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PROCESS COOLING APPLICATION

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COOLING PLUS RANGE OF MULTIPLE SCROLL CHILLERS FROM 1 TO 480 KW ALSO AVAILABLE WITH FREE COOLING

WATER COOLED CHILLERS WITH REDUCED FOOTPRINT FROM 3 KW TO 2.5 MW

BIG EVOLUTION SCREW CHILLERS INDUSTRY LEADING EFFICIENCY UP TO 1.3 MW SUPER QUIET AND FREE COOLING OPTIONS AVAILABLE

COOLING PLUS ENERGY MULTIPLE SCROLL CHILLERS SBS SERIES WITH MULTIPLE INDEPENDENT CIRCUITS UP TO 1MW

WITH FREE COOLING OPTION AVAILABLE

RECENTLY INSTALLED SYSTEM IN THE UK FOR A MAJORCHEMICAL PLANT TO A HIGH SPECIFICATION REQUIREMENTAND OPERATING DOWNTO -25 C WITH A COOLING LOAD OF 320 KW

TURBOCOR LINE LIQUID CHILLERS WITH OIL FREE TURBOCOR COMPRESSORS AND FLOODED EVAPORATOR 200 KW - 1600 KW

HITEMA, an international Italian Company with 15.000 square meters workshop located in Bovolenta - Padua close to Venice, one of the most wonderful historical city in Italy.

SEARCHING FORRESELLERS

independent refrigeration circuits (mod. 130÷480).

The SBS/SBSF models are all equipped with shell & tube evaporator, modular aluminum finned copper coil condensers, mounted in V configuration, axial fans and scroll compressors (up to 6 compressors) installed on two or on request, three independent refrigeration circuits.

HVAC designs for Data Centre – Total Load 1.5 MWIn the refrigeration and air conditioning sector continuous attempts are made to reduce the energy consumption of all systems by improving the management of cooling power, optimizing the flow paths of water-glycol and providing greater temperature accuracy. Recent research has developed the use of environmentally friendly refrigerants with lower environmental impact and excellent thermal performances. However, large refrigerant equipment still have very high power requirements, especially those demanded from very large air or water cooled chillers with screw compressors. The utilization of screw compressors is traditionally very high amongst larger capacity chillers (>300 kW) and therefore the optimization of partial load performance, which is a condition present in almost all refrigeration plants at various stages throughout the year, is deemed as the goal by Hitema. A modern and intelligent technology is to control the large power demands of screw compressors by inverter driven

electronic devices.

Advantages offered with the Inverter TechnologyAn inverter (VDF) is an electrical device acting on the variation of voltage and frequency. The inverter uses the line alternate voltage (a.c.) to produce a direct voltage (Diode Bridge - d.c.). From this direct voltage an alternate voltage is regenerated (PWM technique) with a frequency f between 0 and fmax (maximum frequency) and voltage V<Vnet (electric net voltage).

Inverters are widely used in film-polyester capacitor configuration, which is similar technique used on photovoltaic plants. The absence of electrolytic materials avoids the early aging due to the temperature, currents and stocking periods. The current distortion THDI is much lower than is electrolytic capacitors since the equivalent electrical capacity is lower. Moreover the compactness and longevity of inverters above film capacitors is also a consequence of superior effectiveness of cooling directly with liquid refrigerant line.

With this technology, the partialization of cooling capacity is achived by reducing the number of revolutions of the motor that drives the compressor or in other terms reducing its power supply frequency. The rotation speed of the screw is adjusted according to the instantaneous thermal load to be disposed. High thermal loads requiring high flow rates of refrigerant gas, so high rotational speeds and low thermal loads

Improved energy efficiency of air cooled chillers

In the last 10 years awareness in energy saving has

continuously increased in both industrial and HVAC

applications, at Hitema we strive to reduce the electrical

consumption of cooling equipment using the most effective,

innovative and efficient techniques. In the refrigeration

and heat pump sectors European standards and directives

are now applied to increase the standard of materials

used, increase innovation and in the application of new

technologies to improve refrigeration system efficiencies.

New ENR/ENRF SERIES from 1 to 480 kW

The ENR/ENRF and SBS/SBSF are chillers from our Cooling Plus Energy series with air cooled condensers operating on R-410A, which can also

come with complete “Free-cooling” sections (only for models ENRF and SBSF) to guarantee energy savings.

