Chiller Centralised cooling plants Energy management. Perfect cooling

Transcription

1 Chiller Centralised cooling plants Energy management Perfect cooling

2 For over 40 years Perfect cooling and temperature control For over 40 years Gesellschaft Wärme Kältetechnik mbh has been manufacturing high-quality temperature control and cooling equipment and supplying this equipment worldwide. Today more than 300 employees design, produce and install complete process solutions for heating and cooling in customer specific designs. More than 30 sales and service locations worldwide represent the global character of our work and guarantee our permanent success. In addition to a huge product range of serial products we also offer tailor-made solutions for challenging applications. These individually designed units are available for a temperature range between 100 C and +400 C, and are developed and produced in Kierspe according to the customers demands. As one-stop manufacturer of compact units, cooling plants and temperature control units, up to water treatment and heat recovery systems and complete container systems, gwk is a competent and innovative partner. Headquarters in Kierspe, Germany 2

3 One of gwk s production halls Expertise in cooling plants gwk units are essential all over the world. They are used by the plastics industry in Europe, international automotive groups or world-renowned sweets manufacturers, for cooling of metal processing and in chemical plants worldwide. The high reputation of gwk is owed to units being individually designed and built for specific customer requirements. U-bundle heat exchanger Perfect cooling 3

4 Minimising costs through energy efficiency Without exception, all industrial manufacturing processes involve the in- and output of energy, which has to be supplied or taken away in the form of heat. The heat energy to be released is given off into the environment in the form of heat by the use of cooling plants. Heat recovery systems allow the heat to be converted into heat energy. Optimised combined systems minimise the energy consumption of the cooling plants and utilise energy by means of heat recovery at the same time. Warehouse fl oor heating system Energy Recycling The adjacent schematic diagram shows that cold water can be produced by several cooling systems, that clearly differ with view to investigation and operation costs. Depending on the application the most suitable cooling system can be chosen. Primarily the expected operating costs have to be taken into consideration. Heating unit Heat Energy efficiency for the optimum cooling plant gwk follows the principle that the optimum cooling plant for the specific application can only be found by analysis. This analysis is included in our expertise in energy efficiency and is used as a primary factor for a decision on the investment. 4

5 Energy flow diagram optimised cooling of a production process Central cooling plant 30/35 C Air compressor water cooled Emergency heating with electrical heater Industrial manufacturing processes Central cooling plant 10/15 C Cooling ceiling Offi ces, fl oor heating system or hot water Venting unit Heating / Cooling recovery from the heating condenser of the chiller Production In most cases only a combined system can offer the best solution, i.e. a centrally controlled combination of different cooling units in connection with heat recovery, capacity control of chillers and relief of the primary heating. With its unique product range, gwk plans combined systems with lowest operating costs for production. That means to you, that gwk provides the complete guarantee for correct calculation and planning and installs its systems on a turnkey basis. gwk produces combined systems and heat recovery sytems for more than 40 years now. Not only do the systems installed to date save several hundred million kilowatts of heating energy, they also save a similar quantity of electrical energy hereby the amount saved is even larger due to the reduced operating costs. Apart from the advantage for the operator, gwk also renders an extraordinary contribution to protect the environment. Perfect cooling 5

6 gwk-cooling plants for free This is an unconditional promise. A gwk cooling plant can be acquired at no cost. The reason is that the investment costs for a new plant are amortised by the saved operating costs. Capital-free plant leasing makes plant contracting with liquid funds possible. (This offer is valid for Germany and the countries of the European Union). gwk project study optimising energy consumption For minimal operating costs: Calculation of the optimised combined systems (cooling and heating systems) for injection moulding factories Exceeding the heat from the production machines under consideration of the best process reliability high product quality shortest cycle time Selection criteria: Production plant and products = cooling power requirement = lowest necessary water temperature Economic efficiency of the cooling plant = operating costs Energy management of the total production = potential of heat recovery Customer: Company Mustermann Project: Replacement Cooling Capacity: Quotation No.: Project Study 200 kw 923xxx In this project study the following cooling systems have been compared: chiller with refrigerant R22 available on site new chiller with refrigerant R134a in split-design and hermeticool-function Perfect Cooling and Temperature Control hours / year Basic data DN 4710 meteorologic data to calculate the energy consumption heating and air conditioning systems Berlin 0-24 h Berlin 7-18 h Outdoor temperature [C ] gwk uses outdoor temperature to reduce the operating costs Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str. 306 D Kierspe Tel Fax By means of a detailed project study gwk calculates the most efficient and cost-saving solution info@gwk.com Operating costs at inlet temperature Cooling water inlet temperature [C ] Influence of the cold water temperature 6

