HVAC HEAT OF THE MOMENT
Advances in heat transfer herald a new dawn for efficient and cost-effective temperature control argues Kilfrost.
The design and installation of efficient temperature control within heating, ventilation and air conditioning systems has been subject to a lack of innovation for decades, and installers have long-suffered a dearth of choice.
Ammonia has been used as a primary refrigerant in air conditioning systems for more than 150 years. It is also the go-to refrigerant in many applications including other building services, process applications and food processing and storage.
Although environmentally sound, the hazards and acute toxicity associated with ammonia mean the safe design and operation of refrigeration systems is paramount. The dangers of its use are pulled sharply into focus when something goes wrong, and deaths associated with large leaks only serve to underline this. So it could be argued that industrial temperature control is overdue a step change and that building management system designers deserve better.
how they have been working behind the scenes to bring their expertise to bear on heat transfer.
Michael said: “There’s simply no choice, no options. And it’s been this way for decades. We went into the lab and worked tirelessly to come up with something that would for once provide a viable alternative to what’s currently out there, and save money.
“We knew we had to make a fluid that was more efficient and non-toxic. So we formulated it with organic, approved inhibitors and viscosity modifiers. We developed it to reduce the incidence of pressure drops across the system. It was essential to reduce pumping effort, and costs, and increase hydraulic efficiency, while remaining environmentally friendly.
“We were pleased, but needed to see ALV in operation out in the field to truly understand the potential benefits to industry,” Michael continued.
The Advanced Low Viscosity (ALV) fluid is part of a range of fluids produced by Kilfrost to suit different industries and applications. ALV Plus, a variation of the fluid used in the food and beverage industries, has been shown to be 66% less viscous than the Monopropylene Glycol alternative and offer a lucrative 35% in energy savings. It has an operational temperature down to -40°C. “We took ALV Plus to Canadian energy management consultants I.B. Storey, who had been asked by a chocolate manufacturer in Ontario to review its plant’s energy efficiency.
“The hazards and acute toxicity associated with ammonia mean the safe design and operation of refrigeration systems is paramount.”
Chemists who study the flow of liquids have been working hard behind the scenes to innovate, and the results are paying off. New developments promise to herald potential new options and cost savings for industry - for the first time in a century and a half.
Scientists at Kilfrost Ltd., a British-based firm recognised as the original pioneers of safety critical anti- and de-icing fluids for the aviation industry, took on this challenge two- and-a-half years ago.
Technical Manager, Michael Reynolds, said he and his team had responded to industry feedback that highlighted the need for a new cost-effective solution, and explained
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“After trialling ALV Plus, results identified potential electricity savings of over $14,000 (£8,120) per year through a saving of 39% of pump operating costs. Due to a reduction in fluid viscosity of 15%, capital costs were also reduced, representing construction cost savings of over $17,500 (£10,150).”
Data from external tests on the performance of the fluids is being submitted to OEM simulators, allowing them to demonstrate the efficiency and performance benefits as well as evaluate the use of smaller hardware.
“I understand that ammonia is efficient, and environmentally sound, but as a chemist starting out on an experiment, my first thought is whether the substance is toxic - if it is, I immediately ask myself if it has to be used at all and if so, is there a substitute?
“Our results could show benefits for the primary refrigerant setup in terms of efficiency and equipment installations, but maybe they will also herald a new dawn for heat transfer and temperature control altogether. Heaven knows we’ve waited long enough,” Michael concluded.
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