Efficient heating of high-bay warehouses using decentralised ventilation units

The logistics sector plays an important and dynamic role in today's economy. This means that this sector is also subject to continued advancement and modernisation, which above all results in an increased number of logistics centres at the main distribution hubs that are pivotal to efficient transport organisation. These logistics centres are, for the most part, single-storey warehouses that are at least 10 m high, and have level concrete floors, corresponding parking zones and transportation routes. These buildings are generally equipped with an airconditioning or automatic ventilation system. Unfortunately, those involved in planning often do not pay sufficient attention to this topic, despite the fact that considerable savings can be made both in terms of investment and operating costs when selecting a system. This article therefore discusses air heating systems in high-bay warehouses (Fig. 1), and focuses in particular on the issue of air distribution as well as on economic and technical efficiency.

Fig. 1: Logistics centre with a high-bay warehouse

Efficient heating of high-bay warehouses using decentralised ventilation units

Air heating systems in high-bay warehouses

The efficiency of air heating systems depends primarily on the direction in which the air is routed, as temperature distribution is mainly determined by rising currents of air. In inefficient systems, this leads to a significant temperature gradient, which in turn results in unsatisfactory conditions in the occupied area and in excessive energy consumption [2]. The goal, therefore, is uniform temperature distribution from floor to ceiling, so that the temperature remains sufficiently low, even in the upper areas of the warehouse (generally, a maximum of 30 C is permitted). An analysis of different air heating systems shows that the most efficient systems route air directly downwards into the occupied area [1, 2, 3]. This article therefore examines in detail three different air diffusers used for this purpose: Jet nozzle diffuser Swirl diffuser Air injector

The different types of supply air current and how they dissipate in an open room are illustrated in Fig. 2.

a) Jet nozzle diffuser

b) Swirl diffuser

c) Air injector

Fig. 2: Air distribution in an open room

However, high-bay warehouses constitute enclosed rooms containing barriers such as walls and storage bays, the structure and arrangement of which in turn determine the shape of the air currents. The typical arrangement of storage racks in logistic centres and the dissipation of the supply air currents described above under these conditions are illustrated in Fig. 3.

a) Jet nozzle diffuser

b) Swirl diffuser

c) Air injector

Fig. 3: Air distribution in enclosed rooms

The storage racks in particular cause deformation of the air current; its initial round shape is "flattened" and elongated along the length of the aisle. This results in two aerodynamic effects. Firstly, the range of coverage of the supply air

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Efficient heating of high-bay warehouses using decentralised ventilation units

is increased in one direction due to the barriers. Secondly, the increase in air velocity and air pressure beside the storage racks results in greater air current resistance. The impact of these effects on the air current can vary, and depends on the type of air diffuser and on the structure of the storage racks, particularly with regard to the amount of air that can pass through. Gravitational forces occur due to the difference in density between the air injected into the room and the surrounding air in the room. These forces also affect both the air supply current and the general air circulation in the room [3]. If air is injected vertically, the air current is slowed down if the gravitational forces counterbalance inert forces. The range of coverage, on the other hand, is increased if these forces are acting in the same direction. In order to determine the ratio between gravitational and inert forces, the Archimedes number that was used to define the characteristic range of coverage is applied. Assuming that the current is virtually isothermal, it is calculated according to the following formula [2]: x Arx = Ar0 d 0
2

(1)

........................ Constant, depends on the air diffuser x ........................ Distance between the air diffuser and the cross-section of the current [m] under examination d0 ...................... Diameter of the air diffuser [m] Ar0 ~ t0/tRoom .... Archimedes number in the initial cross-section t0/tRoom ............. Rise in temperature in the initial cross-section of the current in comparison with the surrounding air in the room [K] The equation can be simplified in the case of symmetrical currents (with the exception of the air injector) [2]:

x Ar x = 1.23 H

(2)

H ....................... The geometric index of a current [4] Experience has shown that due to the low level of induction, the temperature gradient at the start of a current is at least 0.4 C/m. This is why the air temperature at ceiling level and in the upper area of the warehouse is only marginally lower than the temperature in the direct vicinity of the air diffuser.
Jet nozzle diffuser

