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Article

Experimental Investigation of Rotating Wheel Speed and Regeneration Temperature Effects on Marine Dual-Stage Desiccant Dehumidification Fresh-Air Pre-Treatment System Performance

by
Guanghai Yang
1,
Wensheng Yu
2,*,
Wu Chen
3 and
Shilong Jiao
1
1
School of Navigation, Xiamen Ocean Vocational College, Xiamen 361012, China
2
College of Transportation and Navigation, Quanzhou Normal University, Quanzhou 362000, China
3
Merchant Marine College, Shanghai Maritime University, Shanghai 201306, China
*
Author to whom correspondence should be addressed.
Processes 2025, 13(3), 669; https://doi.org/10.3390/pr13030669
Submission received: 13 January 2025 / Revised: 21 February 2025 / Accepted: 25 February 2025 / Published: 27 February 2025
(This article belongs to the Topic Advanced Heat and Mass Transfer Technologies)
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Abstract

:
Marine air-conditioning systems face high energy consumption, particularly in humid marine environments. This study is an experimental investigation of the effects of rotating wheel speed and regeneration temperature on the performance of the system, which is a dual-stage desiccant dehumidification fresh-air pre-treatment system using ship waste heat as the regeneration heat source and seawater-assisted cooling to improve the efficiency of energy use. The results showed that the dehumidification capacity and efficiency of the system improved with an increase in the rotating wheel speed from 6 to 10 r/h and in the regeneration temperature from 80 °C to 110 °C. Optimal performance was achieved with a rotating wheel speed of 10 r/h and a regeneration temperature of 110 °C, balancing the maximum dehumidification capacity, energy efficiency, and waste heat utilization.

1. Introduction

1.1. Research Background

Maritime vessels play a central role in international trade because an estimated 85% of the world’s trade volume depends on sea transportation [1]. Although they support economic development, vessels themselves are exposed to numerous challenges related to fuel combustion, emitting greenhouse gasses and pollutants that affect global climatic changes and marine ecosystems. As a response, the International Maritime Organization (IMO) has implemented strong policies to increase the energy efficiency of vessels and decrease emissions, increasing the importance of waste heat recovery technologies. Scholars have relentlessly explored waste heat recovery applications in maritime systems [2], including various technologies such as organic Rankine cycle (ORC) systems [3,4,5], supercritical CO2 Brayton cycles (sCO2-BC) [6,7], additives that enhance engine performance [8,9,10], thermoelectric power generation systems [11], and dehumidification air-conditioning systems [12]. For vessels operating in unlimited navigation areas, the fresh -air ratio of air-conditioning systems is normally not less than 50% [13]; hence, it accounts for a large share of the total air-conditioning load. Thus, conventional marine air-conditioning systems have major drawbacks in terms of energy efficiency and environmental performance, which calls for innovative, energy-efficient, and environmentally friendly alternatives.