7 Project study example 1: Single circuit cooling plant with an process temperature about 15 C for the mould cooling and hydraulic cooling at 235 kw cooling capacity. Before optimization: Single-circuit cooing plant with conventional chiller Industrial compact cooling plant with hermeticool After optimization: Energy optimised single-circuit cooling plant with hermeticool Freecooling up to approx. 5,200 h/a Energy savings up to 240,628 kwh/a = 48 % Energy cost savings up to 20,167 CO 2 -savings up to 168,440 kg Project study example 2: Double circuit cooling plant in split design: Mould circuit 15 C with 87 kw cooling capacity and hydraulic circuit 30 C with 148 kw cooling capacity Before optimization: Conventional design: mould circuit with chiller/ Hydraulic circuit with cooling tower Mould circuit: air-cooled chiller with hermeticool Hydraulic circuit: hermeticool hybrid After optimization: Innovative design: mould circuit with chiller and hermeticool / hydraulic circuit with hermeticool hybrid Energy savings up to 237,608 kwh/a = 46 % Energy cost savings up to 18,510 CO 2 -savings up to 166,115 kg Savings of 1,800 m 3 water per year Perfect cooling 7

8 The centralised cooling plant The gwk project team consists of cooling and control specialists as well as engineers in process technology who have many years of experience at production level. This experience leads to the high technical standard in centralised gwk cooling plants and combined systems. The water chiller is the most important module in a centralised cooling plant. But only the optimal dimensioning of all components leads to a perfect function. There are many options in the choice of the system. gwk prefers a closed circuit, with tanks made of stainless steel or plastic, with manifolds made from stainless steel and with factory piping made of PVC or PE. In order to reduce costs, we recommend a combination of several cooling systems to be controlled by a central computer and the gwk Software Central Energy Management System. Quality is our strongest argument As a rule, a central cooling plant is responsible for the overall production operation. Our gwk engineers therefore emphasize on correct dimensioning when designing a cooling plant for a production. This, in combination with the use of high-quality, longlife and maintenance-friendly components will achieve the highest possible reliability of the plant. A combined system exactly tailored to a specific operation will achieve the required reduction of operating costs by means of the lowest possible energy consumption. Central cooling plant with water treatment 8

9 Electrical cabinet gwk engineers plan and design complete control boards under consideration of specific requirements and site standards. These systems are built by our qualified personnel and afterwards installed on site. The product range covers small operator panels, simple control cabinets up to large control systems. Process visualisation During industrial processes a number of individual parameters have to be measured and calculated. They include physical parameters such as temperature, pressure, flow rate and power consumption. The following data is visualised by the gwk control system: Operation parameters such as temperature, flow rate and pressure, power supplied to the production, operation hours of components and power consumption. The recording and processing of these data allows a centralised energy management. Storage of measuring data. Indication of stored data by characteristics or tables. As a matter of fact communication with a superior network is also possible. The gwk process visualisation is based on the WinCC software system by Siemens, adjusted to the gwk unit systems which thereby allow an individual screen design. Perfect cooling 9

10 SKL and SKL C gwk-energy-saving module gwk-energy-saving module Conventional cooling capacity Cooling capacity R 134a with gwk energy-saving-module COP-value conventional compressor COP-value compressor R 134a with gwk energy-saving-module 7,50 7,00 6,50 Water cooled chillers for industrial use Capacity in kw ,00 5,50 5,00 4,50 4,00 3,50 COP-value Energy-saving industrial water chillers have the task of drawing off heat from a process. This is done by targeted cooling with cold water at suitable points so as to simultaneously increase production and improve quality Outdoor temperature in C Energy consumption at a production period of 7,200 h/a: Conventional solution: 317,355 kwh gwk-energy-saving-module: 216,865 kwh Energy-saving potential: 31.7 % averaged COP-value with energy saving module: 5.15 With hermeticool-function (combined unit): Conventional solution: gwk-energy-saving-module: 3,00 2,50 86,374 kwh 60,177 kwh Except for the low-temperature range, gwk chillers are operated with R 134a, a chlorine-free refrigerant. By choosing this refrigerant, the pressure conditions in the cooling circuit are clearly lower than in systems that use other products. 10

11 As a result, the installed components are exposed to less stress, clearly less wear and the COP value is higher. Higher COP values mean lower operating costs. gwk chillers of the SKL series are cold water aggregates with externally set-up condensers. These chillers are equipped with screw condensers; the power regulation of the capacity to be dissipated is continuous. Since shell and tube evaporators manufactured by gwk are used, these machines are especially suitable for industrial cooling processes. The gwk energysaving module, in combination with an electronic expansion valve allows realization of a continuous condenser regulation. With this type of operation, the ongoing operating costs are reduced by approx. 25% compared to common cooling units. gwk-energy-saving module Use of electronic expansion valves reduces operating costs. Advantages: Fast reaction time Even overheating regulation Variable implementation Water-cooled cooling units by gwk are preferably used when cooling water at a higher temperature level is inexpensively available. With correct dimensioning of exchanger surfaces on evaporators and condensers, the output figures of the machines are further optimised. Perfect cooling 11