In the case of an air heating system in combination with a compressed current (Fig. 3a: Jet nozzle diffuser), this means that the temperature in the air diffuser t 0 should not exceed the ambient temperature t L by more than a few degrees. Otherwise, the upper storage rack areas will overheat, resulting in infringement of regulations or damaged goods. Important restrictions therefore apply when

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heating using freely-circulating, compressed air currents. The fact that the type of goods being stored is not generally known must also be taken into account.
Swirl diffuser

The option using a swirling air current (Fig. 3b) poses even greater difficulties. A large proportion of the warm supply air that is intended for the occupied area only shows a low level of vertical inertia. As a result, the trajectory range is quite low, significantly lower than in the case of compressed air currents. For this reason, t L ~ t 0 applies in high-bay warehouses that are heated using swirl diffusers. In other words, only some of the storage bays in the upper area of the warehouse are aerated. In order to extend the area that is heated, the heat output must be increased. This inevitably results in even higher temperatures at ceiling level. This in turn causes the upper storage rack areas to overheat and results in considerable energy loss due to the significant difference in temperature beneath the roof. It should be noted, however, that this type of air distribution (Fig. 3b) is wellsuited to cooling warehouses. This is because the density of the supply air in such cases is greater than that of the air in the room. As a result, the supply air sinks, and circulates evenly in the occupied area, without causing a draught.
Air injector This current is characterized by a high level of induction, which is necessary in order to efficiently heat high-bay warehouses. In this case, a decentralised heating system is assumed that comprises multiple ventilation units that supply

different zones in the building [5]. The ventilation units are secured to the ceiling and inject air downwards into the room (based on the principle of ventilating the occupied area) [6, 7]. Ventilation ducts are not required. The units are comprised of two components: the heating element (with a fan and heating coil) and the air injector (Fig. 4). The air diffuser is comprised of two elements, each of which has an opposing effect on the formation of the air current: A combination of a deflector and a jet nozzle that is responsible for the formation of an air supply stream with the maximum possible range of coverage; A vortex device that rotates the air current, thus increasing the scatter angle (induction) of the air current.

The air injector operates based on the following principle: the air supply is directed off a disc-shaped deflector, and then routed along the vanes of the vortex device and through the outlet nozzle into the room. The deflector plays an important role; it provides for a high level of induction using negative pressure at the root of the air current. This leads to the formation of a long, compressed air stream at the start of the current. The scatter angle here is almost 0 (unlike the value of 11, which is characteristic for freely-circulating compressed air currents).

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Efficient heating of high-bay warehouses using decentralised ventilation units

Fig. 4: Cross-section of a decentralised air heating unit with an air injector

Depending on the discharge angle , the vanes rotate the air current; however, due to the negative pressure at the start of the current, this has virtually no effect. However, the further away the air moves from the jet nozzle, the lesser the impact of the negative pressure zone. The rotation then diffuses the air current via induction of the surrounding air. The shape of the current is similar to that of an inverted mushroom with a thin stalk and a large cap. In this way, a large area at a large distance from the jet nozzle can be reached. The high level of induction causes air to circulate from the upper storage racks towards the air stream. As a result, the temperature in the jet nozzle can be high without causing the upper storage rack areas to overheat (t L << t 0) . It is therefore possible to use each unit to heat with more power, i.e. with a higher temperature. On its way downwards, the supply air current is cooled down via induction of the surrounding air, so that it reaches the required value on arrival in the occupied area. The formula (3) for determining the Archimedes number for air injectors in an open room is based on a number of experiments:

d Ard0 = 2.66 0 H EQ

(3)

d0 ...................... Diameter of the air diffuser [m] HEQ = Hh - 1.5 .... Equivalent geometric index of a turbulent current Hh ...................... Warehouse height [m] If formulas (2) and (3) are compared, it becomes clear that induction more than doubles the coverage range of the air stream.

