ESTA Extraction

How does an HVAC system ensure fresh and healthy air?

An environment with good air quality promotes our health, well-being, and productivity. Poor indoor air, on the other hand, can lead to concentration problems, fatigue, and health issues. To create a comfortable and healthy indoor climate in enclosed spaces, a ventilation and air handling system (HVAC system) is used.

What is an HVAC system?

 

A ventilation and air handling system (HVAC system) is primarily used in buildings to improve indoor air quality. It is designed for the ventilation, heating, and cooling of office buildings, shopping centers, hospitals, and other public facilities.

HVAC systems are often also referred to as air conditioning systems because they not only provide ventilation but can also regulate room temperature.

An HVAC system can be used centrally for the entire building or decentralized for individual areas or rooms.

Comparison of HVAC systems and process air technology

HVAC systems and process air technology (PLT) are two different types of ventilation systems used for different purposes. While HVAC systems are designed for the ventilation and air conditioning of buildings, PLT systems are mainly used for extracting dust, welding fumes, and emulsion mist in industrial processes. Despite their different applications, there are some similarities and differences between these two technologies.

Similarities

HVAC and PLT systems play a crucial role in improving indoor air quality. These ventilation systems ensure optimal fresh air supply, effectively remove used or harmful air, and help create a healthy and comfortable indoor environment.

Differences

HVAC systems are primarily responsible for conditioning, cleaning, and ventilating occupied spaces. In contrast, PLT systems are used for specific production process needs, such as extraction, filtering harmful substances, drying, air transport, and ensuring compliance with limits set by law.

Efficient production processes through HVAC systems and process air technology

Ventilation and process air systems often work closely together to create optimal conditions for industrial production processes. The perfectly coordinated control of HVAC systems and process air technology—such as those offered by ESTA—combines health protection with a comfortable indoor climate for employees.

For example, exhaust air cleaned by PLT systems can be fed into HVAC systems via heat recovery to efficiently heat indoor spaces. Moreover, both systems contribute to the effective removal of pollutants and the overall improvement of air quality. Careful planning and coordination of these systems are essential to unlock synergies and boost both productivity and employee well-being in the workplace.

ESTA provides powerful solutions in the field of process air technology that can be seamlessly integrated with existing HVAC systems.

 

ESTA System design

Different types of HVAC systems

Air conditioning systems (full air-conditioning systems), on the other hand, combine all functions: fresh air supply, exhaust air removal, heating, cooling, humidifying, and dehumidifying. By precisely controlling temperature and humidity, they ensure a constant and comfortable indoor climate.

HVAC systems can be divided into different types, each serving specific functions to improve air quality:

Exhaust air systems are designed solely to remove used or contaminated air. They operate with fans that extract air from a room and discharge it outside.

Ventilation systems (supply and exhaust systems) provide controlled fresh air supply and exhaust air removal. Many modern systems are equipped with heat recovery, which allows the energy from the exhaust air to be used to preheat or partially cool the incoming fresh air.

Partial air conditioning systems offer, in addition to ventilation, at least one more air conditioning function such as heating, cooling, humidifying, or dehumidifying. While they can adjust the indoor climate to some extent, they do not offer full climate control. For example, a partial air conditioning system might supply fresh air and provide cooling, but it would not include air humidification or dehumidification.

TYPE FUNCTION
Exhaust systems No air treatment
Ventilation systems Fresh air supply Exhaust air removal
Partial air conditioning systems Heating and humidifying/dehumidifying/cooling Cooling and humidifying/dehumidifying Humidifying and dehumidifying
Partial air conditioning systems Heating, cooling, and dehumidifying/humidifying Heating, humidifying, and dehumidifying Cooling, humidifying, and dehumidifying
Air conditioning systems Dehumidifying Humidifying

Applications of HVAC systems and process air technology

Office buildings

The applications of HVAC systems are versatile and span across various industries and buildings. In offices, good air quality promotes the health and productivity of employees. Ventilation systems with heat recovery continuously supply fresh air and remove used air. In modern office buildings, partial air conditioning systems are useful when additional heating or cooling is required.

Healthcare sector

In the healthcare sector, sterile indoor air is important to prevent infections. Hospitals, laboratories, and pharmacies require especially clean air as well as precise control of temperature and humidity. Full air conditioning systems with special filters ensure the highest air quality in these settings.

 

Industry & manufacturing

In industry and manufacturing, heat and dust are often generated through the use of machines and material processing. Particularly sensitive production areas, such as in the electronics or pharmaceutical industries, also require precise control of temperature and humidity. Partial air conditioning systems are used here to ensure optimal conditions. Central extraction units provide an effective complement to HVAC systems by immediately removing locally generated pollutants.

 

Residential buildings & hotels

In residential buildings, natural ventilation is often not enough to prevent mold or high CO₂ levels. Ventilation systems with heat recovery minimize heat loss and ensure a comfortable climate, especially in passive houses. In larger residential complexes, partial air conditioning systems are useful because they can selectively cool or heat individual rooms or areas.

