YEARS
Sponsored by Climalife
Chiller O
CO2 Chiller
Greencold in association with Advansor of the year
ur client is a world leader in innovative packaging products for all industry, whose business
operation has a heavy demand for production machinery cooling, writes Greencold. This cooling load has historically been satisfied by several existing chiller systems, which were now reaching the end of their reliable working life. We were approached by the client for
our proposals to replace their existing plant with more efficient and environmentally sustainable new equipment, to become their main chiller base cooling load on site. The existing plant installation comprised
two rather old Industrial Frigo units (R407C), one very old F&R chiller (R422D) and a more recent twin compressor pack (R134a). All units had been progressively connected to a single centralised water buffer tank system as site cooling requirements expanded to form a common chilled water ring main serving the factory’s many packaging material manufacturing machines. The client’s initial requirement was for
new water chiller of 300 kW cooling capacity with water flow conditions of 12°C inlet and 7°C outlet, to be provided by cooling equipment which used a non-HFC, low global warming effect refrigerant, but with good energy efficiency. The client was aware that there may be an
increase capital expenditure required for a more environmentally friendly chiller system choice; they were however prepared to make that additional investment to achieve a more sustainable installation for the
future. At Greencold we made the point to the client that although they could expect the capital cost of such a chiller installation to be more expensive than an HFC unit alternative, with a careful design approach significant seasonal operational savings can be easily achieved. Indeed, with the added system efficiency during the winter months and the reduced overall energy consumption, such a new chiller unit using CO2
refrigerant would be
expected to accomplish a full payback of the additional capital cost differential perhaps in one year of plant operation. The installation was duly carried out
recently and the new CO2 chiller was installed
on to the existing factory ring main system alongside the existing plant, which allowed direct operational energy comparisons to be made, before the existing plants are retired from service. The new CO2
chiller was
carefully brought online mid-way through a full production day’s cooling load, and with site full cooling load progressively transferred to the single new CO2
chiller unit as
the existing chillers were removed from service. An instant drop in the site chiller energy input in the order of 30% was clearly seen on the client’s energy recording equipment, providing the client with the operation savings levels as predicted.
Dominic Holland (left) with Anders Monsted, Simon Andrew and Vanessa Smith from Greencold and Allan Harper (far right) from sponsor Climalife.
40 May 2022
www.acrnewsawards.com
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