12 gwk-cooling tower in use around the world gwk cooling towers are used to carry off heat from production plants with higher temperature levels and work acc. to the principle of evaporation. Cooling towers are a part of a central cooling plant supplied on a turnkey basis which can be controlled by a fully programmable microprocessor. To prevent pollution of the consumer by contaminated water from the cooling tower circuit, the cooling circuits of consumers and cooling tower are separated by an installed plate heat exchanger. As a rule, water treatment and water purification are part of our supply and service program. 12

13 The GVK series of allplastic cooling towers Covering a range of capacities from 50 kw to 1200 kw, gwk all-plastic cooling towers resist the most extreme climatic conditions, because all the parts are produced from durable plastics. The interior parts are produced from high-quality, high-impact plastics and are integrated into a housing made of glass-fibre reinforced plastic. Axial fans with pole-changing motors are matched to the capacity and operate at a reduced noise level. In addition, sound absorbers are optionally available in case of special requirements for noise emission. The gwk stainless steel cooling tower of the GHKV series The cooling tower pack is made from a plastic honeycomb structure with a high heat exchange capacity and high mechanical loading capacity. The housing is constructed from stainless steel, forming a completely installed unit together with the water basin. Low pressure high capacity fans with a high level of efficiency and a low noise level force the cooling air through the fill-pack. Water return from the process is distributed equally by polypropylene hollow cone spray nozzles. Perfect cooling 13

14 Clean process water with gwk KU-plants KU-plant as closed cooling circuit for industrial cooling with direct connection to the pump and tank group of a cooling tower Water is an excellent cooling medium. KUplants from gwk utilise the cooling energy provided by water to carry away heat from production machines in the most troublefree and cost effective way possible. Fresh water from a well, from rivers and from other surface reservoirs is always saturated with oxygen and includes a large number of minerals and suspended particles which can block up the cooling channels in production units through corrosion or by producing deposits. KU-plants from gwk do not allow such problems to arise. A plate-type heat exchanger made of stainless steel separates the clean closed circuit that is used to cool the production from the natural fresh water circuit that is contaminated with all kinds of impurities. Cooling tower water loaded with concentrated solids and particles should not be passed through the cooling channels of production machines. Here too, gwk KU-plants provide clean working. A microprocessor controller working in combination with a continuously operating motorised valve provides precise temperature management regardless of the temperature of the fresh water available. Consumption of fresh water is minimised and expensive water treatment is not required. The operating pump works continuously at the same pressure and thus ensures consistent flow conditions. Automatic water feeding prevents the water level dropping too low. Providing a standby pump that is switched in automatically and also emergency cooling via the fresh water feed increases safety in operation. KU-plants are an ideal tool to reduce maintenance costs, since all the production machines remain clean and ready for operation. 14

15 The use of KU-plants provides a closed cooling circuit and reduces maintenance costs Perfect cooling 15

16 Energy saving hermeticool cooling plants hermeticool units can be used wherever the cooling water temperature is at least 5K above air temperature. The function of the system hermeticool is to transport heated water to the external free cooler where the heat is transferred to the ambient air by means of direct heat exchange. Douple-circuit cooling plant with energy saving hermeticool-technology Common free coolers must be filled and operated with a water-glycol mixture in order to prevent freezing in case of a plant standstill in winter. In order to not contaminate the consumers with glycol and thus limiting heat transfer, a heat exchanger must be installed to separate the circuits. This is not necessary when using gwk hermeticool units, which are operated all year without glycol. Constructive details and an integrated safety system prevent freezing even without additional heating. Compared to glycol operated free coolers this system achieves considerable savings in operating costs. 16

17 Free cooling with hermeticool hybrid gwk-freecooler are space saving and energy efficient cooling systems. The hermeticool hybrid circuit, often known as adiabatic freecooler, is a closed circuit cooling system. The position of the unit is usually on the roof of the production building. At low night temperature the hermeticool is most efficient. The integrated hybrid function also permits the reliable function at high day time temperatures. gwk-hermeticool hybrid works in a closed cooling water circuit functions cleanly, maintenance-free and without water loss is the ideal replacement for open evaporation cooling towers and prevents disadvantages of pollution, salt and oxygen enrichment works according to the air cooling principle lowers the temperature of the cooling air down to dew point this type of system provides cooling water of a temperature below outside temperature is available at power levels of 50 kw to 6 MW nominal cooling capacity Perfect cooling 17