Shopping centers & recreational facilities

In shopping centers, cinemas, and restaurants, air quality quickly deteriorates due to high visitor numbers. Efficient ventilation provides fresh air and removes odors or pollutants. Partial air conditioning systems are the preferred solution here, as they handle fresh air supply as well as heating and cooling functions.

Structure and operation of an HVAC system

HVAC systems consist of various central components that work together harmoniously. This creates a comfortable and healthy indoor climate.

Air filtration units

Air filters are essential for every HVAC system because they remove dust, allergens, and pollutants from the air. Different filter classes are used depending on the requirements. Coarse and fine dust filters capture larger particles. HVAC systems can also be equipped with HEPA filters and activated carbon filters. HEPA filters remove up to 99.995% of all particles. Activated carbon filters additionally absorb odors and gaseous pollutants.

Heat exchangers

A sustainable component of many modern HVAC systems is the heat exchanger. It enables the recovery of energy from exhaust air to temper the supply air. Plate heat exchangers achieve efficiencies of up to 80%. Rotary heat exchangers can transfer humidity as well, with efficiencies up to 85%. This allows for more efficient use of heating or cooling capacity and reduces energy consumption.

Air heaters and air coolers

Air heaters and air coolers ensure a consistent supply air temperature and a stable indoor climate. Air heaters operate with hot water (50–90 °C), electric heating elements, or direct evaporation, providing heating capacities from 5 kW to over 100 kW.

Air coolers use chilled water (6–18 °C) or refrigerants to prevent overheating. Their cooling capacity ranges from 10 kW to over 500 kW. When combined with heat exchangers or adiabatic cooling systems, they operate especially efficiently and contribute to energy savings in HVAC systems.

Air humidifiers

Air humidifiers in HVAC systems regulate humidity levels and maintain them at an ideal range between 40% and 60%. Balanced humidity improves indoor air quality and helps prevent health issues such as dry mucous membranes and respiratory irritation. It also protects sensitive materials, like wooden furniture or technical equipment, from damage caused by overly dry air.

Zuluft- und Abluftventilatoren

Zuluft- und Abluftventilatoren sorgen für einen kontinuierlichen Luftaustausch und regulieren die Luftqualität. Ihre Förderleistung reicht von 500 m³/h bis über 100.000 m³/h, je nach Gebäudegröße. Moderne EC-Ventilatoren arbeiten besonders energieeffizient und passen ihre Leistung automatisch an. Ihr Wirkungsgrad liegt bei über 90 %.

Sound attenuators

Sound attenuators reduce the operating noise of HVAC systems caused by fans or airflow. Baffle silencers lower the sound pressure level by 10 to 30 dB(A). Absorption silencers, on the other hand, dampen low-frequency noises in the range of 63 Hz to 250 Hz.

How an HVAC system operates

An HVAC system ensures effective air treatment through the sophisticated interaction of various components. Outside air is drawn in through an intake and cleaned by the first air filter to remove dust and pollutants. It then passes through the heat exchanger, where some of the energy from the exhaust air is used for preheating or precooling. A supply air fan, equipped with sound attenuators to reduce noise, moves the conditioned air forward. The air passes through the air heater, air cooler, and humidifier, which regulate temperature and humidity as needed. Afterward, the air is filtered again by a second filter before flowing as supply air into the rooms. Used exhaust air is drawn from the room through an exhaust air outlet and filtered by a third filter. Part of this air is recirculated into the system to save energy, while the remainder passes through the heat exchanger and is expelled outside by the exhaust air fan, which is also equipped with sound attenuators to minimize noise.

This fan is also equipped with sound attenuators (SD) to minimize noise levels. Through this process, the HVAC system ensures a continuous supply of fresh air and removes used air, CO₂, and pollutants from rooms. The multi-stage filtration also reduces dust, allergens, and microorganisms. This promotes people’s health and sustainably improves air quality.

Ideal location of an HVAC system for best results

The location of an HVAC system influences its efficiency, air quality, and ease of maintenance. A central position within the building ensures even air distribution, short air paths, and reduced airflow resistance, which lowers energy consumption. The outside air intake should also be located in an area with low pollution and be at least 10 meters away from the exhaust outlet to prevent exhaust air recirculation.

HVAC systems are often installed in technical rooms, attics, or basements. These spaces must provide enough room for maintenance and component replacement, be well-ventilated, and protected from frost. To reduce noise and vibration, HVAC systems should be installed on vibration-damping mounts, which help minimize the transfer of operational noise to walls and floors.

 

CONSULTING AT THE HIGHEST LEVEL

50 YEARS OF ESTA SYSTEMS ENGINEERING – INDIVIDUAL EXPERTISE FOR YOUR EXTRACTION SOLUTION

For over five decades, the name ESTA Systems Engineering has stood for first-class consulting, innovative technology, and the highest quality in air purification. Our experienced experts develop customized concepts that intelligently combine indoor air and process air technology to sustainably improve the air quality in your production.

Our Services at a Glance:

  • Personal contact with a qualified regional sales manager
  • Expert technical consultation in the field of ATEX
  • Optimal system design based on fluid dynamics analysis
  • On-site measurements
  • Installation & commissioning by ESTA technicians
  • And much more
     

ESTA System Design
 

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