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Figure 3. The AirVac 4 kiln before installation. The new kiln is smaller than its predecessor with a 5' × 25' footprint and 5' in height. The mechanics of the vacuum kiln vary slightly from the traditional kiln. Heat can be provided by a variety of sources as either hot water or steam, since the heating requirements are so low – approximately 180oF and 200,000 Btu/hr for the proposed model. Like its predecessor, the vacuum kiln has air circulation fans – a total of four at 5 hp each to ensure that the wood dries evenly. In addition, a 7.5 hp vacuum pump is used to maintain the partial vacuum in the kiln. Finally, two 1⁄2 hp condenser fans allow the moisture in the air to be condensed and expelled from the kiln. The kiln construction involves an airtight seal to prevent infiltration. The tight control of interior conditions reduces the likelihood of checking of the wood, reducing the product that needs to be discarded. The vacuum kiln is a fundamentally different technology than a conventional kiln. Rather than rely solely on heat delivered at atmospheric pressure, the vacuum kiln offers a redesign that makes use of the physical effects of a vacuum – that liquid will evaporate at a lower temperature. This change in design offers a level of energy efficiency that not even the best maintained conventional kilns can reach. A switch from a conventional to vacuum kiln can result in energy savings of up to 75%. Energy Analysis The energy study began with a quantification of the energy used by the existing kilns. Trends were created with the assistance of the Steinway staff to monitor the number and duration of opening of the valves controlling the dry steam, live steam, and roof vents for a period of several weeks. In addition, current transformers (CTs) were installed on each of the kiln fans to measure electric energy use. Two of the kilns utilize one fan each (10 hp), while the other two kilns have three fans each (10 hp per fan). The additional fans allow for increased air circulation and speed up the drying process. However, the process can still take several weeks to complete and the savings pale in comparison to those achieved with the proposed vacuum system. 5PDF Image | Quick-dry Partial Vacuum System
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