Case study: Air filter & heat recovery textile industry

The exhaust air purification at stenter frames is particularly challenging, because the resulting exhaust air mixture includes a considerable amount of oil, fibre and possibly also wax particles and can be odor-intensive in certain cases. Depending on the location of use strict regulations and legal requirements exist concerning emission limit values at stenter frames.

Energy costs have a large portion of the production costs of the stenter frame

Stenter frames are widely used in the textile-finishing sector for heat treatment of woven and knitted fabrics. The textile is not only dried in the stenter frame, but also heat treated for fixing. The operating temperature is mostly around 200°C depending on the process. In addition to the use of electrical energy (e.g. for motors and ventilators) the stenter frame needs a high thermal input, produced by expensive gas and thermal oil heating.
An unsuitable filter cell would rapidly clog up by the exhaust air from stenter frames, which results in high follow-up and replacement costs. Moreover, the exhaust air from stenter frames contains valuable waste heat, which can be used for follow-on processes.

Case study – Heat recovery for the heating of air & water

Double heat recovery for double efficiency

Through the energy recovery of 720 kW per hour more than 72.000€ of annual energy costs could be saved. Furthermore, the CO2 emissions are reduced by more than 680 tons every year. With an amortization period of 2 years the following energy savings benefit the operating result.

  • Reduced energy consumption of the stenter frame
  • Heating of process water (e.g. for dye works)
Client application Our solution The result
Heat recovery reduces energy consumption of stenter frames

Heat recovery reduces energy consumption of stenter frames

A customer from Turkey processes many types of different textiles in his production plant.

He was looking for an energy-efficient way of heat recovery and exhaust air purification for his new stenter frame with an exhaust air volume of 30.000 m3/h.

The goal was to reduce the high energy consumption of the stenter frame and to use the valuable heat from the exhaust air. The temperature of the exhaust air was 180°C on average.

Heat energy recovered for the stenter frame

Heat energy recovered for the stenter frame

For the customer two ULTRAVENT 20.000 filter systems were equipped with double electrostatic filter and double heat exchanger.
The KMA ULTRAVENT® filter system makes use of the valuable waste air in an energy-efficient manner. The integrated heat exchanger extracts thermal energy from the hot exhaust air, which is utilized for follow-up processes.
The recovered heat is employed to heat up the incoming supply air for the stenter frame.
This reduces the high energy consumption of the stenter frame by 1.400 € per week.
In addition, the washing water for the dye-work is also heated by heat recovery system.

Lower energy consumption means lower costs

Lower energy consumption means lower costs

The energy recovery of this filter system amounts to 720 kW per hour.

The saving of energy realizes a reduction of energy costs by more than 72.000€!

The CO2 emissions are reduced by 680 tons every year which substantially improves the carbon footprint of the company.

The profitable heat recovery led to an amortization period of 2 years.

The following energy savings benefit the operating results of the company.

Contact our expert in air filter systems for textile applications

Hannes Berteit, Sales Manager at KMA Umwelttechnik

Hannes Berteit

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Case Study – AUNDE

Heat recovery at the stenter frame for immense cost savings

Energy recovery saves the company 469kW per hour and thus 2,345,000 kWh of energy per year. This corresponds to a cost saving of more than 90,000€ per year. At the same time, annual CO2 emissions are reduced by 469 tons.

Case study – Heat recovery for heating air

Heat recovery for the supply air system of the stenter frame

Through the energy recovery of 287 kW per hour the CO2 emissions could be removed by more than 270 tons every year. With an amortization period of 4 years the following energy savings benefit the operating result of Freudenberg Performance Materials a leading global manufacturer of innovative technical textiles.