18 Tailor-made compact chillers for special production processes Chillers need to be adapted to the specific requirements of the application to ensure an exact temperature regulation and a reliable operation. Explosion-proof compact chillers In many processes simple cooling with industrial water is not adequate. Individual process-controlled temperature management requires the use of chillers directly in the production plant, especially if materials that are a fire hazard are being produced or processed. Explosion proofed chillers are offered as standard by gwk and can be equipped with a wide variety of options. Chiller in Ex-design 18

19 Compact chiller with two individually controllable cooling circuits Explosion-proof chillers for the Ex-zones 1 and 2 are part of the gwk standard range Low temperature chillers In chemical processes reactions are initiated and monitored according to temperature and pressure. Using a wide variety of machine components, chillers can be produced in modular form with one or more temperature circuits over a total temperature range from -60 C up to +220 C. Machines of this type basically have microprocessor controllers which regulate the timing sequence and the temperature of the process. We recommend discussions with our process engineers to ensure correct sizing. Low temperature chiller with integrated heating circuit Perfect cooling 19

20 gwk-energy recycling and heat recovery gwk-energy recycling Every industrial production requires energy in order to make products. Often, electrical or primary energy is induced as heat, used for operation and must then be dissipated, converted or destroyed. Our gwk process engineers analyse and calculate production processes and the overall thermal periphery with the objective of lowering the necessary energy by means of energy recycling, of reducing the energy requirement at the individual stations, of converting energy or using it several times and dissipating it sensibly. The result is considerable energy saving, which results in cost-cutting and contributes to preserving the environment. gwk-heat pumps Heat pumps are cooling machines which are primarily regulated by the cold water temperature and are mainly used to draw off heat from production units. In winter this heat is pumped to a higher temperature through the compressor and made usable for heating purposes. In the summer the heat is drawn off into the outside air by means of externally-located condensers. gwk heat pumps are filled with R 134a refrigerant and can produce hot water of temperatures of up to 60 C. In order to heat service water all year round, a desuperheater is placed before the heating condenser to heat the service water up to a maximum of 70 C. Desuperheaters are an extremely useful option for each water chiller. Heat pumps in combination with air extraction and ventilation units can be used in summer to provide cooling by extracting the heat from large rooms and halls to provide cold air at specific points to cool production equipment such as blown film units, and to support the hall heating in winter by passing hot air directly from the heating condenser into the air ducts. 20

21 gwk-heat pumps have the task of cooling production machines and saving heating energy. They help the environment and reduce annual operating costs for their users. The use of gwk-air heaters means that the heat from production machines provides heating energy at no cost. gwk-air heaters gwk-air heaters consist of copper tubes with metal fins which give off the heat from production machines into the circulated ambient air. These aggregates convert heat energy without utilizing additional primary energy. In a direct circuit the heat produced in the process is pumped directly to the air heater, for example the heat given off by a hydraulic circuit. By comparison, in an indirect circuit the heat is given off first by a heat exchanger into the heat transfer medium in the heat exchanger circuit. This is in principle much the same as in a central heating system. gwk-air heaters are of two types: of open construction with an axial fan for the heating of large rooms and halls, and a more presentable form with a nice housing and a radial fan for use in office or apartment. Perfect cooling 21

22 Centralised cooling plants in containers save space and money A complete centralised cooling plant, including the required peripherals, can be set up in the absolute shortest possible time at the subsequent place of installation and is immediately ready for use by means of prefabrication and installation in a container. This way, the otherwise high investments for an operating building, the costs for installation and start-up of the plant are reduced. Container cooling plants almost have no limitations in terms of their capacity and variety of possible combinations. They are supplemented by peripheral systems such as water treatment and water preparation systems or compressed air compressors. If the production operations are re-located, then the container can be moved as well without any difficulty. Generally it is not necessary to obtain a special construction permit. The decisive factor for the selection of a container cooling system are of course the future operating costs. A series of different cooling systems and the combined systems composed of these units are primarily available: Chiller Heat pump systems for heat recovery Cooling tower combined with a KU system as a closed, clean cooling circuit Air heaters for direct recovery of heat hermeticool-units hermeticool hybrid-units A containerised cooling plant can be set up in the absolute shortest possible time and is immediately ready for use Containerised cooling plants are designed acc. to the individual demands 22

23 All containers for installation of the cooling plants are tailor made, tuned to specific needs and requirements. The walls are insulated in terms of sound and heat; openings for pipe connections and electrical supply are provided. The roof of the container is prepared to receive exterior aggregates. Since container cooling systems are set up outside, they do not cause building costs or result in losing valuable production space. Containerised pump and tank group Perfect cooling 23

