Energy Sustainability for Drying & Evaporation Plants
How does energy sustainability look for the drying and evaporation industry?
There has been a higher demand in the drying and evaporation marketplace due to regulations coming in for Dedert’s customers to change their energy sources to more renewable energy sources. This demand comes from customers wanting to be more ecofriendly within their business practices and with their technologies and systems. Dedert is a supplier of dryers and evaporators that use a lot of energy, and we must consider utilizing alternative energy sources for our processes.
This poses some significant challenges, especially for systems which require high inlet temperatures (150oC to 600oC). These systems are currently heated by burning fossil fuels which costs much less than using electrical power to generate high temperatures.
Most renewable energy systems are based on producing electricity even if they use thermal energy to generate electricity. This has an efficiency loss which means that turning the electricity back into heat has both a negative effect on efficiency and consequently an economic impact.
The use of renewable electricity is growing significantly, and it is paving the way for sustainability in various industries. The main source of renewable energy that Dedert would use is generated electricity. This energy is often converted to either chemical energy or stored electricity. In some special cases, it could be possible to reuse heat and generate electricity from sources like geothermal or nuclear energy.
How do Dedert’s dryers use energy now?
Most dryers that Dedert provide are convective. Convective dryers use heat from high temperature air to dry the product. The water in the feed evaporates which cools down the incoming hot air. Dedert’s dryers typically use inlet air temperatures between the range of 150°C to 600°C.
High inlet temperatures (above 200oC) are generated by burning some type of fuel. Below 200oC dryers can be heated using steam. Even so, today, most commercial steam boilers use some form of fossil fuel as the heat source.
To date, industry has focused on the reduction and conservation of these conventional energy sources because this offers the lowest operating cost. Consequently, the reduction of CO2 footprint of dryer installations is concentrated on heat recovery systems, or the re-use of heat designed to make the overall plant operation more efficient. Dedert offers state-of-the-art designs of this type which are well established in the marketplace. These include:
- Air preheating systems using hot water or other waste heat sources
- Condensate sub-coolers to improve steam heater performance
- Combined heat and power systems where dryers reuse hot air from the exhaust of gas engines, gas turbines, thermal oxidizers, boilers, or other high temperature exhaust streams.
- Process gas recycling of convective dryers: In these systems dryer exhaust is recycled to the dryer inlet and reheated. This minimizes the heat loss to atmosphere and maximizes the dryer efficiency. This is often used in direct fired dryers and has the side effect of reducing the oxygen level in the drying medium.
- Superheated steam drying: These drying systems are indirectly heated and recycle 100% of the drying medium. This results in all the air being expelled from the dryer replacing it with steam driven off the material being dried. The net steam generated by these dryers can be condensed in another system (e.g., a waste heat evaporator or a distillation column) and the energy reused.

Direct Fired Ring Dryer

Direct Fired Spray Dryer

Steam Heated Fluid Bed Dryer
How do Dedert’s evaporators use energy now?
Dedert’s evaporation systems currently use three main sources of energy for heating and evaporation. These are steam, electricity, or waste heat usually in the form of high humidity air.
These evaporators operate under vacuum so that water boils at temperatures lower than 100 oC. This has the advantage of reducing thermal degradation of the product and reducing fouling.
Several evaporator bodies (effects) can be connected and run at progressively lower pressure such that the steam generated in one body can be used to heat the next effect. In this way the heat can be reused several times. This technique is most used with steam heated evaporators and waste heat evaporators.
The efficiency of evaporators can be improved by recompressing the evaporated steam to raise its temperature and reusing it. Two technologies which are commonly used are Thermo-recompression (TVR) and Mechanical Vapor Recompression (MVR).
The MVR system is effectively a heat pump which uses an electrically driven fan to raise the temperature of the evaporated steam so it can be reused to heat the evaporator. The electrical power required to drive the fan is about one-third of the energy required to evaporate the water in the system. Dedert is a prime supplier of this state-of-the-art technology.
Dedert has increased its efforts in finding ways to reuse energy from other parts of a processing plant. The use of waste heat recovery is one way in which Dedert is contributing to energy sustainability in the evaporation industry. Integrating evaporators to take advantage of the free energy from dryers or distillation columns reduces the plant’s overall energy consumption and impact on the environment. This also leads to a reduction in energy requirements for the downstream emissions handling equipment. An evaporator can use alternative energy sources in lieu of steam, and Dedert has considerable expertise in using otherwise wasted energy sources:
- Waste heat recovery evaporators utilizing a dryer's exhaust or turbine exhaust,
- Evaporator systems integrated with strippers, scrubbers, and distillation columns,
- Thermocompressor for boosting low temperature vapors to a usable temperature,
- Water-heated evaporators using process water as an energy source.

