{"id":73988,"date":"2018-08-06T00:00:00","date_gmt":"2018-08-06T00:00:00","guid":{"rendered":"https:\/\/ics-cool-energy.local\/case_study\/replacement-chiller-increases-cooling-capacity-and-reduces-energy-costs\/"},"modified":"2024-01-30T11:41:58","modified_gmt":"2024-01-30T11:41:58","slug":"replacement-chiller-increases-cooling-capacity-and-reduces-energy-costs","status":"publish","type":"case_study","link":"https:\/\/www.icscoolenergy.com\/ie\/case-studies\/uncategorized\/replacement-chiller-increases-cooling-capacity-and-reduces-energy-costs\/","title":{"rendered":"Replacement chiller increases cooling capacity and reduces energy costs"},"content":{"rendered":"<h2><strong>The Challenge<\/strong><\/h2>\n<p>A manufacturer and bottler for some of the world\u2019s most prestigious beverage brands needed to replace an aging 650kW chiller due to a controller failure that subsequently caused the evaporator to rupture and freeze.<\/p>\n<p>The chiller provided cooling to three pasteurising lines. Lines 1 and 2 can produce up to 24,000 ltr\/hr of carbonated product and the third up to 11,000 ltr\/hr.<\/p>\n<p>To maintain production, the client was forced to install a rental chiller to provide temporary cooling which was less efficient and not a low-noise version.<\/p>\n<h2><strong>The Solution<\/strong><\/h2>\n<p><strong>Site visit and cooling load calculation:<img loading=\"lazy\" decoding=\"async\" class=\" wp-image-34077 alignright\" src=\"https:\/\/www.icscoolenergy.com\/ie\/wp-content\/uploads\/sites\/6\/2024\/01\/Replacement-chiller-increases-cooling-capacity-and-reduces-energy-costs-1-231x300.jpg\" alt=\"Replacement chiller\" width=\"303\" height=\"412\" \/><\/strong><\/p>\n<p>Thanks to a recommendation from the pasteurising line specifier, ICS Cool Energy were asked to visit the site and carry out a survey and consultation to determine their exact cooling requirements and address any operational needs.<\/p>\n<p>Lines 1 &amp; 2 were calculated to require 800kW (150kW more than the previous chiller provided) of cooling with a fluid supply temperature of 0\u00b0C. Line 3 had a cooling load calculated at 320kW with a fluid supply temperature of 5\u00b0C.<\/p>\n<p>Lines 1 &amp; 2 run for 24 hours a day, 7 days a week, whereas line 3 can operate for as little as 1 day per week, depending on production demands. The total cooling load required for maximum production on all three lines was calculated at 1,120kW.<\/p>\n<p>To support the manufacturer\u2019s environmental policy, the consultation period considered several low GWP refrigerant options, including ammonia.<\/p>\n<p><strong>Chiller Specification:<\/strong><\/p>\n<p>To provide the manufacturer with options to make a reduction in energy consumption and meet potential budget restrictions, the ICS Cool Energy sales engineer proposed two cooling solutions.<\/p>\n<p>The most energy-efficient solution included two chillers; one to provide chilled water at 0\u00b0C to lines 1 &amp; 2 and a second chiller to provide chilled water at 5\u00b0C to line 3. This was supported by a detailed energy analysis audit which demonstrated that an energy saving of 3% per annum and a Co2 reduction of 48,950 tons per annum could be made in comparison to a single chiller serving all three lines.<\/p>\n<p>To reduce the initial capital expenditure, the decision was made to phase the project. Phase one comprised of a single 800kW chiller, with phase two allowing for line 3 to be separated from the main hydraulic circuit and to be fitted with the second chiller unit.