24 Clean water is also part of it Due to its good heat transfer properties and high specific heat, water is extremely suitable as a heat transfer medium. On the other hand, a large number of substances is dissolved in water and this can cause unwanted side-effects in a cooling system, such as deposits. Water can take up and release oxygen and thereby cause corrosion. We want you to use only water that will cause you no problems. Our laboratory will prepare an analysis based on a sample of water. The water analysis is the basis of a recommendation for the water preparation required and to determine how the water should be treated. Water preparation means in every case the production of treated water which is suitable for use in cooling units. In this connection water softening units of different sizes are applied. For maintenance of the water we recommend our after-sales service and the completely automatic water treatment, type active. We can deliver test equipment, cleaning equipment and the necessary chemicals for your own maintenance personnel. Double water softening unit to remove the minerals that form lime scale and dosing station for inhibitors to prevent corrosion, integrated into a container unit 24

25 gwk active-mk 100-2: compact system for cleaning and conditioning of cooling water for dual-circuit cooling systems Infrared image of an injection mould. Left: Inhomogeneous increase of temperature due to the use of contaminated heating/cooling channels Right: Homogeneous temperature distribution after flushing the mould and conditioning the water Perfect cooling 25

26 One-stop turnkey plants Our tasks include the complete planning of a cooling plant including all the peripheral equipment and instruments. Above all, the planning of the entire piping system for a specific and consistent supply of all consumers rounds off our package of services. On request we can produce for you complete layouts for cooling water, material supply, power supply and compressed air lines. Our installation teams are experienced in the laying of piping systems made of steel, copper, stainless steel, PVC, polyethylene and polypropylene. On the basis of our detailed plans you can also have the work carried out by installation companies which you prefer. The connection between the cooling plant, heat recovery system and the existing heating unit is made through hydraulic switching systems. gwk makes use of all current serial and analogue interfaces for data transfer between the production machines and the cooling system or the cooling system and the heating unit or to communicate with a process controller. 26

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28 gwk-service worldwide and round-the-clock With gwk-service......increase of process reliability Increasing product quality requirements and reduction of downtime in futureoriented manufacturing plants make maintenance most essential to avoid unscheduled standstills....increase of warranty Warranty periods of new units can be individually extended by means of service contracts....increase of productivity This includes adjustment of parameters to improve production processes as well as the exchange of spare and wear parts. The equipment of our service engineers allow to immediately carry out cleaning of water circuits....make life easier for maintenance We ensure this with our service contracts. 28

29 Retrofit refrigerant R 22 Acc. to EG regulation: 2037/2000 it is not allowed to use new refrigerant (R22) for maintenance or repair starting from Jan 1, it is no longer allowed to operate cooling plants filled with R22 from Jan 1, Many cooling plants can be retrofitted to an alternative refrigerant. Our Services: Plant evaluation Retrofit to alternative refrigerant Commissioning Reduction of the greenhouse-effect It is based on the EU regulation 842/2006. The objective is to reduce the greenhouse effect, which is caused by refrigerant that has escaped from cooling plants. Since July 4, 2007 all cooling equipment needs to be checked regularly, depending on the amount of refrigerant. Project planning Infrared analysis Performance measurement Project studies Mould dimensioning Contracting Used machines Contracts Financing The number of leakage tests may be reduced down to one test per year when suitable leakage monitoring systems are installed. Our Services: Leakage test on T & M basis Maintenance contract including leakage test Test book and certificate Support Maintenance In-house service inspection Teleservice Mould cleaning / system cleaning Training Spare parts Optimization Retrofi tting / redesigning Advice / support Water analysis Perfect cooling 29

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31 Perfect cooling 31

32 Perfect cooling and temperature control Production costs Cost reduction Increased productivity In many areas of the industry, cooling and temperature centrol provides a great potential for increasing productivity and thus for lowering costs. Many factors serve to improve productivity: Reduction of cooling time, therefore savings in required machine hours Improvement of product quality Increasing availability of production plants Decreasing running cost Reduction of maintenance cost gwk-teco cw Most economic system to extract heat from consumers at very low temperatures by patented cold water temperature control. gwk-tecma High process stability with customised temperature control solutions for all applications with high performance requirements up to 400 C. gwk-ku-plants The simplest and cheapest solution to increase the availability and to decrease the maintenance cost of open cooling systems. gwk-weco Controllable production in variable climatic conditions and high flexibility with compact, energy saving water chillers using environmentally friendly refrigerant. gwk-hermeticool hybrid Innovative cooling system to decrease the running and maintenance cost in comparison to conventional cooling systems. gwk-container-plans Highest flexibility and lowest expenses for planning installation and movement of a centralised cooling plant. gwk-skl/skw Reliable and economic supply of cooling water in the low temperature range, even under the toughest ambient conditions. gwk-hsw Cost reduction by means of advanced heat recovery systems. gwk-active Adjusting and maintaining optimum capacity by means of constantly clean water, delivered from a fully automatic water treatment device. gwk-service Decreasing the maintenance cost and protection of company owned resources through professional installation and service including maintenance of cooling water. KA.0909-EN / Subject to technical modification without notice! Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Straße 306 D Kierspe Tel Fax info@gwk.com

