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INDUSTRIAL COOLING
feed throat and 7-24°C to enable the mould tool to be at the right temperature for cooling the plastic items to be released from the mould. At the same time, the hydraulics actuators involved required cooling between 10-18°C. In addition to two large chillers, adiabatic coolers were employed for both elements of the process. This was achieved by bridging the mould and hydraulic cooling circuits with a packaged heat exchanger unit, facilitating energy transfer without compromising circuit integrity. In a transition period when the ambient temperature goes above 10°C, a chiller is needed to maintain the desired level. During low ambient temperatures, the combined system of this type can use the surplus capacity from an ambient cooling system, such as cooling towers, air blast, or adiabatic coolers, to pre-cool water returning from the chilled water circuit before it reaches the refrigeration plant, reducing the amount of energy that needs to be consumed. Whilst the circuits continue to function normally, the chiller plant is less utilised, extending the life span of its components, reducing the cost to the environment, and achieving The relative humidity of the air in the UK is 40 to 60% most of the time. Adiabatic cooling systems remove heat by evaporating water in a stream of warm, low humidity air. In the process of transition from a liquid to a gas, the evaporated water simultaneously stream to within a few degrees of the wet-bulb temperature. In the large pads are saturated with water from their top edge to raise the relative humidity of the air close to 100%. Following the latent heat of evaporation process, damp air hitting the warmer surfaces creates a temperature drop and cooler.
These coolers replace water
spray cooling towers, pumps, and their power costs. At the same time, the risks of water spray and spills associated with Legionella generation are minimised. The cooler’s pad irrigation system saturation point is reached. As a closed feedback system, no water is wasted, and costs for water treatment and water make-up are drastically reduced. On the company’s original 2018
proposal, the total running cost of the existing system was calculated as £248,000 per annum, using an electricity unit cost of £0.056/kWh. The recommended centralised adiabatic cooling and chilled water systems with energy-saving control would reduce that down to £46,000 per annum with a payback period of 19.8 months. But that scenario, when
reviewed against today’s electricity prices (assumed at 48p/kWh), would see running costs of the original system increase to £1,84m p.a. Yet even allowing for a 25% increase in capital would reduce dramatically to just £391,000. Furthermore, the payback would also reduce to as little as 3 ½ months. So, if on top of that substantial result, the government’s super tax deduction is taken into account, the proposition has to be a no-brainer In summary, a chiller/cooler combination system can lower manufacturing overhead and maintenance costs and reduce water consumption and carbon footprint/CO2
tonne equivalence.
In addition, it minimises exposure to environmental risks such as Legionella and can improve water quality (when the system involves replacing cooling towers). This has resulted in a system that takes full advantage of the energy-saving opportunities presented through the UK’s temperate climate.
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www.acr-news.com • November 2022 17
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