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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - IHS (WATER AND ENERGY EFFICIENT INDUCTION HUMIDIFICATION SYSTEM FOR TEXTILE APPLICATIONS)

Teaser

Summary

The IHS technology aims at a versatile and real-time control of relative humidity and temperature of textile plants integrating with a nebulizer with an adiabatic air conditioning system. This innovative machine is supported by a special air flow system, which is related to an AC system of 4 modules and in 1 year:
The amount of air to be saturated and introduced into the shed (thus reducing the energy need): - 80%
The correct water consumption: - 65%.
CO2 emissions linked to energy consumption: - 80%
Reduced concentration of inhaled particles into the working environment that could cause health risks to employees: -85%
To reach these outstanding results we have introduced a new design that is based on the following features:
- Inductive Circular Design of air ducts with customized micro-hole patterns for air diffusion - stagnant ambient air is drawn into the airflow creating a larger airflow.
- Integrated Series of spray nozzles - water flow will be optimized to allow optimal control of airflow and allow precise control of humidity levels.
- Intelligent control system - temperature, pressure and humidity levels of interior and exterior air will be monitored to ensure precise control of the required parameters.

Work performed

TECHNICAL WORK

The personnel supporting the project was increased in April 2018 with the employment of 4 new professional figures with excellent technical experience, 3 to dedicate to the technical development of the project and 1 marketing manager dedicated to commercial promotion, who will follow the future marketing of the finished project.
The following items are the object of the technical work of the first period.

A. HYDRAULIC SYSTEM OPTIMIZATION
including:
- High pressure pipe fittings
- Volumetric high-pressure pump
- Humidification splitting
- Spray nozzles
optimization necessary to eliminate the fragility of the hydraulic system and possible water leaks, both from the hydraulic circuit of the pressurized water supply and from the spray tips of the nozzles, the optimization has also affected the water pressurization pump and relative valves, replaced with models specially designed for continuous work without any maintenance.
The changes were verified by means of stress tests, simulating 3 years of continuous operation of the system.

B. IMPROVEMENT OF AIR QUALITY VALIDATION
Test of the capacity to capture and reduce respirable dust in the conditioned departments with IHS system by means of detection of ambient dust without and with IHS plants in operation.
Confirmed reduction of approximately 80% of the breathable dustiness of the environment, with final values largely within the limits dictated by the regulations in force regarding the working conditions into textile mills.
tests carried out at LV facility, first functional prototype in operation, to be repeated for validation in every future functional prototype (WP3).

C. OPTIMIZATION OF DIMENSIONING SOFTWARE
Basis for the development of dimensioning IHS systems fluid dynamic software as well as flow simulator.
Contract signed with the University of Milan (Politecnico di Milano) for software development.
Start of thermodynamic data collection to be provided to developers for design verification.

D. OPTIMISATION OF CONTROL SOFTWARE
New control software designed to manage the new water pressurization pumps, the valves for humidification steps control, the anti-drip control of the spray nozzles.
Included data recording, new HMI user friendly with synoptic view, visualization real time of power and water consumption.

E. HARDWARE PLATFORM FINALISATION AND FIRMWARE INTEGRATION
The PLC has been implemented in remote control assistance mode for remote display of the IHS prototype in real time and downloading of recorded data

F. SELECTION OF STANDARD MARKET COMPONENT AND AERIS COMPONENT DESIGN
Selection of standard market components included possible alternative.
Design of property components according for industrial prototype construction.

G. TESTING AND VALIDATION OF FINAL INDUSTRIAL PROTOTYPE
Construction and assembling final industrial prototype composed by n0.2 units IHS
Installation in testing facility
Testing and Validation, performance data recording for flow simulator implementation.

E. EXECUTIVE AND FINAL DESIGN OF THE COMPONENTS
Included:
- Proprietary design components
- Standard market materials â€“ list, specification, alternative
- Technical design documents

DISSEMINATION AND COMMERCIALISATION WORK

IHS project born to be applied expecially in Textil Mills, area of competence of our subsidiary company Mazziniici, and conseguently, also perfect for NonWoven market, productions line that have exactly the same needs of the textile ones. To accelerate the penetration of the new IHS systems in this big potential market, we have set up in April 2018, a new company called AlenA NW.
Following the list of the works carried out in the first period

F. WEBSITES
Updating of the following web sites:
- AERIS HOLDING : www.aerisgroup.it
- MAZZINI ICI: www.mazziniici.com
creating 3 new web sites
- IHS Induction humidification system : www.ihs-tech.eu
- ALENA NW for non woven: www.alenanw.it
- AERIS S.R.L. for other industrial applications: www.aeris-tech.it
with

Final results

The tests performed with the final industrial prototype gave results that were even better than expected; the efficiency of the IHS system is 4 times greater than any other traditional adiabatic humidification system, with an energy consumption of one fourth compared to the best
performing humidification super-saturated systems on the market and with limited water consumption, 100% of the water introduced by the IHS system is transferred to the environment without any make-up.
The initial sales projection to 2024 remains confirmed of 764 units with 4 IHS modules.
Basis on the performance data collected during the test of the final prototype the new savings you will get with IHS projected on 5 years work will be: 5,4 M m3 water, 429 GWh of elettricity and more than 210,037 tonnes of CO2 ( calculations according to ISPRA data).