  • Reduced energy consumption of the stenter frame and improved the carbon footprint
Client application Our solution The result
Freudenberg Performance Materials – Textile manufacturer from Germany, Weinheim

Freudenberg Performance Materials – Textile manufacturer from Germany, Weinheim

Freudenberg Performance Materials is a leading global manufacturer of innovative technical textiles in very different industry sectors.
At the request of the customer, an existing ULTRAVENT 15000 filter system was combined with a new ULTRAVENT filter system 20000.
The integrated heat recovery system of the ULTRAVENT system shall reduce the energy demand of the stenter frame through the heating of the supply air.
The temperature of the exhaust air was 130°C on average.
The goal was to reduce the energy consumption of the stenter frame and to improve the clean air quality.

Heat recovery for the supply air system

Heat recovery for the supply air system

For Freudenberg Performance Materials the 20000 ULTRAVENT Filter System was equipped with lint pre-filter, double electrostatic filter and triple heat exchanger.

This new filter system was combined with the existing filter system ULTRAVENT 15000 upon request of the customer.

The recovered heat from the hot exhaust air is utilized for heating the incoming supply air. Through the heat exchangers the supply air is heated from 10°C to 100°C and led into the stenter frame.

Due to the heating of incoming supply air the stenter frame needs less energy and thus reduces its gas consumption.

Our contribution to more sustainability

Our contribution to more sustainability

Due to the energy efficient operation of the electrostatic precipitator and the high energy recovery of 287 kW per hour Freudenberg Performance Materials saves more than 270 tons of CO2 emissions every year through the KMA filter system.

Thanks to the good clean air quality Freudenberg Performance Materials produces less than 10 mg/m3 according to the EU Standard.

The mentioned cost advantages enable an amortization period of less than 4 years.

Case study – Heat recovery for the heating of water

Heat recovery for heating of process water

The company Kirayteks saves 300€ energy costs every day and more than 600 tons of CO2 emissions annualy due to the KMA filter systems. The cost advantage of the heat recovery leads to an amortization period of the new KMA exhaust air filtration system of less than 2 years.

  • Reduced energy consumption due to integrated heating of process water (e.g. for dye-works)
Client application Our solution The result
The company Kirayteks – Textile manufacturer from Turkey, Bursa

The company Kirayteks – Textile manufacturer from Turkey, Bursa

The Company Kirayteks processes many types of different textiles in his production plant in Turkey.

For 6 stenter frames with an exhaust air volume of 18.000 m3/h an energy-efficient possibility for heat recovery and exhaust air purification should be realized.The temperature of the exhaust air was 180°C on average.

The goal was to reduce the energy consumption of the overall textile production and to use the valuable heat from the exhaust air for heating process water.

Heat recovery reduces energy consumption for heating water

Heat recovery reduces energy consumption for heating water

For the company Kirayteks the 20000 ULTRAVENT Filter System was equipped with lint pre-filter, double electrostatic filter and double heat exchanger.
The existing ventilators and pipelines could be kept.

The recovered heat is utilized for heating water for the laundry and dye-works.

By means of the automatic filter cleaning system not only the electrostatic filter cells and the heat exchanger are cleaned, but also the reuse of the process oil is possible.

Our contribution to more economy

Our contribution to more economy

Due to the high energy recovery of 450 kW per hour the company Kirayteks saves almost 300€ every day through the KMA Filter System.

The CO2 emissions are reduced by more than 600 tonns every year. Thanks to the good clean air quality Kirayteks produces less than 10 mg/m3 according to the EU Standard.
The daily recovery of 35 - 50 liters of process oil for a second use reduces the acquisition costs.

The mentioned cost advantages enable an amortization period of less than 2 years.

Case Study – PASA

Textile company Pasa invests in exhaust air filtration system by KMA Umwelttechnik

Thanks to the filter systems, Pasa Tekstil can save 1,691,500 kWh per year.  This enormous cost saving means that KMA’s systems pay for themselves in a very short time. In addition, the company saves more than 532 tons of CO2 per year, thus improving its carbon footprint.

Client application

For a stenter frame with an exhaust air volume of 20,000 m3/h, an energy-efficient option for heat recovery and exhaust air purification was to be implemented. The aim was to reduce the energy consumption of textile production and to use the valuable heat from the exhaust air for heating process water. The temperature of the exhaust air was 129°C on average.