Free Cooling freezes energy costs by up to 70%
23/10/2013 ICS Cool Energy Ltd
With the record breaking highs of summer 2013 now behind us, it's a good time to remind ourselves of the benefits of the UK's more traditional cooler climes and how the plastics industry can utilise such impending low ambient air temperatures to save energy and reduce cooling costs by as much as 70%. Here, the engineering team at ICS Cool Energy tell us more, and provide a technical case study showing exactly how a Midlands-based plastics company are reaping the benefits of Free Cooling technologyFree Cooling is a fast, effective and economic method of utilising low external air temperatures to assist in the cooling of water for industrial temperature control applications or in HVAC (heating, ventilation and air conditioning) systems. Within industrial temperature control applications a free cooler can be installed in series with a chiller system's evaporator so in lower ambient conditions, partial or 100% Free Cooling can be achieved.
According to official Met Office statistics, last year the UK experienced some of the lowest temperatures on record during the winter months, and Free Cooling could have saved many process or HVAC applications thousands of pounds in energy costs. When in low ambient conditions, Free Cooling methods remove the need to use a chiller's compressors, utilising external cold air to cool water through a free cooling unit, which in turn can be used for a process or building's cooling needs.
There are two main options available to achieve Free Cooling:
· A chiller working alongside an Independent Free Cooler
· A chiller with an Integral Free Cooling coil
Independent Free Cooling
A dedicated Independent Free Cooler is designed to maximise the energy efficiency benefits of a circuit, and is not restricted by the size of a chiller. An independent Free Cooler has a greater capacity for heat exchange as it is sized to maximise efficiency, enabling a greater area for the transfer of thermal energy.
An independent Free Cooler is installed in series with the chiller system's evaporator, so that in lower ambient temperatures, partial or 100% Free Cooling can be achieved, and can result in massive energy savings. This method of operation utilises naturally low ambient temperatures, and in doing so, benefits from a reduction in energy costs which can reach as much as 70%.
By combining a class A energy-efficient scroll compressor chiller with an independent free cooler, maximum savings can be achieved when compared to standard screw compressor chiller.
As the ambient air temperature drops three to five degrees below the required process supply water temperature, 100% Free Cooling can be achieved, consequently providing an environmentally friendly and cost effective approach to process and HVAC cooling.
Free Cooling can be applied to both new, and existing chiller systems through the use of Free Coolers which are uniquely balanced to provide the greatest levels of efficiency at both full and partial loads.
Integral Free Cooling coils
Where space is limited, Free Cooling can be achieved through integral Free Cooling coils. The units are designed to offer high energy efficiency levels in all seasonal conditions and provide a more compact footprint.
Energy efficiency and savings
Whichever avenue of Free Cooling is adopted, the benefits remain constant: increased reliability as each system monitors temperature and automatically switches from 100% compressor load to partial or total Free Cooling as climate conditions allow; use of ambient air temperature in place of compressors to facilitate Free Cooling and savings on running costs; and less wear and tear on chiller components and consequently a reduced life-cycle cost.
Case study: Plastics
ICS Cool Energy has recently supplied equipment to support Free Cooling technology to a manufacturer of plastic window profiles in the Midlands to maximise efficiencies.
ICS Cool Energy implemented Free Cooling technology and supplied a one-off Imperium 2197 CA chiller with screw compressors and twin R134a refrigeration circuits, to produce 580kW cooling capacity with a supply temperature of 13°C and a return of 18°C at 28 litres/second.
The units work with Free Cooling technology and can be used during spring, summer nights, autumn and winter months by using ambient air helping to save up to 68% on the plastic manufacturer's annual energy bill.
After saving over £50,000 following use of the Free Cooling units, the plastic manufacturer has since reinvested in a second machine in the bid to achieve even further savings and fully reap the benefits that Free Cooling technology can offer.
For more information, please contact:
ICS Temperature Control
ICS House
Stephenson Road
Calmore Industrial Estate
Southampton
Hampshire
SO40 3RY
Tel: 0800 169 3861
Email: info@icstemp.com
Web: www.icstemp.com
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