Steam-Heated Triple Effect Evaporator

Waste Heat Evaporator Using Dryer Exhaust

Mechanical Vapor Recompression Evaporator
How can energy sustainability principles be implemented in dryers?
Once it is not possible to use fossil fuels, then electricity, hydrogen, or biogas would be the energy sources most likely used to generate heat in the future.
Dedert is now preparing designs for its systems to use energy from new emerging technology which uses renewable resources as they are adopted by industry. This will include but is not limited to the processes listed below:
- Use of high temperature heat pumps for preheating or used in internal heat exchangers. The available temperatures are relatively low ranging from 120oC to 150oC.
- Use of green or white hydrogen as a fuel. Green hydrogen is generated by using renewable electricity to electrolyze water. White hydrogen is emerging as a new source, which naturally emerges from underground.
- Recovery of surplus renewable energy in heat batteries. When renewable sources are generating surplus electricity, then this can be used to heat inert blocks of concrete or beds of sand or rock up to 600 oC. This energy can then be stored in the inert bed until it is required by passing air through the bed to heat downstream processes such as dryers. It is important to note that this type of heating would be supplementary rather than the primary heat source.
Some of Dedert’s fluidized bed dryer systems already have heat exchangers inside the bed instead of using an air heater on the outside. Most of the heat is provided by heating tubes immersed in the fluidized material with steam. The inlet temperatures are relatively low, ranging from 120°C to 150°C. A heat pump could be used to transfer heat from the dryer exhaust to the tubes using a high temperature refrigerant. Conversely, an MVR (mechanical vapor recompression) system like that used in Dedert’s evaporator systems could be used by compressing the exhaust steam and feeding it back into the heating tubes. This would reduce the energy input by approximately 60%, which would come from electricity.

Fluid bed dryer with internal heating tubes


Today’s best Technology: Superheated Steam Dryer heated by natural gas with waste heat evaporator recovering energy from the dryer

Future application of superheated steam drying heated by burning green hydrogen and oxygen generated by electrolysis
How Does a Heat Pump Work?
Purpose of Heat Pumps
The purpose of a heat pump is to upgrade low temperature energy by inputting electrical energy. A heat pump takes energy from a cold source and drives the temperature upwards to transfer that energy to a hotter temperature. Generally, the work put into the heat pump compressor is about one third of the heat which is transferred to the heated element.
Working Principles
A heat pump system is essentially the opposite of a refrigerator in your home. The system takes energy from a cold source and converts it to a higher temperature using a compressor. There is always one side that is heating up and one side that is cooling down. The lower temperature source is used to evaporate liquid refrigerant in a heat exchanger, transferring heat into it at the lower temperature end of the heat pump. If this were to be a dryer exhaust, it would be in the range of 60oC to 100oC. The now gaseous refrigerant passes through a compressor which increases its temperature and pressure. This high temperature gas then passes into a second heat exchanger where it is condensed at a higher temperature (for modern refrigerants this can be 120oC to 150oC) heating the incoming cold dryer inlet air. The condensing heat exchanger discharges hot liquid refrigerant at high pressure through an expansion valve which reduces the pressure of the liquid, cooling it down so it can pick up heat in the evaporating heat exchanger at the cooler end of the heat pump.

Challenges with Implementation
Industrial heat pumps are supplied as packaged systems with the evaporator and condenser included on the same skid as the compressor. To use the heat pump with a dryer, two heat exchangers must be added to the inlet and outlet of the dryer. A heat recovery exchanger is installed at the dryer outlet and connected to the refrigerant evaporator on the skid via a glycol loop. A preheater is installed at the dryer inlet and connected to the refrigerant condenser via a second glycol loop. Every time a heat exchanger is used, a bit of temperature difference is lost. It would be more helpful to install the evaporator and condenser in the dryer inlet and outlet so we can eliminate the additional heat exchangers and maximize the temperature difference. However, heat pump systems are not yet used in large scales for heating process plants and are not currently available for commercial purchasing. They are relatively expensive but are becoming more of an economical solution for the future because the cost of current energy sources has risen drastically over the years.
Generating Steam with Fans
As a response to rising energy costs, generating steam using a heat pump is a viable and attractive option. Suppliers of MVR fans have created steam recovery systems that work as an industrial heat pump. A heat pump chain is a series of several MVR fans that would normally be used individually in an evaporator system. The basic principle of an industrial heat pump is to recover waste heat and provide it at a usable temperature level. The maximum temperature that one MVR fan can raise is around 20°C. This is not particularly useful for achieving high temperatures, so this heat pump chain is beneficial because it works by connecting each fan together to gain higher temperatures. As you start with inputting low temperature steam, you then get higher temperature steam as an output.