1.2. Current Research Status

Rotating wheel desiccant dehumidification technology has been one of the promising methods to enhance the efficiency of marine air-conditioning systems with its excellent dehumidification performance and energy savings. The working principle of this technology is based on the use of desiccants for the efficient processing of humid air; hence, it provides independent control over the temperature and humidity parameters. The properties of the desiccant material are critical for determining dehumidification efficiency. Conventional silica gel desiccants are widely used because of their low cost and high stability. To enhance adsorption efficiency, researchers have developed composite desiccants, including ceramic fiber matrix modified with 25% of MgCl2 and CaCl2 [14], silica gel grafted with PNIPAM and lithium chloride [15], composite desiccant with silica gel and calcium chloride [16], novel PAM-LiCl&GFP [17], LiCl@Al-Fum composite [18], and honeycomb glass fiber hydrogels [19]. Metal–organic frameworks (MOFs) outperform conventional silica gels because of their high porosity for moisture removal in high-humidity environments [20,21]. High-density monomeric zirconium-based MOFs are renewable below 100 °C [22], and researchers have explored their energy-efficiency limits by optimizing their design [23]. Scholars emphasize integrating MOFs’ adsorption mechanisms with real-world conditions [24] and focus on synthesis and molding complexity [25].
The performance of the desiccant wheel dehumidification system is affected by several factors. Hou et al. [26] found that the temperature and humidity of fresh and regeneration air significantly affect system performance. Ding et al. [27] investigated the optimal rotational speed of a single-wheel, two-stage rotor dehumidification system. Saputra et al. [28,29] suggested optimizing performance by rotational speed control. Yu et al. [30] indicated that a high regeneration temperature enhances desorption capacity, while Guan et al. [31] analyzed the outlet air parameter distribution effect on thermal performance. Zhu et al. [32] revealed that a pore size range of 1.09–1.53 nm has an adsorption advantage. Vivekh et al. [33] found that countercurrent airflow enhances dehumidification performance.
Scholars have improved system energy efficiency through innovative approaches. Tu et al. [34] verified the feasibility of a heat pump-driven system. Chen et al. [35] proposed a complementary system of solar energy and heat pump, resulting in a 58.4% operating cost reduction. Huang et al. [36] optimized the system using load clustering with 8.3% energy saving. Chun et al. [37] developed a solar-driven evaporative cooling air-conditioning system (SDEAC) saving 1283–1617 kWh of electricity at 670 m3/h air supply. Wu et al. [38]’s coupled solar–ground source heat pump system is 42.1% more energy efficient than conventional electric heating. Liu et al. [39] reduced system energy consumption to 42.77% using metal–organic framework materials. Maqbool et al. [40] combined a vapor compression heat pump with a desiccant wheel and reduced the power consumption of a compressor by 47%. Su and Venkatesh et al. [41,42] proposed a hybrid air-conditioning system that has significant energy-saving potential in hot and humid environments.
Despite the foundational understanding of rotating wheel desiccant technology, research on marine dual-wheel dehumidification systems for fresh-air pre-treatment is still limited. Compared with a single-wheel system, the dual-stage system has better dehumidification performance and energy efficiency, making it suitable for application in marine environments [43]. However, related research is still in the discussion. Further, a more comprehensive study of the effect of the rotating wheel speed and regeneration temperature on the system under different marine environmental conditions is needed to optimize the system design and operational performance.

1.3. Research Objectives and Significance

This study provides the first systematic investigation of how rotating wheel speed and regeneration temperature affect the performance of marine dual-wheel dehumidification systems, which treat fresh air before use. The performance metrics of the system, including the dehumidification effectiveness, energy consumption characteristics, and overall performance, were analyzed through experimental investigations at various rotating wheel speeds and regeneration temperatures. The effects of these vital parameters on system performance are explored in this study. This study contributes to the literature by presenting a new understanding of the marine dehumidification systems’ optimization, as there is a gap in the experimental data within this field. The results of this research provide practical recommendations for the design and operation of energy-efficient marine air-conditioning systems, which are especially important to decrease energy consumption in marine environments.

2. Materials and Methods

2.1. System Overview

The dual-stage desiccant wheel is a novel, high-efficiency, energy-saving air-conditioning technology for dehumidifying fresh air in high-temperature and high-humidity marine environments. The practical benefits of its application are huge for marine vessels. In the present paper, a dual-stage desiccant wheel is presented, which is constituted by two series-connected desiccant wheels and two intermediate coolers to achieve deep dehumidification and cooling. It recovers waste heat from the vessel to regenerate the desiccant and cools with seawater, hence reducing the primary load on the air-conditioning system.

2.2. Operating Principle

As shown in Figure 1, the operating principle is as follows: fresh airflow first passes via the primary desiccant wheel, where it becomes dehumidified initially, and as a result of this process, the temperature of the desiccant increases slightly and is cooled by the intermediate cooler. Next, the air is further dehumidified by the secondary desiccant wheel, passed through a second cooler, and mixed with the return air before entering a compressible refrigeration unit for final comfort adjustments. The regeneration air required for the regeneration process comes from the cabin air, which is heated by a waste heat heater. The heating temperature is usually 80–120 °C, and the heated air is sent into the regeneration area of the desiccant wheel to heat the moisture-absorbing saturated desiccant for regeneration. The moisture-saturated desiccant wheels are regenerated in a continuous cycle to recover their dehumidification capacity using high-temperature air. This creates a continuous cycle of moisture absorption and regeneration to maintain efficiency and stability. The dual-stage rotary dehumidification experimental platform is shown in Figure 2.

