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With the rapid development of the downstream market and power batteries have entered a new cycle of scale expansion. In order to meet the demand for larger volume of production, it is necessary to save energy in the manufacturing process.
Dehumidification air conditioner are a process that consumers lots of energy in the production of lithium batteries.the cost of energy consumption for large-scale manufacturing is calculated in units of tens of millions or even billions.it become the primary problem faced for power battery and even new energy manufactures that how to reduce energy consumption,increse corporate profit margins and realize low-cost operation of dehumidification links.
As an excellent supplier of core components in the field of global air treatment,Puresci first put forward the “medium temperature regeneration dehumidification system concept and solution”in 2019,in which the dual-rotor dehumidification system can make the regeneration temperature from the traditional 120-140°C reducing it to 80-90°C,which can greatly reduce the energy consumption in the production enterprises.
After nearly two years of in-depth research, trial and error, and test analysis, Puresci has once again launched the fourth-generation dual-wheel low dew point and medium temperature regenerative dehumidification system. At present, it has been practically applied to the lithium battery dehumidification industry, and breakthroughs have been made in cost reduction and energy saving.
Puresci fourth-generation dual-rotor low dew point and medium temperature regeneration dehumidification system realizes a fundamental change in heating methods,exploring for new types of regeneration:steam decompression,gas hot water boiler,heat pump hot water station,and one-to-one heat pump direct expansion Energy way.
In order to further realize the utilization of four types of new renewable energy methods,Puresci cooperated with Bitzer(famous independent manufacture of refrigeration compressors) to develop a dehumidification and air conditioning system(heat pump and runner coupling system) for the lithium battery industry,the final energy saving efficiency reaches 40%-60%.
1.The medium temperature regeneration system fundamentally changes the heating method.
The reduction of the regeneration temperature in the medium temperature regeneration dehumidification system is not only a reduction in energy consumption, but also a fundamental change in the heating method.
The way of renewable energy is changed from high-grade energy (electric heating, steam heating) to low-grade heat source heat (water boiler to supply hot water, condensation heat), so that the operating cost of the entire system is lower.
| Traditional electric heating dehumidification air conditioning system consumption analysis | |
| Supply air volume(m³/h) | 33000 |
Supply air dew point | -60℃DP |
| Fresh air volume(m³/h) | 6600 |
| Primary wheel regeneration air volume(m³/h) | 2357 |
| Second wheel regeneration air volume(m³/h) | 3300 |
| Elect heating system | |
Rear wheel heating input power (KW) | 76.47 |
| Front wheel heating input power(KW) | 60 |
| Total input power | 136.47 |
Because safety is significant important in the production of lithium batteries, the temperature of the lithium battery production workshop is controlled at lowest level, and the failure rate of dehumidification and temperature control equipment is strictly required to be 0.
At present, most of the dehumidification air-conditioning systems used in the production of lithium batteries use traditional high-temperature regeneration dehumidification rotors, the regeneration temperature is as high as 120-140℃, and the regeneration heating energy consumption is huge. Relying on its solid industry foundation, Puresci independently developed a medium-temperature regenerative dehumidification air-conditioning system based on customer pain points and needs to help customers upgrade their regenerative heating methods while providing a precise temperature and humidity control environment.
Based on scientific principles such as thermodynamics and fluid mechanics, Puresci conducts a large number of application tests and data fitting on various heating methods such as solar thermal storage heating, infrared heating, electromagnetic induction heating, microwave heating, and semiconductor heating. , Excluding the option of excessively high cost or unable to be combined with the regenerative heating of the medium-temperature regenerative double-wheel system, and finally four new types of renewable energy methods have been determined.
2.Four new renewable energy methods
(1)Steam decompression
In larger or super lager lithium battery production plants,and lots of usage scenarios,and steam energy from power plants or municipalities is used.The conventional steam pressure is 0.3Mpa~0.5Mpa(temperature 120~160℃).
The medium temperature regenerative dehumidification air conditioner can use 0.3~0.5Mpa steam for heat exchange to 90℃,a large amount of condensed water will be generated,which is easy to produce liquid shock in the hot water heat exchanger,and the hot water heat exchanger is pretty to demage and requires special design.Manufacture of liquid-shock-proof heat exchangers,and at the same time add emptying measures on the pipeline.
According to puresci’s test,it can save about 30% of steam when the steam pressure is 0.3Mpa~0.5Mpa(temperature 120℃ and the steam is exchanged to 90℃.
(2)Gas hot water boiler
This energy method is suitable for large factories with abundant gas energy, using special cast aluminum boilers and long service life. The dual use of sensible heat and latent heat promotes high heat exchange efficiency, with a total heat efficiency of 108%. Stepless adjustment during use can achieve a stable outlet temperature of 95-98°C. In addition, the gas-fired hot water boiler has no pressure, and the installation does not need to be reviewed. It is economical and environmentally friendly. The 1t boiler emits 600,000 kcal heat and can supply 6 units with 30,000 air volume.
