ZWL LEIPZIG

COMPRESSED AIR WASTE: NEW ZAHNRADWERK LEIPZIG GMBH

2016

Drive heat: compressed air waste heat

Refrigeration: Factory train and machine cooling

The NZWL Group is an international manufacturer of engine and transmission parts (gears, synchronizers, shafts), gearbox assemblies and fully assembled gearboxes for the automotive industry. In order to utilize the thermal energy of its compressors more efficiently, in 2016 it commissioned two eCoo 2.0 I 10 IPS adsorption chiller units.

The cold produced in this way is used to cool tools. The company has a solution that is as economical as it is ecological - especially against the background of multi-shift operation, which requires almost constant demand for compressed air and cooling.

Drive power
46 kW
Drive temperature
70°C
Cooling capacity
24 kW
Cold water temperature
12°C
Dry cooler
dry
Operating hours
approx. 6,000 / a
Commissioning date
2016
Annual Net savings
8,300 €
Avoided CO2 emissions
76.8t p.a
Payback
3.3 years

ERKO CNC

PROCESS COOLING WITH COMPRESSOR HEAT: ERKO PRECISION AND CONTROL TECHNOLOGY

2016

More than three quarters of the heat produced by compressed air generators can be recovered for hot water systems.

The ERKO Präzisions- und Steuerungstechnik GmbH (also “ERKO CNC”) is u.a. specializing in the production of high-precision components in CNC milling and turning technology. In order to use the thermal energy of its compressors more efficiently, in 2016 it commissioned five adsorption chiller units.

The cold produced in this way is now used for cooling tools. The company has a solution that is as economical as it is ecological – especially against the background of multi-shift operation and thus an almost constant need for compressed air and cooling.

Drive source
compressors
Drive temperature
75°C
Cooling capacity (nominal)
63 kW
Refrigeration temperature
20°C
Recooling
dry
Commissioning date
2015
Running time per yearapprox.
6,000 hours
Annual Net savings
8,300 €
Avoided CO2 emissions
76.8t p.a
Payback
3.3 years

F.U.N.K.E. COMPONENTS GMBH

TURNKEY KWKK SOLUTION IN CONTAINERS: F.U.N.K.E. COMPONENTS GMBH

2015

f.u.n.k.e. Components produces around 75 million plastic articles per year on 25 injection moulding machines. The demand for energy, heat and cold is correspondingly high.

The energy-efficient and sustainable solution: FAHRENHEIT integrated a turnkey energy, heating and cooling module into the existing infrastructure. The cold generated by adsorption is now used all year round for production processes – for example for the cooling of tools. The drive heat for this comes from the CHP of the entire system. This compact CHP solution is housed in a container in a space-saving manner.

Power source
combined heat and power plant
Drive temperature
85 – 70°C
Cooling capacity (nominal)
40 kW
Refrigeration temperature
19 – 15°C
Recooling
dry
Commissioning date
2015
Running time per year
6,000 hours
Annual Net savings
8,300 €
Avoided CO2 emissions
76.8t p.a
Payback
3.3 years

GUMMIWERK KRAIBURG

PROCESS COOLING WITH COMPRESSOR WASTE HEAT: GUMMIWERK KRAIBURG

2016

The specialist for rubber floor coverings is a leading manufacturer, which relies on sustainable raw materials and environmentally friendly production: high-quality raw materials, especially old car tires, are optimally recycled through ingenious manufacturing processes.

There is hardly any waste in the production of KRAIBURG rubber flooring. The process makes it possible to recycle tailor-made products back into the recycling cycle. Another important contribution was made in 2016, together with FAHRENHEIT, namely the saving of electricity and the reduction of CO2 emissions.

The task of the FAHRENHEIT adsorption refrigeration plant is to cool a switching and server room with 72 kW waste heat from the condensate of a steam process as efficiently as possible. A highly efficient eCoo 2.0 | 30 IPS adsorption system has been implemented, which constantly reduces the temperature in the control room with 37 kW of cooling capacity to 18 ° C. Thus, the switching and server room can be cooled by adsorption cooling for a large portion of the runtime almost cost- neutral.

Drive power
72 kW
Drive temperature
90 – 81°C
Cooling capacity
37 kW
Cold water temperature
18 – 14°C
Dry cooler
dry
Compression cold
for peak load coverage
Commissioning date
2015
Annual Net savings
8,300 €
Avoided CO2 emissions
76.8t p.a
Payback
3.3 years

Alupress

Process cooling with compressor waste heat: Alupress manufacturing of aluminium die-cast components

2018

Alupress GmbH is a leading manufacturer of innovative aluminium die-cast components and systems. The company has become a key supplier for the automotive industry through continuous further development in the areas of technology and quality. Here, the environment and the economical use of resources is always viewed as a main concern.

For this reason, in 2018 Alupress chose to use the energy-saving adsorption technology from FAHRENHEIT on their site.
In collaboration with the innovative system engineers GALEK And KOWALD from Mühlhausen (Thuringia), a highly-efficient eCoo 20 X adsorption cooling system was installed. The adsorption chiller unit in this system is powered by the heat from the air compressors. A large part of the cooling capacity, approx. 41 kW, is used all year round to predry the compressed air immediately after it has left the air compressor. As such, the eCoo 20 X saves over 60 MWhe per year and pays for itself in less than 3 years.

Drive power
76 kW
Drive temperature
75°C
Cooling capacity
41 kW
Chilled water temperature
16°C
Recooler
dry
Operating hours
Approx. 8000/a
Commissioning date
2018
Payback
3 years

HERDING GMBH FILTER TECHNOLOGY

OFFICE COOLING USING FLUE GAS WASTE HEAT: HERDING GMBH FILTER TECHNOLOGY

2016

Herding® Filter technology – Pure productivity…

…not only does this mean clean, pure air, but also a more economic and environmentally-friendly use of resources. Herding GmbH Filter technology is amongst the leading manufacturers of filter media, de-dusting systems and filter systems for the industry.

Herding reduces environmental pollution during the production process and product life-cycle by minimising the use of non-renewable energies and manufacturing long-lasting products. Herding® products help to conserve the environment, protect the air, people and the environment from harmful emissions and make a significant contribution to the safeguarding of the future. The company sees it as their obligation to also put environmental protection at the top of the agenda on their own premises.

For this reason, any exhaust gases produced by the in-house filter systems are used for the CO2-neutral cooling of the server rooms and office spaces. The three photovoltaics, with an overall output of 100 kWp, also significantly contribute to the protection of the environment. Since their installation over 10 years ago, they have generated valuable solar energy and as a result save around 52.4 tons of CO2 per year. In addition, the company has installed 4 charging stations for electrical vehicles that Herding employees and customers can use for free.

During the summer months, Herding employees can enjoy the environmentally-friendly air-conditioning, made possible by an adsorption system from FAHRENHEIT, which can actually be easily used over the existing underfloor heating.

Simply clever.

Adsorption cooling system
eCoo 2.0 | 20 IPS
Location
Amberg
Commissioning date
2016
Heat source
Waste heat from production processes
Drive temperature
80/65°C
Cooling capacity
26 kW
Chilled water temperature
17/21°C
Cold distribution
Fan coil (Server)
Recooling
dry
Economic efficiency
Avoided CO2 emissions
Net savings
19.7 to /p.a.
Payback
<3 years