1. Lou Zavala, National Sales Manager – Frigel North America
Intelligent Process Cooling: Saving Money, Protecting the Environment and Curing Process Headaches
Lou Zavala, National Sales Manager – Frigel North America

2. Presentation Overview
The state of today’s manufacturing resources
Traditional process cooling technology vs. the intelligent process cooling alternative
Opportunities for water, energy and chemical savings while greening your operations
Improved productivity through implementing a central chiller alternative
How process cooling can improve your profitability and ability to better serve customers

3. Today’s manufacturing resources

4. Energy use in manufacturing
Approximately 92% of a manufacturer’s energy consumption is attributed to processing machinery and associated services
16% of that energy goes to process cooling (chillers & pumps)
Energy savings of 25% are easily achievable with virtually no technical risk
Improperly maintained cooling towers lose heat transfer efficiency and scale causing chillers to consume 2.5 to 3.5% more energy for each degree rise in condenser temperature
Source: Dr. Robin Kent, “Energy Management in Plastics Processing – Strategies, targets, techniques and tools” and U.S. Department of Energy

5. Energy cost and consumption trends
By sector, nominal2 prices,
Source: US Government Energy Information Administration

6. Water use in manufacturing
Industry uses 22% of the earth’s available clean water
That number increases to 45% in developed countries
One of the top 5 ways water is wasted in industry is inefficient and poorly maintained methods for cooling
In process cooling, over consumption occurs as a result of evaporation and blow down
Source: Arlington Institute “Global water crisis overview” and Water Wise “How to save water in the workplace”

7. Water considerations
Water is likely to be the most important strategic resource by the end of the next decade
Clean water is one of the major concerns of the U.N.
Local governments are imposing high disposal costs for concentrated and contaminated fluids
This includes cooling tower waste water in some areas
Source: The World Bank and IATP “Bio-fuels and global water challenges”

8. Traditional solutions for process cooling

9. Cooling tower basics Temperature: 85°/90°F Open System
Method of heat rejection = water evaporation
The center of industrial cooling for over 80 years

10. Cooling tower costs Continuous water consumption
evaporation & blow down loss
Increasing costs for water & fluid disposal
Ongoing water treatment
Regular heat exchanger maintenance
Very high pumping energy consumption
Changing laws and regulations
Constant fan operation creates energy waste

11. Cooling tower disadvantages
Poor quality water to process
Harmful emissions
Difficult cold-weather operation
Permanent contamination hinders heat transfer and performance
Water evaporation & blow down loss
Contaminated air in the system creates contaminated process water

12. Cooling Tower: Very high pumping energy consumption
Nozzles
Nozzles
Open circuit tower system
Closed circuit tower system
Plate heat
exchanger
1st Filtering
process
process
Filtering
2nd Filtering

13. Effect of a Scale layer on Heat Transfer
Effect of Scale on Energy Consumption of Chillers
Thermal Conductivity of Microbiological Film and Calcium Carbonate Scale

14. Traditional set up
Open tower water consumption is up to 1.3 million gallons annually/ 100 tons of cooling due to evaporation, drift and blow down based on water quality
Centralized chiller system utilizes more energy to achieve flow & pressure at the process
Thermal gain increases as distance increases
Two sets of insulated pipes needed 1 4 3 2

15. Intelligent process cooling

16. Intelligent process cooling set up
Closed-loop, dry-cooling technology using ambient air to cool process water
Small reservoir tank for automatic draining in cold temperatures to avoid freezing
Single set of non-insulated pipes for simple and inexpensive installation
Machine side temperature controller/ chiller for high performance cooling 1 3 2 4

17. Intelligent cooling basics
Temperature: 90°/95°F
Closed System
Method of heat rejection = air heat exchange
Revolutionizing process cooling

18. Intelligent cooling cost savings
Dramatically reduced energy consumption
Lower pumping capacity
No continuous water or chemical consumption
No fluid disposal saving fees and the environment
Little to no downtime
Free cooling opportunities

19. Intelligent cooling advantages
Clean water to process
No scale/corrosion on heat exchangers or piping
Constant efficiency of process equipment for better productivity
Minimal maintenance
Simple & expandable system
Decreased green house gas emissions

20. How intelligent cooling works
Process water is pumped through heat exchangers and cooled by ambient air
Additional air flow is generated by axial fans with variable DC motors
Water temp is held <10°F above out-door dry bulb temperature and to operating range set at control

21. Adiabatic cooling for minimum water consumption
Ambient air at high temperature passes through the adiabatic chamber
In the chamber, spray nozzles create a think mist of water
The humidification of the air drops its temperature before it reaches the coils
The sprayed water volume is automatically controlled by microprocessor
Finned coils are kept completely dry and free of scale

22. Brushless DC Fans Motors with individual automatic control of speed The Lowest Energy Consumption
0.03 kW/ton*
Extremely high efficiency under partial load operation (reduced speed)
Annual average consumption less than 0.03 kW/ton
Very quiet operation – less than 57 dB(A)
Increased reliability and durability, maintenance free
Each fan can be substituted with the equipment running
* Based on LWT = 90F in LA, CA

