seals

Aqua Seals The Deal With Retro-Fit Free Cooling

The Client –

London Based Seal Manufacturer


The Challenge –

Increase Energy Efficiency Of Existing System


The Solution –

Free Cooling Upgrade

For a client running air cooled chiller units to feed their injection moulding hall, the simple addition of a bolt-on Free Cooler to their existing cooling system is forecast to save them over £34,000 in energy costs every year.

Our London based client specialises in producing seals and sealing solutions which are used in the fluid power industry worldwide. Their production facility runs 24/7, so it’s essential that any system downtime is kept to an absolute minimum.

The benefit of adding Free Cooling into a system is that overall power, or energy use, is greatly reduced. Because the lower ambient air temperature is used to cool the process return water wherever possible, the need for mechanical cooling is much less. In addition, by reducing the running time of the equipment you automatically extend its lifetime and lower lifetime maintenance costs. You also gain built in redundancy – if your chiller fails the Free Cooling side can still operate.

The technology within the Free Cooling unit senses both the return fluid temperature and the ambient air temperature. When the ambient is lower than the return water temperature, the fluid is passed through a coil that exchanges the heat in the fluid to the ambient air, using just the mechanical effect required to drive the fans to pull the air through. This means the load is either partially or totally (in the winter months in the UK) reduced – giving partial or full Free Cooling.

Our client already had two chillers on site, to which we added a 280kW Free Cooler. Whilst their system operated on plain, we added a heat exchanger between the system and the Free Cooler, so the latter could run on glycol to prevent freezing during extreme temperatures.

Full system included:

  • 280kW free cooler
  • 280kW heat exchanger
  • Single pump & tank

As the site operated 24/7 the client allocated our installation engineers just a 3-hour window one Monday morning to break into the existing system. Using isolation values, our engineers could then continue with the Free Cooler install whilst production restarted.

Installed in the Autumn, whilst being monitored for the first 3 weeks of running the system operated solely on Free Cooling. Due to the energy savings our client is on target to receive complete system payback in just over one year.

Aqua Sales Manager, Shaun Lancaster, explains; “This is a fantastic example of how retro fitting free cooling can really make an impact when it comes to putting money back on the bottom line. By lowering the plant’s running costs we’ve helped our client increase gross profit without even involving their sales team!”

free cooling

windows

Anglian Windows Carbon Home Improvements

The Client –

Windows And Doors Company


The Challenge –

Improve Energy Efficiency And Costs At Production Sites


The Solution –

Resize Chillers And Add Free Cooling

Anglian may already be well known for producing energy efficient windows and doors, but over the last year they have been taking a detailed look at the energy efficiency and related costs at their own production sites. Anglian employed specialist energy consultants Energy 2000 to establish an energy management programme for the company.

Detailed scoping studies were undertaken at six main sites to establish the current energy usage habits, with every significant item of manufacturing equipment being monitored and logged. Reports were then produced identifying all potential energy saving measures, from no cost/low cost recommendations through to high capital expenditure projects.

It was identified that the water chilling plant for the plastic extrusion process was consuming a large proportion of the Norwich site’s total usage and further investigations confirmed the inefficiency of the current plant. A recommendation was put forward to replace the chilling plant with the introduction of a “free cooling” process to meet current demand. In addition, new chillers were sized to give an extra 50% capacity as provision for future expansion.

Aqua Cooling Solutions were recommended by Energy 2000 and were chosen to provide the equipment and to install and commission the 1.6 MW system. The integral free cooling facility uses the ambient air to cool the process water as soon as the ambient air temperature falls below water temperature returning from the extrusion machines.

The system has been closely monitored since start-up in August and it is calculated that Anglian will save over 850 tonnes of carbon per annum, equating to a financial saving of approximately £175,000 per year. The entire cost of the new cooling system will be recovered by energy savings made within just the first two years of operation.

Chris Dixon is Engineering Director at Anglian Windows. “With energy costs beginning to spiral upwards, and with our commitment to reducing our Carbon Footprint, we needed to implement a comprehensive Energy Management Programme. We accepted that this required specialist skills and, therefore, made the decision to outsource. Energy 2000 were selected as our partner because of their positive approach, cost effectiveness and their commitment to work with, and not just for, Anglian. We have enjoyed a very successful first year with Energy 2000. Savings have been identified and prioritised and, with their pro-active approach and Aqua’s equipment, we will continue to drive down our energy costs and reduce our carbon emissions.”

Aqua’s Director, Kevin Lancaster, comments: “We were delighted to be recommended by Energy 2000 for the Anglian Windows project. Aqua are committed to coming up with innovative, energy efficient solutions for clients and the Anglian system is an excellent example of how the free cooling concept can have a considerable impact, both from an environmental and financial point of view, in a relatively short space of time.”

anglian

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