33 Preliminary Report K 2010 Apart from KraussMaffei and Krallmann, the Fach gwk Focuses on Energy Efficiency, Part Quality and Process Safety On the occasion of this year s K 2010 exhibition in Düsseldorf ( ), gwk Gesellschaft Wärme Kältetechnik mbh, Kierspe, focuses all its energy on the topic energy efficiency and presents innovations in cooling and temperature control at its stand J 39 that is enormously extended compared with K in hall 10. mould, produced by Messrs. Krallmann, is executed with ceramic power heaters. In the centre of customer s attention are still system solutions regarding saving of energy costs and optimisation of applications in plastic processing by means of innovative temperature control systems. Particularly increasing costs and competitive pressure are more and more a burning issue that forces the plastic processor to increase his activities in this subject. gwk will not only show the complete range of cooling and temperature control with actual themes by means of static exhibits, but also by presenting live injection moulding applications. In the focus of the customer s attention is the production of high-quality surfaces by means of dynamic cavity temperature control. New Perspectives due to Dynamic Temperature Control Systems Within a common project, sponsored by BMBF with partners in industry and science, that aims at developing efficient temperature control systems in plastic processing, the status of development will be presented on a 800-kN KraussMaffei injection moulding machine with view to the prevention of weld-lines on high gloss surfaces. In order to achieve the required mould wall temperatures during injection without major extension of cycle times, a Dynamische Formnesttemperierung Für bindenahtfreie Hochglanzoberflächen Installed only a few millimetres behind the cavity, they accelerate the heating process at a minimal energy consumption rate at the same time. Heating rates up to 25 K/sec are achieved, at a heat flux density of 150 W/cm², with the tenth of the total energy requirement of fluid heating systems. Directly underneath the heater are the close-to-cavity channels for the water cooling. As the thermal conductivity of the special ceramic material is approximately two times higher than that of tool steel, the cooling through the switched off heating is very effective. As temperature modifications without major extensions of cycle times are possible, this system is entitled to be called dynamic cavity temperature control. The complete temperature control including water supply is effected by a temperature system, type integrat evolution, that is connected with the injection moulding machine via a VARANbus and is communicating in a real time mode. gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com

34 Preliminary Report K 2010 hochschule Rosenheim and the Fraunhofer-Institut für Produktionstechnik und Automatisierung IPA, Stuttgart, are partners of this development project. Economic Production of High-quality Surfaces Ceramic heaters for dynamic cavity temperature control are also part of the second application. On an Arburg injection moulding machine with vertical clamping unit, the high-quality back injection moulding of metal films is shown, that was developed in cooperation with the IWK, Rapperswil/Swiss and the Swiss mould manufacturer Georg Kaufmann. the ceramic heaters in dependence on the cycle while, during the following cooling phase, another module supplies the cooling via proportional valves. All control modules are installed vertically, one on top of the other in a common frame that only requires 60 x 60 cm space. Data input is effected via a central operating panel. All process data are shown graphically and numerically on a touch-screen with coloured display. Based on permanently increasing energy costs and the demand for higher productivity, the dynamic cavity temperature control system is an ideal approach to produce in future high-quality plastic materials with complex demands in a cost-effective way, too. Famous Machine Manufacturers Integrate Dynamic Cavity Control System Dynamische Formnesttemperierung Am Anwendungsbeispiel Hinterspritzen von Metallfolien In this process the bonding agent of the metal film is activated by means of integrated power heaters before the plastic material is injected into the mould. This leads to a homogeneous connection between metal and plastic material, stress-relieved with high dimensional stability and a cycle time reduction by 40% at the same time. The heating and cooling is effected by the optimised multi-circuit temperature control system integrat evolution. Several segmented temperature circuits control the basic temperature of the mould body. An electric control module controls So, the dynamic temperature control system is applied twice by KraussMaffei for their exhibition highlights. With view to the cover-form procedure for the scratch-proofed coating of PMMA parts, that was developed together with Evonik, the dynamic temperature control is responsible for the initiation of the chemical reaction. By this, a reasonable integration of an expensive and until today succeeding finishing process is possible. In a second application, which presents the moulding and coating of organo sheets for structural components in lightweight construction in one step for the first time, the gwk integrat evolution technology is used. Ceramic heaters that are integrated in the mould and the corresponding control technology take over an important function in the injection moulding process. For its innovative adiabatic multi-component procedure, that the IKV developed and presented for the first time to the public on the occasion of the cluster Integrative Produktionstechnik für gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com

