The next level of energy efficiency and flexibility

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Emil Allison
5 years ago
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1 The next level of energy efficiency and flexibility

Flexcool, utmost flexibility of application and efficiency of operation from Aquatech Innovation always comes from paradigm shifts Aquatech, one of the recently established companies of the Piovan

2 Flexcool, utmost flexibility of application and efficiency of operation from Aquatech Innovation always comes from paradigm shifts Aquatech, one of the recently established companies of the Piovan Group, with core competences in industrial cooling systems, makes its debut on the market with an engineering solution that supersedes the principles of centralized systems, to ensure greater energy efficiency and savings of between 35 and 50%. The Flexcool solution, in fact, can use ambient temperature to cool the processing equipment. Such a peculiar strategic feature makes Flexcool ideally suitable to serve sets of injection moulding machines having diverse characteristic, that is, in work situations where different users are present and operating at varying processing conditions (temperature, flow, pressure). Flexcool ensures the highest level of control, flexibility and energy efficiency. The conventional design of a centralized cooling system suffers of substantial thermal energy losses. The chiller, for example, produces cooling water at one temperature, the lowest necessary, for all equipment, moulds, and hydraulic circuit of the machinery. No matter whether some of the inj.m.machines are of the latest generation or the moulds that equip those require a higher temperature or a lower flow, the cooling system will operate in the worst condition possible forever. Flexcool instead consists of a central dry cooler of the Aryacool line coupled to a series of thermochillers of the DigitempEvo line. One DigitempEvo each inj.m.machine. In this way, it is possible to achieve the optimum operating cooling temperature, water flow and pressure for each machine, depending now on production specifications and not anymore on equipment limitations. The first improvement, immediately appreciable, is the obtainment of an average electricity savings of 35%. Each DigitempEvo is equipped with a digital scroll compressor and an electronic expansion valve: these two components allow optimization and stabilization of the water temperature control and reduction of the energy required to cool it, without fluctuations or losses. The Flexcool solution can produce savings in excess of 50%, as under normal operating conditions most of the heat load is handled by the Aryacool drycooler, while the DigitempEvo refrigerant circuit is only activated for those moulds requiring a cooling temperature lower than that produced by the Aryacool unit. The heat load issue is crucial to understanding the technical reasons behind Flexcool. At a manufacturing site, the cooling system must be sized for the maximum heat load, which can only be achieved if all the machinery is in operation at the highest throughput, while the ambient temperature is the highest along the course of the entire year. This condition reflects a purely theoretical operating model. In reality, a cooling system will always work at partial loads, which is a critical condition by nature, as it imposes alternate cycles of start-up and shut-down, that make the system highly inefficient.this problem is completely eliminated by Flexcool, which optimizes cooling capacity distribution as a function of the individual mould characteristics. The digital compressor with which each DigitempEvo is equipped, modulates its capacity between 20 and 100%, depending on the thermal load. The flexibility of Flexcool is therefore particularly appreciated in the presence of partial and variable loads: a condition that systematically occurs. The main components of a Flexcool solutions are two, the Aryacool drycooler and the DigitempEvo thermochiller. 2_Flexcool

Industrial cooling technologies evolve at a high pace, so to keep up with the demand of being more and more process centred and adaptive to increasingly variable production conditions.

3 Industrial cooling technologies evolve at a high pace, so to keep up with the demand of being more and more process centred and adaptive to increasingly variable production conditions. Flexcool was developed to cope with those stringent conditions of operation and to deliver the highest accuracy of control, flexibility of duty and efficiency of energy utilization. Aquatech s newly introduced range of thermochiller of the DigitempEvo series, along with the new line of Aryacool dry cooler units, are the main elements of the Flexcool solution and represent the state of the art in the design of modern cooling equipment and controls.. Flexcool components: Aryacool Dry cooler Adiabatic Self drain DigitempEVO thermochiller Integrated high efficiency chiller Integrated TCU Automatic free cooling Self-Adaptive technology Aryacool, next generation dry-coolers, is an air-to-liquid heat exchanger, that uses the environmental air flow to cool a liquid through one or more coils. Digitemp-Evo is a thermo-chiller, the combination of a temperature control unit and a water chiller. It delivers three functions for process water control: COOLING - the compressor is activated to perform the cooling duty HEATING - the heating elements are activated to heat up the process water and reach the working temperature FREE COOLING - the unit uses water from the dry-cooler to cool down the process through a heat exchanger; compressor and heating elements are off. Flexcool application Flexcool_3

Sustainable cooling solution Benefits Clean process water, without contamination. The closed water circuit system reduces maintenance costs, avoiding incrustations at heat exchangers, pipes and molds.

Key features: - Flexibility: different sizes and thermal capabilities, several options of pumps and stainless steel tanks.

4 Sustainable cooling solution Benefits Clean process water, without contamination. The closed water circuit system reduces maintenance costs, avoiding incrustations at heat exchangers, pipes and molds. Increase of water saving, since there are no evaporation losses. Significant reduction in costs for chemical water treatment. Constant process temperature by using electronic control. Key features: - Flexibility: different sizes and thermal capabilities, several options of pumps and stainless steel tanks. - No rust: fully built in stainless steel plates and structures, heat exchangers in copper pipes with aluminum fins. - Increasing electricity saving: use high efficiency fans with variable speed control. - Minimum water consumption: the system uses water evaporation only in case of high environment temperature, in association with the process needs. - Reduction of temperature: spraying system much more efficient, by using evaporative panels. - Longer lifetime for the heat exchanger: efficient adiabatic system which protects the heat exchanger from direct contact with water, avoiding calcium formation. - Protection and durability: the exclusive air filter minimizes dirt accumulation in the heat exchanger. The Aquatech Dry Cooler offers several advantages for process industrial water cooling. With an intelligent process of water cooling by closed loop, it keeps clean the process water, without waste and reducing the operating costs. Designer in two versions for full adaptation to the different types of processes, the Aquatech Dry guarantees an optimal control of any process in a sustainable way. Dry System: it uses high efficiency heat exchangers, limiting the temperature of the process water at 5 C above the environment temperature. Adiabatic system: in periods of high temperature, it associates an intelligent system that sprays small amounts of water, saturating the air and promoting further reduction of temperature. 4_Flexcool