2.3. System Features

Compared to single-stage systems, the dual-stage design provides enhanced dehumidification capacity and energy efficiency. By optimizing the rotating wheel speed and regeneration temperature, the system achieves an optimal balance between performance and energy consumption. The main components and characteristics of the experimental system are shown in Table 1.

2.4. Experimental Parameter Settings

In this experiment, the controlled variable method was applied to investigate how system performance is influenced by the rotating wheel speed and regeneration temperature. Through preliminary experiments, baseline values and variation ranges were strictly defined and selected. The experimental parameters and settings are detailed in Table 2. In order to determine the optimum conditions for dehumidification capacity and energy efficiency, the optimization process implied a systematic modification of the rotating wheel speed and regeneration temperature. The effects of regeneration temperature (80–120 °C) and rotating wheel speed (6, 8, 10, and 12 r/h) were investigated. The optimal conditions were chosen based on the experimental data and theoretical analysis to obtain the maximum dehumidification capacity with the lowest energy consumption.

2.5. Experimental Data Collection and Analysis Methods

To ensure scientific validity and reproducibility, the following data collection and analysis methods were adopted:
First, the system stability was guaranteed, and then the data acquisition system was turned on to measure the temperature, humidity, and flow volume continuously at each measuring point. Second, the data were recorded at one-second intervals for a period of no less than 30 min to ensure adequate sampling. Third, each experiment was conducted three times, and the average values were used to minimize random errors.
Three types of performance indices were calculated and analyzed from the measured data:
(1) System Dehumidification Capacity (Δd): This measures the dehumidification capacity of the system in g/kg and is expressed as
Δd = d1 − d4
where d1 is the fresh-air moisture content before the first-stage dehumidification, and d4 is the moisture content after the two-stage dehumidification.
(2) Dehumidification efficiency (η): This is the dehumidification performance of the system, which is defined as the ratio of the total moisture removal to the initial moisture content:
η = Δd/d1 = (d1 − d4)/d1
A higher value indicates better dehumidification performance.
(3) The thermal coefficient of performance (COPth): This measures the effectiveness of the system in using energy and is defined as the ratio of fresh-air cooling capacity to regeneration-air heat input:
COPth = Qp/Qr = [mp(h1 − h5)]/[mr(hIII − hII]
where mp and mr are the mass flow rates of fresh air and regeneration air; h1 and h5 are the fresh-air enthalpies before and after treatment; and hII and hIII are the regeneration-air enthalpies before and after heating.
The influences of wheel speed and regeneration temperature on system performance were determined by analyzing these performance indicators, providing a theoretical basis for the optimization of system design and operating parameters.

2.6. Error Analysis

For the purpose of increasing the credibility of the experimental results, the uncertainty of the experimental results was analyzed using the error propagation method to check the correctness of the results. Errors in the measurement of key parameters like temperature and humidity were assumed based on the sensitivity of the sensors used in the experiments. Specifically, the temperature sensor has an accuracy of ±0.5 °C, while the humidity sensor has an accuracy of ±3%. It is calculated that the total error in dehumidification effectiveness is found to be within ±5%, which is quite reasonable for this kind of experimental study. Moreover, some errors may exist in the system: (1) Thermal Variations: even with insulation in place in the air supply ducts and interfaces, the results could still be affected by the temperature difference between the laboratory and the supply air. (2) Thermal Interface Limitations: the thermal insulation between the dehumidification and regeneration and the rotary wheel is provided by polytetrafluoroethylene silicone strips, which may result in a small amount of air leakage and thermal bridging.

3. Results

3.1. The Effect of Rotating Wheel Speed on System Performance

The rotating wheel speed was considered as an independent variable in this study. Five different values (6, 8, 10, 12, and 14 r/h) were screened against the other parameters to study their effects on the system performance. The experimental results are shown in Figure 3. No noticeable deviations are observed in the experimental results.

3.1.1. Trends in Dehumidification Performance

As the rotating wheel speed increased from 6 r/h to 10 r/h, the dehumidification capacity of the system gradually increased (Figure 2). At 10 r/h, the dehumidification capacity peaked at 15.43 g/kg. However, when the speed increased from 10 r/h to 14 r/h, the dehumidification capacity decreased. The trend of dehumidification efficiency mirrors that of dehumidification capacity. At 10 r/h, the dehumidification efficiency peaked at 0.66, whereas its overall variation remained relatively stable.