35 Preliminary Report K 2010 Hochlohnländer (integrative production technology for high-wage countries) the IKV as well applies the gwk dynamic temperature control system. For the production of heatable sports glasses with integrated metal conductors that were injected into the plastic material, this mould was equipped with the highly dynamic gwk integrat evolution technology as well. The processing of the metal components in the second mould station is effected by means of integrated ceramic power heaters that are integrated in the mould insert in connection with close-to-cavity temperature control channels. The temperature control of the complete system is effected by an integrat multi-circuit system. The energetic and high-quality foaming process presented by the machine manufacturer Teubert, is also based on the cyclic, dynamic temperature control in the mould. For this purpose gwk developed a 200 C version of the teco vario system, consisting of a two-circuit hot water temperature controller and a close-to-cavity energy storage and switching unit subordinated to a central control system that communicates with the machine s control system. A second system with identical construction is presented on the gwk stand. In addition to the dynamic cavity temperature control with fluid media, gwk also works on temperature control systems with gaseous media. A demonstrator presents the development status of a variotherm CO2 -temperature control system, that for the first time is heating and cooling with CO2 with minor energetic expenditures. Development partner of this innovative temperature control concept is Linde AG, Unterschleißheim as well as the ISK, Iserlohn. solutions gwk advanced the continuous expansion and modernisation of its range of single temperature control units and adapted those to the market requirements. The teco cs-series that proofed a success has been upgraded by a touch-screen with new, integrated functions. The units in standard execution, too, are now equipped with a flow meter and simultaneous indication of its set and actual values on a coloured display. The temperature profile is shown graphically according to the corresponding menu functions. By means of touching symbols on the start page, practical functions like limit comparator, leak stop operation etc. can be selected. The teco cs units can now be executed with the super fast VARAN interface. To increase the operational safety a service page shows maintenance intervals and advice in clear text indication. teco cs-units are designed for the operation with water as circulation medium and allow an use up to 95ºC/140 C/160 C. The 95 C series has been extended by three additional models with higher capacities. The new, cost-effective models are designed for larger consumers and dispose of heating capacities from 18 to 36 kw, cooling capacities from 50 to 120 kw and flow rates from 110 up to 170 l/min. As some particular applications require temperature control units that are operated with oil as circulation medium, gwk also revised the teco to series up to 180 C as well as the teco tt series up to 300 C in order to correspond to the customers requirements. Innovations With View to Standard Temperature Control Systems Apart from the development of innovative system As far as the segmented cavity temperature control is concerned, gwk has taken the requirements for higher mould temperatures into account. After an extensive testing period, the successful multi- gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com

36 Preliminary Report K 2010 circuit temperature control system integrat 40 is also available in a 140 C execution now. The temperature range of the flow meter control system integrat direct, in the past restricted to temperatures under 100 C, has been extended to temperatures teco cs Serie mit Touchscreen of 120 C. According to the customers demands the standard version has been completed by a more reasonable basic version, which still allows the control of the flow quantity in each circuit via the interface compatible integrat process control system with touch-screen operation, only the setting and modification of the water quantity has to be effected manually. By contrast, in case of the more comfortable standard version, the requested water quantity can be set and controlled automatically via touch-screen or alternatively by means of the set temperature difference between water supply and return monitored and controlled by the control system. gwk Energy-Recycling Besides the temperature control technology the company will present the latest developments in cost-reducing cooling technology at its stand under the key word gwk Energy-Recycling. It will also be represented at numerous stands of other companies that present innovative cooling and temperature control solutions. gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com