Steam generation using fans in series (Picture courtesy of Piller GmbH)
The main advantages of the heat pump chain include:
- High primary energy savings
- CO2 reduction
- Overall improved economic efficiency of the system
What are some examples of renewable sources of energy?
- Geothermal (heat from the ground)
- Wind turbines (land and sea)
- Nuclear
- Hydro
- Biomass (Large amount of land is needed, takes a lot of time to recycle biomass around system)
- Solar panels
- Hydrogen from renewable sources
Most sources of renewable energy are used to generate electricity which cannot be stored; therefore, to fully utilize these sources, the electricity can be used to store the energy in different forms:
- Batteries which are effectively a chemical storage method
- Electrolyzing water to produce green hydrogen. This is also chemical storage.
- Hydro storage power where water is pumped uphill when there is a surplus of supply and then released to generate power when demand is high. Gravity Storage.
- Heat batteries which are used for converting surplus power to heat and storing it in insulated inert media for later use. Heat Storage.
Green, Blue and White Hydrogen
Presently the principal method of producing hydrogen is by reacting natural gas with steam using a catalyst. This reaction produces hydrogen and CO2. The CO2 is then captured usually in underground containment. This is a transitional production of hydrogen and currently the only method of production at gigawatt scale.
Green hydrogen can be produced by electrolyzing water, also known as electrolysis. A hydrogen electrolyzer is used to create ionization on an industrial scale. There are already pilot hydrogen electrolyzer systems being used today, and they are typically connected to wind turbines, hydroelectric powerplants, or a set of solar panels to generate electricity, and in turn, generate hydrogen. The hydrogen will be collected from the wind turbine or solar panels and then it will be stored as hydrogen gas. Once the hydrogen is burned, you will get the energy back in return. One issue with the hydrogen electrolyzer system is that it generates hydrogen and oxygen together. In most cases, the oxygen is not being used for anything and is exhausted into the atmosphere. This is wasteful dumping of a vital resource. The oxygen makes burning of hydrogen far more efficient, and therefore they should be burnt together. But this can be dangerous because mixing hydrogen and oxygen is potentially explosive. However, a well-designed system should be able to overcome this issue.
Recently there has been interest in exploring the use of hydrogen which is naturally occurring and can be collected from wells in much the same manner as natural gas. This is termed “white hydrogen” and because there is no carbon content it will not produce any CO2 when burnt. This may become a low-cost energy source in the future.
If green hydrogen is to become a significant source of energy for industrial purposes, then it is quite possible that wind power and solar systems in remote locations will be dedicated to electrolyzing systems producing hydrogen which can then be shipped or piped to industrial users. Some of the infrastructure for transferring the hydrogen could be repurposed from that which is currently moving natural gas.

Using hydrogen as a fuel in dryers
Many existing designs of drying systems which use fossil fuels can be adapted to burn hydrogen as a direct replacement for natural gas or other fossil fuels. For open cycle dryers, the use of hydrogen with preheating from waste heat and heat pump systems could be a way of eliminating CO2 emissions.
For process gas recycle dryers and superheated steam dryers which can operate with recycled exhaust gas, the use of burners fired by hydrogen and oxygen would offer the opportunity to produce steam in the dryer exhaust and recover the energy by condensing the steam in other processes.
Dedert presently uses superheated steam dryers fueled by natural gas. A future possibility for Dedert is to heat our steam dryers directly with oxygen and hydrogen to reduce our carbon footprint. Hydrogen could also replace natural gas in convective drying systems.

SSD Dryer using Natural gas

SSD dryer heated by burning Hydrogen & Oxygen
Thermal Batteries
A thermal battery is something that can be heated up to a high temperature and will stay hot for a long period of time. A few different types of thermal batteries are currently being proposed. A Finnish company has created hot batteries made of sand, where the energy will be stored. Essentially, holes are made in the sand and are then filled with tubes. Surplus electrical energy is used to heat up the sand to 600°C by blowing hot air into the tubes. If insulated well enough, this bed of sand can stay heated for months. Recovery of the heat is achieved by drawing air through the tubes to heat whatever system is desired.
An alternate system for storing energy is the use of a nest concrete thermal battery. In this type of thermal battery, energy is stored in tubes filled with concrete that have pipes running through them. Heat passes down through the pipes and heats up the concrete. The fluid passes through the pipes, and you can then recover energy from the heat battery. These systems can store a lot of energy, as they are usually stacked very tall and wide.

All in all, the future is bright for energy sustainability within drying and evaporation technologies. As the demand increases for renewable energy sources amongst the food, chemical, and pharmaceutical industries, so does the need for more efficient and sustainable technologies for Dedert’s customers around the world. Whether it is an industrial heat pump chain, the use of green hydrogen or heat batteries, there are numerous ways in which the process equipment industry is working to meet the demands of our everchanging world. Dedert plays a principal role in applying the latest economically sustainable energy sources within our technologies. Though Dedert has incorporated some of these practices into our systems already, implementing more energy-efficient options is crucial in transitioning to a cleaner and greener future.