and passed back into the factory production area.
  • the two-way heat exchanger has dedicated air zones that are not connected with each other and the air streams do not mix and as such, the absolute moisture levels, i.e. water contents of the air, are not changed. Due to the complete separation of the air streams, adiabatic cooling processes can be installed in the external factory air entering the heat exchanger that gives additional cooling power without changing humidity of the factory air.
  • FIG. 1F depicts this scenario where the ducts are shown that feed the air back into the process.
  • FIG. 1F depicts the same elements as shown in FIG.
  • a method to enhance this process is to capture air-conditioned air that would normally exit the building and use this cooler dryer air to boost the performance of both the heat exchanger and the adiabatic cooling process.
  • a well designed HVAC system typically exchanges respectively replaces the air about 10 times per hour, and this air which is continuously being re-circulated has new fresh conditioned air from outside injected into this air stream at values of around ten percent.
  • air within the factory is typically vented to the environment and the energy invested to de-humidity this air is lost.
  • FIG. 1G where the factory air enters the heat exchanger to aid in this process.
  • the system depicted in FIG. 1G has the same elements as the system shown in FIG. 1F , however, the heat exchanger used in this factory configuration is more than a basic two-way heat exchanger and the heat exchanger has additional inlets to allow the processing of factory air where the ducting diverting this air from the factory production area into the heat exchanger.
  • FIG. 1H depicts the same embodiments as shown in FIG. 1G , however, the factory air, and or process air treatment system ( 160 ) has dedicated air humidity control and as such, the standard HVAC systems as outlined in FIGS. 1A to G is no longer required.
  • FIG. 2 A to D depict schematically and exemplarily various air management systems according to the present invention.
  • a system ( 200 ) can be used in a manufacturing set-up or a production factory ( 210 ) with a production area ( 215 ), which is separated from the external ambient environment ( 205 ) by a wall ( 217 ) and in which at least one, but typically more, sometimes even up to 50 or more production system(s) ( 230 ) or lines is/are placed.
  • a production system ( 230 ) comprises at least one, typically more, often more than 20 production steps on particular production step equipment ( 245 ).
  • Such production step equipment may be—without any limitation—hot melt application systems, ultrasonic system, separation or cutting systems, defiberization systems, separation systems, web handling drive system, web handling friction systems, etc.
  • the air properties of the process air in the direct vicinity of this equipment are often impacted ( 250 ) such as by an increase in temperature, dust level, or change in relative or absolute humidity, thusly also the aerial environment of the production system, i.e. the process air ( 240 ) exhibits a change in properties.
  • the production equipment may be separated by a housing ( 235 ) from the production area ( 210 ).
  • the air management system further comprises an air treatment system ( 260 ).
  • Duct work ( 270 ) may transfer air from the process ( 240 ) and/or the production room ( 220 ) to the air treatment system ( 260 ) and back to the production system or the production area.
  • the air treatment system may comprise filter elements (not shown) but very preferably comprises a heat exchange system for exchanging energy between the process and optionally production room air and external ambient air as entering the air treatment system at an air entry ( 262 ) and leaving it at air exit ( 268 ).
  • FIG. 2B further options for the air management system are schematically, shown, such as a fan element ( 280 ), or further temperature adjustment elements ( 282 ) (like cooling elements preferably cooling water at ambient temperature, heating elements, energy exchange elements between other elements connected via said duct system, or heat pumps, preferably by exploiting geothermal energy), dust reduction elements ( 284 ), e.g. filter elements, air humidity adjustment elements ( 286 ), or flow adjustment elements, in particular valve elements ( 288 ).
  • air flow may be dedicated towards particular and predetermined process step elements, e.g. by an air flow splitter ( 272 ), optionally followed by one or more of such treatment in such elements (generally indicated by 285 ).
  • FIG. 3D a further option is depicted, namely that the factory room air is extracted separately from the process air, and treated in the heat exchanger in a separate heat exchange system, e.g. as the one depicted in FIG. 4F .
  • FIG. 3 A to C more exemplary details of a filtration and heat exchanger system ( 300 ) to execute the respective processes are depicted.
  • incoming air ( 305 ) is delivered via ductwork to the air filter with the air filtration system ( 310 ), where air passes between interfaces (not shown in this layout) into the heat exchanger ( 315 ).
  • an adiabatic cooling process can be attached, optionally with additional air inlets ( 330 ) where internal factory room air can be added and where also an adiabatic cooling process can be attached. Then, air passing through the heat exchanger ( 315 ) exits the heat exchanger and factory to the exterior environment via air exit ( 335 ). The original process air from the convertor can be refed from the heat exchanger back into the factory room production area ( 340 ).
  • FIG. 3B a further more detailed view of the filtration and heat exchanger system of FIG. 3A is shown, with air filter ( 375 ), through which air ( 345 ) passes, optionally via fans (not shown) into the heat exchanger. Also indicated are internal plates ( 350 ) of the heat exchangers, and low pressure suction fans ( 355 ) adapted to pull air through the heat exchanger.