37 Preliminary Report Cooling Technology K 2010 gwk increases the energy-efficiency of water chillers by 36 % On the occasion of this year s K 2010 exhibition in Düsseldorf, gwk Gesellschaft Wärme Kältetechnik mbh, Kierspe, focuses all its energy on the topic energy efficiency and also presents in addition to innovations in temperature control, highly efficient water chillers and central cooling systems. The company located in the Sauerland will not only show the complete range of cooling and temperature control with actual themes by means of static exhibits, but also by presenting highly topical live injection moulding applications. Here the production of high-quality products with lowest energy input is in the focus of the customers attention. New intelligent composite systems reduce the energy costs as well as the CO2-consumption Trend in cooling technology is saving the utmost operating costs in the cold water production and use of waste heat for heating processes. The permanently increasing costs for fuel oil, gas and electric energy put the customer under pressure in a way, that more and more de-mands are made how many kilowatt hours have to be used for the processing of one kilogram of plastic material. Those boundary condi-tions can only be fulfilled by tailormade composite systems with integrated energysaving modules. At the K 2010 gwk presents such a composite system in connection with the two injection moulding machines, that is capable of meeting all process demands with view to the required temperatures and water quantities through a minimum energy input at the same time. This means that temperature controllers and water chillers are operated in a neatly aligned energy composite system. Of course, environmental aspects are taken into consideration here as well. So, for more than 15 years gwk has used the highly efficient refrigerant R 134a, that is chlorine-free and has no ozone depletion potential. The system pressures that are low in comparison to other refrigerants, reduce signs of wear and increase the working life of the components in the refrigerant circuit. Recalculated and technically modified evaporators and condensers as well as energetically optimised screw compressors with improved control concept lead to another capacity improvement. So, the maximum energy efficiency of the complete system can be reached and a major contribution to the reduction of CO2-emissions is made. New energy-saving modules are efficient costcutters The hermeticool cooling system shown by gwk uses the differences of night and day temperatures as well as those of the seasons in order to produce cold water for production facilities in a cost-effective manner. Here the running time of the energetically cost-intensive water chiller is reduced to a minimum. Sophisticated energy-saving modules to control the refrigerant flow and motor speed in dependence on the ambient temperature and load, increase the efficiency by 36 % in comparison to conventional systems. By means of the new gwkmotor management the actual power consumption of the fans is continuously monitored and adapted to the capacity demands via speed control, so that the lowest energy consumption is always attained. These new motors with a high efficiency rate in comparison to conventional technologies can be operated with an extremely low rotational speed, gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com

38 Preliminary Report Cooling Technology K 2010 so that in combination with the optional nighttime temperature reduction a major decrease of the sound level can be achieved. The individual operating parameters of each motor can be stored and in case of an eventually required motor exchange, be reintegrated in the comfortable motor control system. By means of different installations gwk shows, how operating costs can be reduced by 75 % compared with conventional cooling systems. Energy-saving adiabatic function now integrated in the new generation of compact water chillers up to kw nominal cooling capacity With the presentation of a compact water-cooled injection moulding machine with 180 kw nominal cooling capacity, gwk shows - in addition to the already mentioned modifications to increase the energy efficiency - now as a premiere at the K 2010 the new adiabatic technology, that is known for its maximum efficiency with a minimum water consumption. This innovative energy-saving function as well as the installation of the new high-capacity evaporator are available as integrated option in the extended SKLC-water chiller series (min. 100 kw, max kw nominal cooling capacity). In order to increase the operational safety, the new water chillers from 200 kw nominal cooling capacity upward are equipped with two separate cooling circuits. Integrated water treatment and use of waste heat guarantee high productivity while saving costs at the same time The longterm efficiency of a temperature control and cooling system is guaranteed by a water treatment system that is adapted to the process temperatures and the materials used in the machine components that are in contact with water. In the interest of short cycle times and low energy input, the production of deposits that reduce the heat transfer in the temperature control channels is prevented by a central, compact water treatment system. In such a central, completely functioning cooling unit gwk presents the whole range of required components from latest filter technologies via dosing of chemicals up to a unit for the cleaning of calcified temperature control channels. For example gwk-energy recycling components are demonstrated by using the return water of the hydraulic cooling of the two injection moulding machines for heating purposes via under floor heating and heat exchangers. Cost-efficient cooling in a gwk containerized cooling system By means of the extremely fine atomization of water in the suction area of the condensers, it is possible to extend the scope of applica-tion for the reasonable production of cold water through the ambient air without expensive compressor energy. The biggest exhibit at the gwk stand will be a central cooling system for an injection moulding process, that is completely integrated in a container. In addition to the pumps and water collection tanks for the outside mould cooling and the hydraulic gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com

39 Preliminary Report Cooling Technology K 2010 cooling installed on the roof of the container, this exhibit with a length of 10 m will also contain the equipment for cleaning and conditioning of the cooling water. A visualisation system and the gwk energy recycling components to connect a hall heating system with heat exchangers complete the containerized concept that will be applied 500 times worldwide. Beyond the presentations at its own stand, gwk will be represented with innovative cooling and temperature control concepts at a large number of other stands like for example Arburg, Krauss- Maffei, Sumitomo Demag and many more. gwk Gesellschaft Wärme Kältetechnik mbh Friedrich-Ebert-Str Kierspe Telefon: Telefax: info@gwk.com