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Efficient heating of high-bay warehouses using decentralised ventilation units

The adjustment of the air current is based on the vortex effect and is achieved by rotating the vanes: the distance at which diffusion exceeds compression varies depending on the discharge angle. At a discharge angle of = 0, the maximum possible length for a compressed stream is reached; at a discharge angle of 0 < < 50, the length decreases. The absolute limit is reached at a discharge angle of 50, when the horizontal air current dissipates along the ceiling (swirling current). This is ideal where cooling is required. The air injector for high-bay warehouses therefore offers: Configurable, uniform heating of the occupied area without the risk of overheating the upper storage rack areas Minimum temperature stratification, and, as a result, low energy loss through the roof Where cooling is required, ideal air and temperature distribution via switchover to a swirling current

Optimum solution
Once it has been determined that air injectors represent the best solution for air heating systems in high-bay warehouses, some thought should be given to unit size and arrangement.
Unit size and quantity The minimum number of units required is calculated as follows:

Based on the criterion: aeration of the entire area S:

nS = S s

(4)

Based on the criterion: entire heat output Q:

nQ = Q q

(5)

s ........................ Flooar area reached per unit [m] q........................ Heat output per unit [kW] The heat output of the unit q is calculated using the equation (6):
& q = V t

(6)

........................ Coefficient, depends on the design of the heat generator & V ...................... Air flow rate [m/h]

t = t0 - tRoom ...... Difference between the air supply temperature t0 and the room temperature tRoom [K]

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Efficient heating of high-bay warehouses using decentralised ventilation units

The maximum mounting height is calculated based on the formula (7): & Hmax = V t Raum d 0 3 t (7)

........................ Coefficient, depends on the design of the heat generator Based on the formulas (6) and (7) as well as on (4) and (5), the following important conclusion can be drawn: From an economic standpoint, selecting the largest possible heat generator is the most appropriate decision. This is also a conceivable option, as there is generally no limit in terms of air velocity (draughts) in warehouses. However, if greater comfort is required, the installation of several smaller units is recommended.
Arrangement of the units

The heat required in warehouses can vary considerably. It is therefore necessary to arrange the units accordingly in different zones in the warehouse or, in other words, to create appropriate control zones. The air distribution is affected by the storage racks. The supply air current is "flattened" along the length of the aisle, with the result that a longer floor space is reached. Nevertheless, not all aisles should be equipped with units, as neighbouring aisles are also supplied by each diffuser. This requires space between the shelving of the storage racks, which is in fact standard practice as storage racks are only filled up to a certain point in order to ensure that goods are easily accessible. It is therefore sufficient if units are merely installed in every third aisle (or at even greater intervals).

Fig. 5: Air distribution using air injectors in a high-bay warehouse

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Efficient heating of high-bay warehouses using decentralised ventilation units

Our deliberations here, supported by technical publications and practical experience, show that decentralised air heating units with an air injector constitute an optimum air heating system for high-bay warehouses. A system of this kind offers the following specific advantages:

Uniform temperature distribution as a result of optimum air distribution. The vertical temperature gradient constitutes only 0.1 to 0.15 C/m. This ensures appropriate use of energy for heating the occupied area and reduced energy loss through the roof. Minimum number of units and thus reduced investment thanks to the large area reached by each unit. No supply and exhaust air ducts required. The principle of decentralisation guarantees a high level of operational reliability and the expandability of existing installations.

Practical experience with air injectors [5, 7] confirms the high level of costeffectiveness and supports the recommendation of solutions of this kind for air heating systems in modern logistics centres.

Literature
[1] Agafonova I.A., Strongin A.S., Shilkrot E.O. "Heating and ventilation of modern warehouse complexes", V, 6, 2004 Grimitlin M. I. "Distribution of air indoors", St. Petersburg, 1994 Balandina L.J. "Features of distribution of warm air indoors with air heating systems", C..K., 1, 2007. Shepelev I.A. "Aerodynamics of air streams indoors", oscow: Stroyizdat, 1978. Vishnevskij E.P. "Experience of ventilation of objects of the industry and social appointment with use of the decentralized units of manufacturer by HOVAL", V, 5, 1999. [6] Grimitlin M. I "Energetically effective ventilation of industrial buildings", Technologies of safety and engineering systems, 6, 2005. Balandina L.J., Vishnevskij E.P. "Ventilation of large industrial and public constructions with use of the twirled streams", Works of VII congress VK, 2000.

[2] [3]

[4] [5]

[7]

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