3.1.2. Trends in Thermodynamic Coefficient of Performance (COPth)

The thermodynamic coefficient of performance (COPth) is an important index reflecting the energy efficiency of the system. The experimental results showed that COPth first increased with the increase in rotating wheel speed, reached a maximum value of 0.52 at 10 r/h, and then decreased. This trend was consistent with the change in the dehumidification capacity, which meant that the best energy efficiency occurred at 10 r/h.

3.2. The Effect of Regeneration Temperature on System Performance

In this chapter, the system performance was tested by varying the regeneration temperature to 80, 90, 100, 110, and 120 °C while keeping all other parameters constant. The experimental results are shown in Figure 4.

3.2.1. Trends in Dehumidification Performance

As the regeneration temperature increased from 80 to 120 °C, the dehumidification capacity of the system increased gradually from 10.99 to 14.74 g/kg by 34.12%. The increase in the total dehumidification capacity was clearly tailed off when the temperature reached 110 °C. Dehumidification efficiency also showed a steady increase with regeneration temperature, with a peak value of 0.65 at 110 °C, and remained stable beyond that. This implies that the regeneration temperature has a very imperative influence on the dehumidification performance of the system. Higher regeneration temperatures provide the desiccant with more thermal energy so that the regeneration will be deeper, the regeneration efficiency will increase, and its moisture-absorbing capacity will increase.

3.2.2. Trends in Thermodynamic Coefficient of Performance (COPth)

As the regeneration temperature increased, the COPth of the system gradually decreased from 0.72 to 0.48, with the lowest value at 120 °C. The steep decrease in COPth indicated an increased energy consumption rate. Nevertheless, the increase in energy consumption is a result of waste heat utilization from the ship and not from its own energy. The higher the reduction in COPth, the more waste heat is exploited, and then the waste has been transformed into value for reducing the ship’s total energy consumption and conserving the environment.

4. Discussion

4.1. Analysis of Mechanism of Rotating Wheel Speed

Rotating wheel speed is one of the significant parameters affecting the system performance, as it involves heat and mass transfer between the desiccant and air, and most importantly, regeneration effectiveness for the desiccants. The residence time of the desiccant in the dehumidification and regeneration zones was determined, and this value further enhanced the dehumidification performance and energy-use efficiency.
This reduces the contact time between the desiccant and humid air, reducing the residence time of the desiccant in the dehumidification zone and thereby its adsorption; hence, its dehumidification capacity and efficiency are also reduced. This will provide more time for heat transfer to the desiccant and increase its full regeneration.
Speeds that are too low will result in overheating in the regeneration zone, which is a waste of energy and reduces the COPth. However, at high speeds, the contact time of the desiccant with humid air is shortened, reducing the residence time of the desiccant in both the dehumidification and regeneration zones.
This reduces heat and mass transfer, forbidding the effective adsorption and desorption of moisture. As a result, the dehumidification capacity, efficiency, and COPth were reduced, as was the energy utilization efficiency.
Therefore, there must be an optimum rotating wheel speed at which the residence time becomes equal in both zones to maximize the dehumidification capacity and energy utilization efficiency. The experimental data showed that the dehumidification capacity, efficiency, and COPth reached their maximum values at a speed of 10 r/h.