High performance thermochillers Benefits: Flexible operation providing water from 5 C to 90 C to each single circuit (in the dual pump configuration the unit controls the process allowing two

energy compared to the standard on/ off units Precise temperature control obtained with the use of: electronic expansion valve, digital Scroll, PLC controller (high precision +/- 0.

5 High performance thermochillers Benefits: Flexible operation providing water from 5 C to 90 C to each single circuit (in the dual pump configuration the unit controls the process allowing two different working temperatures) Reduced energy utilization performed by the digital scroll compressor, that allows to modulate the power from 10% to 100%, saving more than 35% of absorbed electrical energy compared to the standard on/ off units Precise temperature control obtained with the use of: electronic expansion valve, digital Scroll, PLC controller (high precision +/- 0.3 C) Reduced running costs ensured by the integral free cooling feature High efficient heat exchange, braised plate evaporator and condenser in AISI316 stainless steel Long life and reliability Compact design Easy to use HMI, clear display of water temperatures and alarms DigitempEvo is the new flexible solution developed for industrial processes of heating and/or cooling. It integrates both temperature control and free-cooling functions, providing accurate water temperature, pressure and flow rate to every single circuit. The traditional centralized cooling system concept (chiller + TCU) is replaced by the newly introduced Flexcool solution, with one DigitempEvo dedicated to each user coupled with outdoors free cooling capabilities. State of the art design and technical characteristics make DigitempEvo highly performing and flexible to each situation. Technical Features: Integral free-cooling Digital scroll compressor Braised plate evaporator and condenser Medium and high pressure pumps Single or double circuit with independent temperatures Options: Free-cooling kit Heating kit Condensation control Serial interface board Phase sequence control PROFIBUS serial interface board Water filter 500 microns 1 Acoustic visual alarm Flexcool_5

6 Aryacool characteristics Modelo Frequência Frequency Potência Installed instalada power [KW] Capacidade Nominal capacity * nominal * [KW] Dimensões Vazão Water água flow Dimensions [mm] [m 3 /h] Conexões Connections Ventiladores Fans [m3/h] Compr. L Larg. W Alt. H Weight Peso DCP60 50 Hz / 60Hz 3, DCP Hz / 60 Hz 6, DCP Hz / 60 Hz 9, DCP Hz / 60 Hz 12, DCP Hz / 60 Hz 14, *Data are referred to the following conditions: Adiabatic system, T H2Os 35 C, T H2Oe 45 C, TBS 30 C, TBU 24 C DigitempEVO characteristics TECHNICAL DATA DTE DTW DTE 16 DTW551 DTE 22 DTW452 DTE 38 DTW552 DTE 50 DADOS TÉCNICOS Cooling capacity KW 9,8 Mono-circuito 17,4 23,2 Duplo-circuito 38,7 50,4 Compressor absorbed power * Kcal kw ,9 3, , , Capacidade frigorífica * kw 44,77 55,52 44,77 55,52 Condenser heat load KW 11,5 20,6 27,7 45,4 59,8 COP 5,00 4,70 5,00 4,70 Condenser water flow Capacidade de aquecimento m kw /h 2,0 1X12 1X18 3,5 1X12 1X18 4,8 2X12 7,8 2X18 2X12 10,3 2X18 Evaporator Potência Instalada water flow kwm /h 35 1,7 41 3, , ,7 54 8,7 66 Evaporator pressure drops m 3 /h kpa 3,5/1735,4 3,5/17 3,5/17 42,7 3,5/ ,5/17 3,5/17 45,5 3,5/17 44,6 3,5/17 Bomba de água standard ** Condenser pressure drops bar kpa 5,5/3 48,2 5,5/3 5,5/3 57,2 5,5/3 5,5/3 63,8 5,5/3 108,5 5,5/3 5,5/3 81 kw 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 EER 5,14 5,05 4,92 5,38 5,05 Conexões de água gelada - Entrada/saída BSP 1-1/2 1-1/2" 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 Maximum Conexões de heating água condensação power - Entrada/saída BSPkW 1-1/ /2 1-1/ / /2 1-1/ / /2 Height Compressor (Scroll) quant. mm Width Altura mm (H) Dimensões (mm) Lenght Largura (B) mm Comprimento (L) 1257 Refrigerant charge Peso kg Kg 1, ,9 2,3 3, ,05 Oil charge l 1,24 1,89 1,77 3,25 3,25 * Os dados acima são para equipamentos 380/3/60Hz - R410a - trabalhando nas seguintes condições: temp. da água de saída 12 C - temp. água condensação 30 C. ** Min/Max Disponível evaporator em outras water configurações flow sob consulta. m 3 /h 0,45/9 0,75/9 1,29/9 2,13/16,8 2,76/16,8 Data are referred to In/Out evaporator water temperature 15/10 C, In/Out condenser water temperature 30/35 C

EN aquatech.piovan.com

EN aquatech.piovan.com Refrigeration Technologies: scroll-compressor chillers The scroll compressor is the most suitable component for the small and medium duty requirements in the industrial applications.