<\/p>\n<p>The first of the two chillers specified was the <a href=\"https:\/\/www.icscoolenergy.com\/ie\/sales\/product\/screw-compressor-chiller\/\">Imperium<\/a> RTAF 310 SE XLN unit which offers several benefits in comparison to the previous chiller:<\/p>\n<p>\u2022 The unique patented evaporator design offers a reduction in refrigerant charge of 48%<br \/>\n\u2022 The 3 fixed speed stepless capacity-controlled screw compressors provide improved part load performance<br \/>\n\u2022 By utilising R513A refrigerant with a GWP of 631 compared to R134a with a GWP of 1430, the manufacturer\u2019s environmental policy on the use of low environmental impact refrigerants was met<br \/>\n\u2022 The extra low noise option including the use of EC fans with axitop meets the required sound power levels at the manufacturer\u2019s boundary without impacting on footprint<\/p>\n<h2><strong>The Result<\/strong><\/h2>\n<p>The extra cooling capacity offered from the <a href=\"https:\/\/www.icscoolenergy.com\/ie\/sales\/product\/screw-compressor-chiller\/\">Imperium<\/a> RTAF 310 SE XLN (chiller 1) will allow lines 1 &amp; 2 to operate at maximum capacity (an increase of 36%) which has never been achieved in the past.<\/p>\n<p>Now only requiring a single pass through the pasteuriser to cool the product and with an increase in thermal output, the new chiller has provided a 40% increase in production.<\/p>\n<p>As well as increasing their cooling capacity by 36% and production by 40%, the efficient <a href=\"https:\/\/www.icscoolenergy.com\/ie\/sales\/product\/screw-compressor-chiller\/\">Imperium<\/a> RTAF 310 SE XLN unit will:<\/p>\n<p>\u2022 Save them 4% on energy costs when compared to the incumbent unit<br \/>\n\u2022 Use 48% less refrigerant and the lower GWP, more environmentally friendly R513a<br \/>\n\u2022 Occupy a smaller footprint, which means less installation costs and production down time moving equipment to accommodate<br \/>\n\u2022 Meet sound power levels<\/p>\n<p>The <a href=\"https:\/\/www.icscoolenergy.com\/ie\/sales\/product\/scroll-compressor-chiller-range\/\">Aptus<\/a> CGAF chiller installed in the second phase will supplement the cooling capacity further and enable production on line 3.<\/p>\n<p>A secondary chiller also means that the manufacturer has a contingency plan if the main chiller was to fail and enables them to plan more thorough maintenance without halting production.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>The Challenge A manufacturer and bottler for some of the world\u2019s most prestigious beverage brands needed to replace an aging 650kW chiller due to a controller failure that subsequently caused the evaporator to rupture and freeze. The chiller provided cooling to three pasteurising lines. Lines 1 and 2 can produce up to 24,000 ltr\/hr of &#8230; <a title=\"Replacement chiller increases cooling capacity and reduces energy costs\" class=\"read-more\" href=\"https:\/\/www.icscoolenergy.com\/ie\/case-studies\/uncategorized\/replacement-chiller-increases-cooling-capacity-and-reduces-energy-costs\/\" aria-label=\"More on Replacement chiller increases cooling capacity and reduces energy costs\">Read more<\/a><\/p>\n","protected":false},"author":8,"featured_media":73989,"menu_order":20,"comment_status":"closed","ping_status":"open","template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"_editorskit_title_hidden":false,"_editorskit_reading_time":0,"_editorskit_is_block_options_detached":false,"_editorskit_block_options_position":"{}","editor_plus_copied_stylings":"{}","footnotes":""},"applications":[],"products":[],"topics":[],"product_cat":[],"class_list":["post-73988","case_study","type-case_study","status-publish","format-standard","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v24.5 (Yoast SEO v26.9) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Replacement chiller increases cooling capacity and reduces energy costs | Ireland<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.icscoolenergy.com\/ie\/case-studies\/uncategorized\/replacement-chiller-increases-cooling-capacity-and-reduces-energy-costs\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Replacement chiller increases cooling capacity and reduces energy costs\" \/>\n<meta property=\"og:description\" content=\"The Challenge A manufacturer and bottler for some of the world\u2019s most prestigious beverage brands needed to replace an aging 650kW chiller due to a controller failure that subsequently caused the evaporator to rupture and freeze. 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