4.2. Analysis of Regeneration Temperature Impact Mechanism

The regeneration temperature is one of the important parameters affecting the system performance, mainly the desiccant regeneration efficiency and system energy utilization efficiency. According to the theory of heat and mass transfer, as the desiccant absorbs moisture, its absorption capacity decreases. Therefore, regeneration is required to desorb the absorbed moisture and restore the desiccant’s moisture absorption capacity. The regeneration temperature directly determines the desorption effectiveness in the regeneration zone, thereby affecting the system’s dehumidification performance and energy consumption.
At lower regeneration temperatures, moisture is not desorbed completely; thus, the absorption capacity of the desiccant cannot be recovered fully. Therefore, the dehumidification capacity (Δd) and efficiency (η) decrease, energy is wasted, COPth decreases, and the energy utilization efficiency decreases. However, at higher regeneration temperatures, the absorption capacity of the desiccant is fully recovered, and desorption is accelerated, which enhances the dehumidification performance of the system. However, excessively high regeneration temperatures can have negative effects:
(1)
Significantly increased regeneration-air energy consumption, reduced COPth, and overall energy efficiency.
(2)
Potential thermal aging of desiccant materials, shortening of their lifespan, and increasing maintenance costs.
In this study, the regeneration air was heated using ship waste heat. A lower COPth indicates a higher utilization rate of waste heat. However, considering the limitations of the heating equipment and the requirements of the desiccant regeneration performance, the regeneration temperature must be controlled within a reasonable range. An optimal regeneration temperature exists where desiccant regeneration efficiency and energy consumption are balanced. At this temperature, the moisture is fully desorbed in order to regenerate the maximum absorption capacity of the desiccant. The energy consumption for regeneration air is reasonable, and the system attains optimum values for Δd, η, and COPth. The experimental results indicated that the optimum performance of the system was achieved at a regeneration temperature of 110 °C, which is in conformity with the above analysis.

4.3. Strengths and Limitations

In order to evaluate the energy-saving effect, as an example, a 2600 TEU container ship, whose air-conditioning system adopts the traditional compression refrigeration technology, with a total designed air volume of 20,000 m3/h, and the cabin dry-bulb temperature of 27 °C, relative humidity of 50%; the proportion of fresh air is 50%, and the dry-bulb temperature and relative humidity of the air supply state are 17 °C and 65%, respectively. A set of working conditions with a regeneration temperature of 110 °C is selected for comparative analysis, i.e., the dry-bulb temperature of the outboard fresh air is 35.5 °C, and the relative humidity is 59.7%. The traditional compression refrigeration air-conditioning unit requires 249.31 kW of refrigeration capacity to treat the air, while the two-stage rotor dehumidification air-conditioning system only needs to provide 141.39 kW of refrigeration capacity, which is only 56.7% of the traditional air conditioning, and the main refrigeration capacity is used to deal with the latent heat load of the fresh air.
Compared to a single-wheel system, the processed air is dried twice and achieves better dehumidification results in a dual-wheel system, so the advantages of a dual-wheel system are more pronounced in high-temperature and high-humidity marine environments. However, the desiccant could arise thermal aging after a long time of use.
To the best of our knowledge, the experimental setup was devised to mimic real-time conditions as closely as possible; nevertheless, there are still some limitations. For instance, fluctuations in ambient humidity and temperature in real maritime environments may impact system performance. Further studies should be conducted under actual operating conditions and vessel types for wider applicability.

5. Conclusions

This study experimentally investigated the influences of rotating wheel speed and regeneration temperature on the performance of a marine dual-wheel dehumidification fresh-air pre-treatment system. The following scientific conclusions can be drawn from the experimental result analysis:
(1)
The dehumidification capacity of the system is positively correlated with the increasing rotating wheel speed and reaches its highest value of 15.43 g/kg at 10 r/h. The required residence time for desiccant in both the dehumidification and regeneration sections of the system is achieved at this optimal speed, optimizing moisture absorption and regeneration. This optimization produces a better dehumidification performance.
(2)
Through analysis, it was established that 110 °C serves as the regeneration temperature, which optimizes the system performance. At this temperature, the desiccant is sufficiently restored to regenerate, thus keeping its moisture absorption capacity and thermodynamic efficiency in check. Moreover, this temperature has a higher potential to utilize ship waste heat, concurrently turning what could have been lost energy into useful heat. This method effectively reduces energy consumption and emissions while lowering operational expenses.
In summary, the results from this study offer some important theoretical insights into enhancing marine air-conditioning systems’ energy efficiency, thus helping to save energy resources and improve ship operations while finding practical uses for ship waste heat. Further work should be directed toward the verification of these results in actual operations, as well as the examination of the effect of integrating renewable energy resources on the performance of the system.

Author Contributions

Writing—original draft preparation, G.Y.; writing—review and editing, W.Y.; project administration, W.C.; methodology, S.J. All authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by National Natural Science Foundation of China, grant number 51679107.

Data Availability Statement

The original contributions presented in this study are included in the article. Further inquiries can be directed to the corresponding author.

Conflicts of Interest

The authors declare no conflicts of interest.