23. How intelligent cooling works
Adiabatic mode keeps LWT below 90 to 95°F even with ambient temps of 120°F
On cold days with little or no heat load, recirculation pumps turn off and unit drains fully, providing 100% freeze protection
Control and software provide a fully-automatic water and energy savings based on actual thermal load and outdoor temps

24. Intelligent water & energy savings
Water savings
Only during high outdoor temperatures does the system switch to adiabatic mode, minimizing the time additional water may be needed
Example: A typical 100-ton cooling system uses as much as 1.5 million gal/year, intelligent process cooling with the same capacity requires only 20,000 to 40,000 gal/year
Energy savings
During low outdoor temperatures or partial load operation, specialized controls automatically adjust pumps and fans to start and stop as needed, rather than running constantly
Example: A typical 100-ton chiller system operates with 0.8 to 1.2 kWh/ton energy consumption, intelligent cooling uses only 0.05 kWh/ton

25. Free cooling opportunities
Free cooling is defined as using non-refrigeration cooling methods
This generally means using an ambient-air closed-loop cooling system to supply clean cooling water and replacing chillers or turning off chiller compressors.
Many processes can benefit from free cooling depending on process set points and local ambient conditions

26. Boston/Logan, MA Dry-Bulb Temperature Hours For an Average year (period of record 1967-1996)
Water Savings Period Above 85°F 175 hrs 2 % Energy Savings Period Below 40°F 3334 hrs 38%
This summary reflects the typical distribution of temperature in a typical year. It does not reflect the typical moisture distribution.

27. 100 ton tower VS 100 ton Ecodry

28. Improving productivity through enhanced process cooling

29. Process cooling using central chillers
A standard central chiller system is often supplied cooling water by a tower system
They supply single temperature water to multiple processes within a plant and require a large pumping station to distribute the water
Energy loss occurs due to large pumping stations, thermal losses as the water travels to process machines and scale and bio-film buildup in the heat exchangers
It is extremely difficult to get precise water temperature to all process machines causing quality to suffer and loss of profitability

30. Intelligent process cooling at the machine level
Machine side units adjust for required temperature, flow and pressure individually
Cooling parameters optimized at each machine for better quality parts, less scrap and total repeatability with cycle time improvement of up to 20%
As an alternative to central chillers, saves up to 80% on energy costs due to no thermal losses and additional pump HP

31. Achieving maximum productivity and part quality
Maximum productivity = minimum mold temperature
Achieve minimum cooling water temperature
With independent temperature control at each machine
With a high flow rate in the mold assuring max efficiency of heat exchange and minimum ΔT across the mold
High quality product = automatic control of mold temperature
Automatic controls allow for
The ability to “research” the best temperature for each process
Perfect repeatability of the process cooling conditions

32. Injection Molding: Cooling time dominates cycle time
Time (sec)
from 40% of cycle time (high speed packaging)
up to 90% of cycle time (engineering resins)

33. Machine side control: shorter cooling time + better mold symmetry
Mold Temp. Control by flow restriction
(Central Chiller + flow-meters)
LOW FLOW RATE (laminar)
VERY HIGH DT = 20°F
Longer cooling time
Variable wall thickness
High residual tensions
Mold inlet sweating
Higher mold maintenance
and damages to machine
Higher refr. cost
Dedicated Mold Temp. Control
HIGH FLOW RATE (turbulent)
LOW DT = 2°F
Shorter cooling time
Constant wall thickness
Higher stability of part
No mold sweating
Symmetric efforts
on molds & machine
Lower refrg. cost
INCREASED QUALITY = LESS SCRAP

34. Improve profitability and ability to serve customers

35. Look to process cooling to…
Increase profitability and competitiveness
Low operating costs, simple installation, increased productivity
Sustain performance and profits
Consistent and efficient system, total repeatability
Reduce cost of labor, energy and water
No process water consumption, reduced electrical consumption, virtually maintenance free
Address environmental concerns, regulations and pressures
No ongoing chemical consumption, minimal environmental impact

36. Will you be a champion for the future?
The power to change
Changing established methods requires teamwork and extra effort
Company leaders are encouraging and supporting sustainability process improvements
Key champions/functions for change
Maintenance, process/production, health safety and financial managers
The rewards and satisfaction to the new approach is high and proven by thousands
Will you be a champion for the future?

37. The power to save
Rebates from state and local government, as well as utilities, are available for manufacturers implementing energy saving technology
Tax incentives are also available in 2009 giving depreciation deductibles of 60% for new equipment placed in service by the end of the year

38. The power to outperform
Manufacturers often overlook the full potential of cooling technology to improve product quality, increase productivity and reduce operating costs

39. MAPP Member Exclusive Offer
Free spare parts kit equal to 5% of the value of any Ecodry System order in 2010
In addition to the fast ROI realized from energy, water, maintenance, chemical and downtime savings and process improvements
To take advantage, contact us at or and let us know you want 5% in free spare parts as a fellow MAPP member

40. Intelligent Process Cooling Questions?
Frigel’s Ecodry represents a revolutionary way to improve process stability, gain a competitive advantage and experience the economic benefits.
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