However, carbon dioxide is produced during the combustion process (about 40% of the CO2 emissions of coal), which doesn’t comply with the concept of "carbon neutrality" and "carbon emission peaking". The cost is relatively high of gas supply in some areas , and used be restricted.
(3) Heat pump hot water station
It’s suitable for ares or factories lacking steam and gas resources,the system is environmentally friendly.Dehumidification air conditioner regeneration exhaust heat or or other waste heat can be used as a low-temperature heat source to absorb heat on the evaporative side, and the high-temperature condensing side can exchange heat to 100~110℃ hot water, and then the hot water exchanges heat with the air to the hot air at 90~95℃ through the hot water heat exchanger, which is used for the regeneration heating of the medium temperature regenerative dehumidification air conditioner.
Puresci developed high temperature heat pump hot water station with Bitzer,with a comprehensive COP value of 2.57~3,safe operation,convenient and simple maintenance.
It should be noted that in the preliminary design of the plant, the location of the high-temperature heat pump hot water station (preferably on the same floor) needs to be considered to facilitate construction, maintenance and repair.
(4) one to one heat pump direct expansion
It is suitable for small or decentralized layout factories. Considering the complexity of the system, the construction and design problems of dehumidification air conditioning units, and the subsequent maintenance and maintenance problems, the AHU space is increased, and it is best to design a dedicated refrigeration compressor space to facilitate maintenance and repair.
One-to-one heat pump direct expansion is used in the medium-temperature regeneration dehumidification air-conditioning system. It can not only solve the problem of heating to 90°C at the regeneration end, but also solve some of the problem of air cooling after the primary rotor, saving a lot of energy for the cold water system.
It is necessary to emphasize that the one-to-one heat pump direct expansion method is the lowest energy cost among the four heating methods. But it has higher requirements for manufacturing process and logic control.
For the above four new renewable energy methods, Puresci has obtained the theoretical calculation value under the same heating capacity (124KW) after repeated experimental verification, testing and analysis:
First, the steam heating method saves 46% compared with electric heating;
The second is that the heating method of the hot water boiler saves 60% compared with electric heating; it saves 26% compared with steam heating;
The third is that the heating method of heat pump hot water station saves 61% compared with electric heating; it saves 28% compared with steam heating;
Fourth, the heating method of the compressor direct expansion system saves 62% compared to electric heating and 30% compared to steam heating, and can generate 77kw of cold energy while consuming electricity.
| Heating capacity | 124KW | 124KW | 124KW | 124KW | 124KW |
| Heating method | Electric heating | 0.3Mpa steam heating | Hot water boiler | Heat pump hot water station | compressor direct expasion system |
| Dosage | 124kwh/h | 0.19t/h | 13m³/h | 48kwh/h | 47kwh/h |
| Unit price | $0.8/kwh | $280/t | $3/m³ | $0.8kwh | $0.8kwh |
| Total price | $99/h | $53/h | $39/h | $38/h | $37/h |
| It Can generate 77kw of cooling capacity while consuming electricity |
3.Hand in hand with Bitzer, a new way of renewable energy cooperation is implemented
In order to better realize the use of new renewable energy methods, Puresci has cooperated with Bitzer, a world-renowned independent manufacturer of refrigeration compressors, to jointly develop a dehumidification and air conditioning system for the lithium battery industry (heat pump and runner coupling) system). Puresci independently developed a medium-temperature regenerative dehumidification system and a high-temperature heat pump equipped with Bitzer compressors to provide users with high-efficiency and high-performance dehumidification air-conditioning units.
Users can not only save energy through heat pumps, but also obtain the best heat recovery effect in the application of medium temperature regeneration systems, further reducing costs
4.The market prospect of the medium temperature regeneration solution system is broad
The TWh era is approaching, and the lithium battery industry has entered a high-growth channel. In the first three quarters of this year, the total investment in the national lithium battery industry reached 880 billion yuan, of which 460 billion yuan was invested in lithium batteries, and the total planned new lithium battery production capacity exceeded 1TWH.
It is estimated that by 2025, the compound annual growth rate of the industry will reach 45%, and there is huge room for development. Facing the large-scale expansion of battery production capacity, the high-energy dehumidification and air-conditioning system equipment in the lithium battery industry chain is bound to accelerate the transformation to a high-efficiency, low-energy system.
As a global supplier of cutting-edge dehumidification technology in the field of air treatment, Puresci's self-developed dual-wheel mid-temperature regenerative dehumidification air-conditioning system is suitable for all production links in the lithium battery industry chain, and helps while improving safety and production efficiency. Companies save costs and reduce energy consumption.
The medium-temperature regenerative dehumidification air-conditioning system can save hundreds of millions of energy costs for large-scale lithium battery plants through theoretical calculations. Next, Puresci will continue to provide safe, efficient, reliable, energy-saving and environmentally friendly dehumidification air conditioning solutions for the lithium battery industry, and contribute to the cost reduction and energy saving of lithium battery production.
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