CASE STUDIES NEWS
Plastic packaging manufacturer replaces fossil-fuelled equipment with heat pump technologies
T
hanks to technology innovation, many industrial processes such as food and beverage, plastics and rubber, chemical and pharmaceutical, have started looking at heat pumps as an effi cient heating solution for a wide range of their processes. As they have been getting familiarised with the new technologies, they have started recognising the economic benefi ts from a most effi cient use of energy while also providing a signifi cant benefi t towards emission reduction. A manufacturer of plastic packaging and containers decided to future-proof their operations addressing the rising costs of fossil-fuel energy and concerns about its availability and environmental footprint. To do so, they reached out to the ICS Cool Energy team with a request to re-design the existing heating system based on high- effi ciency heat pump technology. During the site visit, the ICS Cool Energy team inspected the four offi ce, production and storage buildings requiring heating. They also examined the two cooling systems already in place and operating under diff erent conditions. One based on a chiller room and dedicated to processes requiring 13/18°C temperatures to work the plastics; the second one dedicated mostly to processes dealing with oil and based on dry coolers with 25/30°C temperatures. Two completely diff erent systems, but perfectly fi tted to work with the industrial Free Heating (i-FH) system from ICS Cool Energy.
The existing fossil-fuelled system was delivering
approximately 600kW of heating. To replace the old equipment and fulfi l that load, the ICS Cool Energy team decided to divide the heating system into two areas corresponding with the existing cooling system. They installed two industrial Free Heating (i-FH) heat pumps – one in combination with the chiller room to deliver 366kW of heating for the space of 9000m3, and another one to deliver 254kW of heating for 4600m3
in combination with
the dry-cooler. Following the installation, the customer immediately noted the diff erence in the cost of generating the heat by the new heat pump systems. In the fi rst set-up for the larger space, generating the
required 366kW of heating with the i-FH unit cost over 25% than the fossil-fuelled system. Additionally, the customer was able to benefi t from 223kW of cooling generated by the i-FH unit at the same time. This additional cooling capacity proved to be crucial when it was used to off set the cooling load suddenly lost when one of the other chillers suddenly broke down. In the set up with the dry-cooler, generation of 254kW of heating with the i-FH unit cost the manufacturer over 43% less compared with the fossil-fuelled system. As a result, the customer has not only future-proofed its heating system but has been saving money and benefi ted from the additional cooling capacity that helped it in its emergency situation.
Following the installation, the customer immediately noted the diff erence in the cost of generating the heat by the new heat pump systems.
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www.acr-news.com • July 2023 33
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