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Processes 13 00669 g001
Figure 1. Flow diagram of a fresh-air pre-treatment system with a dual-stage desiccant wheel.
Figure 1. Flow diagram of a fresh-air pre-treatment system with a dual-stage desiccant wheel.
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Figure 2. Experimental setup of the dual-stage desiccant dehumidification system.
Figure 2. Experimental setup of the dual-stage desiccant dehumidification system.
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Figure 3. Effect of rotating wheel speed on system performance.
Figure 3. Effect of rotating wheel speed on system performance.
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Figure 4. Effect of the regeneration temperature on the system performance.
Figure 4. Effect of the regeneration temperature on the system performance.
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Table 1. System components and specifications.
Table 1. System components and specifications.
No.Component NameStructural FeaturesFunction
1Desiccant Wheel UnitPrimary and secondary wheels with silica gel; 450 mm diameter; 200 mm thickness; 3:1 dehumidification-to-regeneration ratio; speed range: 5–25 r/hContinuous moisture absorption and regeneration
2Regeneration HeaterElectric heating; temperature range: 80–120 °C (±0.5 °C)Simulates waste heat utilization for desiccant regeneration
3Intermediate CoolersShell-and-tube heat exchangers; cooling water temperature range: 26–32 °C; provided by a seawater simulation systemProvides post-dehumidification cooling using simulated seawater
4Environmental Control UnitTemperature: 25–40 °C (±1 °C); relative humidity: 50–80% (±3%); airflow: 600–1200 m3/hSimulates a variety of marine environment conditions
5Fan SystemProcess airflow: 200–500 m3/h; regeneration airflow: 100–300 m3/h; stable air circulation systemKeeps the airway stable and the rates adjustable
6Control SystemAdvanced sensor system (temperature and humidity sensor: 0–80 °C (±0.5 °C), 10–100% (±3%); temperature sensor: 0–300 °C (±0.5 °C); airflow hood: 50–3500 m3/h (±5%)); real-time data acquisition; computer-controlled parameter adjustmentSystem monitoring, performance optimization, and automated control
Table 2. Key experimental parameters and control conditions.
Table 2. Key experimental parameters and control conditions.
No.Parameter TypeBaseline ValueDescription
1Rotating Wheel Speed8 r/hIndependent variable; five speed levels: 6, 8, 10, 12, and 14 r/h to study speed effects on dehumidification performance and energy efficiency.
2Regeneration Temperature120 °CIndependent variable; five temperature points: 80, 90, 100, 110, and 120 °C to analyze effects on desiccant regeneration and system performance.
3Seawater Temperature28 °CConstant value.
4Fresh-Air ParametersDry-bulb temperature: 34 °C; relative humidity: 65%; flow rate: 500 m3/hConstant value.
5Regeneration-Air Parameters170 m3/h per stage (340 m3/h total)Using cabin air (design conditions: dry-bulb temperature 27 °C; relative humidity 50%).
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MDPI and ACS Style

Yang, G.; Yu, W.; Chen, W.; Jiao, S. Experimental Investigation of Rotating Wheel Speed and Regeneration Temperature Effects on Marine Dual-Stage Desiccant Dehumidification Fresh-Air Pre-Treatment System Performance. Processes 2025, 13, 669. https://doi.org/10.3390/pr13030669

AMA Style

Yang G, Yu W, Chen W, Jiao S. Experimental Investigation of Rotating Wheel Speed and Regeneration Temperature Effects on Marine Dual-Stage Desiccant Dehumidification Fresh-Air Pre-Treatment System Performance. Processes. 2025; 13(3):669. https://doi.org/10.3390/pr13030669

Chicago/Turabian Style

Yang, Guanghai, Wensheng Yu, Wu Chen, and Shilong Jiao. 2025. "Experimental Investigation of Rotating Wheel Speed and Regeneration Temperature Effects on Marine Dual-Stage Desiccant Dehumidification Fresh-Air Pre-Treatment System Performance" Processes 13, no. 3: 669. https://doi.org/10.3390/pr13030669

APA Style

Yang, G., Yu, W., Chen, W., & Jiao, S. (2025). Experimental Investigation of Rotating Wheel Speed and Regeneration Temperature Effects on Marine Dual-Stage Desiccant Dehumidification Fresh-Air Pre-Treatment System Performance. Processes, 13(3), 669. https://doi.org/10.3390/pr13030669

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