  • the external cooling air inlet ( 360 ) from the external ambient environment of the factory may provide air that is non treated air or that is cooled, preferably via adiabatic cooling process or similar, optionally driven by low pressure suction fans ( 365 ) that pull air through the heat exchangers. From the air exit ( 370 ) the air exiting back out of the factory to the ambient environment.
  • FIG. 4A to D depict even further details of the heat exchanger systems of FIG. 3 .
  • FIG. 4A shows an end view with plates ( 405 ) within the heat exchanger that conduct heat and prevent the air streams from mixing and with a low pressure suction fans ( 410 ) that pulls air through the heat exchanger.
  • FIG. 4B shows a perspective view, with the air ( 415 ) traveling from the filter, optionally via fans, into the heat exchanger with its internal plates ( 420 ).
  • Low pressure suction fans ( 425 ) are adapted to pull air through the heat exchanger.
  • FIG. 4C the internal block ( 430 ) consisting of multiple internal plates of the heat exchanger is depicted, and in FIG. 4D preferred details of this heat exchanger system of FIG. 4C are shown, with cooling air ( 440 ) entering the heat exchanger, and the hot air entering the heat exchanger to be cooled (not shown), separated by the plates ( 420 ) within the heat exchanger that conduct heat and prevent the air streams from mixing.
  • FIG. 3C outlines a more detailed view of another execution of the filtration and heat exchanger system similar to the one of FIGS. 3 A and 3 B.
  • External air is entering the heat exchanger through an air inlet ( 325 ) through the factory roof ( 320 ) optionally followed by an adiabatic cooling process.
  • internal factory air can be added via additional air inlets ( 330 ), optionally also followed by an adiabatic cooling process.
  • the air After passing through the heat exchanger ( 315 ) the air exits the heat exchanger and factory to the exterior ambient environment through an air exit ( 335 ).
  • the original process air from the convertor exits the heat exchanger and is refed back into the original production process ( 340 ) whilst air ( 380 ) is sucked from the factory air into the heat exchanger where it is heated or cooled and this same air stream ( 385 ) entering back into the factory at changed air properties.
  • FIG. 4E to G outlines a more detailed sectional view of the heat exchanger systems shown in FIG. 4A to D.
  • a two-way heat exchanger system is depicted, with the entry point ( 442 ) of the external ambient air, which passes through the heat exchanger to then leave it at the exit point ( 448 ), with this air flow stream not coming into contact with the horizontal air flow stream passing through the heat exchanger though the void spaces of the heat exchanger ( 440 ).
  • FIG. 4E a two-way heat exchanger system is depicted, with the entry point ( 442 ) of the external ambient air, which passes through the heat exchanger to then leave it at the exit point ( 448 ), with this air flow stream not coming into contact with the horizontal air flow stream passing through the heat exchanger though the void spaces of the heat exchanger ( 440 ).
  • FIG. 4E a two-way heat exchanger system is depicted, with the entry point ( 442 ) of the external ambient air, which passes through the heat exchanger to then leave it
  • 4E shows a four-way heat exchanger system with a first ( 452 ′) and a second ( 452 ′′) entry point of the external ambient air which passes through the heat exchanger and out again at first and second exit points ( 458 ′ and 458 ′′, respectively) with these air flow streams not coming into contact with each other nor with the horizontal air flow stream passing through the heat exchanger though the void spaces of the heat exchanger ( 450 ′ and 450 ′′, respectively).
  • first and second exit points 458 ′ and 458 ′′, respectively
  • a six-way heat exchanger system with a first ( 462 ′), a second ( 462 ′′) and a third ( 462 ′′′) entry point of the external ambient air, which passes through the heat exchanger and out again at first ( 468 ′), second ( 468 ′′) and third ( 468 ′′′) exit points, respectively. with these air flow streams not coming into contact with each other nor with the horizontal air flow stream passing through the heat exchanger though the void spaces ( 460 ′, 460 ′′, and 460 ′′′, respectively).
  • FIG. 5 A to D depicts further particular executions for a diaper convertor platform ( 500 ).
  • a production system respectively it's machine body ( 505 ) is shown, for which process air ( 510 ) is being extracted from the production system via a duct system towards the filter/HVAC system (with the arrow on the duct depicting flow direction), and where treated air ( 520 ) is being returned back to the process areas of the production machine (with the arrow on the duct depicting flow direction).
  • FIG. 5B a similar system is shown, for which the return air ( 520 ) duct has been enlarged to reduce pressure drop and overall resistance (with the arrow on the duct depicting flow). Further, in the system depicted in FIG.
  • the return air is no longer sent back via dedicated duct but is returned back to the production process via a void space ( 530 ) inside the machine body ( 505 ).
  • a duct ( 510 ) may be used to extract process air from the diaper process (with the arrow on the duct depicting flow direction), and re-fed as return air via the void space ( 530 ) in the diaper machine framework ( 505 ).

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Central Air Conditioning (AREA)
US15/881,578 2015-07-29 2018-01-26 Process and equipment capable to achieve zero-energy heating, ventilation, air conditioning operation Abandoned US20180149386A1 (en)

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SG10201505956Y 2015-07-29
SG10201505956Y 2015-07-29
PCT/SG2016/050370 WO2017018948A1 (en) 2015-07-29 2016-07-29 Process and equipment capable to achieve zero-energy heating, ventilation, air conditioning operation

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EP3329189A1 (en) 2018-06-06
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EP3329189A4 (en) 2019-03-13
JP2018528379A (ja) 2018-09-27
CN108139109A (zh) 2018-06-08

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