The ENR/ENRF units are equipped with either stainless steel plate type, self-cleaning coaxial or shell & tube evaporator, aluminum finned copper condenser, axial fans and rotary compressor (mod. 001÷005) or scroll compressors (mod. 008 ÷480, up to 4 compressors) installed on one refrigeration circuit (mod. 001÷100) or two

T E C H N O L O G Y

allow you to work at lower speeds. Going to intervene on the rotation speed of the motor, the absorbed power by compressors is reduced and thus the energy consumption, as opposed to a machine with screw compressor without inverter that operates at constant speed. The application frequency range was widened between 30 Hz to 130 Hz.

Main advantages are:• The starting current is effectively equal to 0, as the current is directly proportional to frequency, the inverter starts the screw compressor with no frequency and it causes an absorption equal to 0, as opposed to a machine with a standard screw compressor without inverter, that would have a typical inrush current when they are started.

• Cooling power can increase up to 20% above the optimal cooling power at 50 Hz, this is because the screw compressors can rotate with higher gears reaching higher frequencies up to 130 Hz.• Higher operating flexibility due to large envelope of control (from 16% to 100%, widest modulation range on the market) and higher power density.• Reduced electrical consumption at partial load between 30 Hz and 50 Hz compared to a standard screw compressor with a slide valve capacity control system. This results in a measured absorbed power being reduced by up to 15%.

Figure 2 – Comparison at typical ESEER conditions for

air cooled chillers

• Reduced CO2 emissions by cutting electrical consumption at partial load.• Superior control of water outlet temperature exhibiting less fluctuation around the set point temperature. Typically tolerances of around +/- 0.5°C are possible.

• Reduced mechanical compressors wear, as the screw will rotate for most of year with reduced r.p.m. (higher MTBF).• Inverter technology with screw compressor variable Vi, using automatic control of Vi the performances of chiller increase.

High-efficiency chillers with magnetic oil-free compressorsNot only screw compressors can use the inverter technology. Another solution recently adopted from Hitema in collaboration with Arctic Cool Chillers Limited, are the Danfoss Turbocor compressors. The Turbocor compressors are centrifugal oil free compressors with magnetic bearings. This

type of compressors has all the advantages of inverter technology and need less maintenance because they are oil-free.

Friction-free magnetic bearings reduce the maintenance costs associated with oil service. One moving part (motor rotor shaft and impeller assembly) is levitated

New SBS/SBSF SERIES from 240 to 1000 kW

Figure 1 – Soft start characteristic

Figure 3 – On left, a semi-hermetic compact screw compressor with integrated frequency inverter mounted in a Hitema chiller. On right diagram of necessary components for inverter technology: line reactor filter (2) and RFI filter (1), this last only required in residential areas according to EU EMC directive (2004/108/EC) and EN 61008-3.

during rotation by a digitally controlled magnetic bearing system, consisting of one axial and two radial bearings, which completely eliminates any metal-to-metal contact and wear surfaces. Sensors at each magnetic bearing monitor the shaft location 100,000 times per second ensuring precise positioning of the shaft.

The advantages of inverter technology in numbersTable 1 shows a comparison between three compressors that having the same capacity under the same operating conditions, working at full load.

Figure 4 – On left, a cross section of Turbocor compressor. On right, the diagram of shaft with the magnetic bearing.

This simple comparison shows another interesting aspect in the use of compressors that use inverter technology compared to compressors that do not: the dimensions and weights are much lower, this is especially true for the Turbocor due to the fact that they are centrifugal compressors instead of volumetric compressors. Finally, in terms of noise again the Turbocor compressors have a sound pressure level measured at 10m well below the most classic screw compressors.

In the European market the adopted index to classify chiller performance is E.S.E.E.R. (European Seasonal Energy Efficiency Ratio) and this is in accordance with

E.E.C.C.A.C. proposal (Energy Efficiency and Certification of Central Air Conditioner). The formula used to calculated this is:

ESEER= 0.03 x EER(100%) + 0.33 x EER(75%) + 0.41 x EER(50%) + 0.23 x EER(25%)

The EER value (%) is the efficiency of chiller at 100%, 75%, 50%, 25% of load under various conditions in accordance with Table 2:

Table 2 - Weighting factors of part load efficiencies for calculating European Seasonal Energy Efficiency Ratio.

Figure 5 and Figure 6 show the advantage of inverter technology in two practical cases: Figure 5 shows the EER how varies as the load varies and the ESEER for three air-cooled chillers product by Hitema with about the same cooling capacity; Figure 6 show the same thing but for three water-cooled chillers.

BRAND BITZER BITZER DANFOSS

Model CSH8583-125Y-40P CSVH24-125Y-40A TT300-H6-1-ST-E-O-CE

Description semi-hermetic screw semi-hermetic screw centrifugal compressor compressor compressor with integrated with integrated frequency frequency inverter inverter

Length [mm] 1540 1434 788Width [mm] 691 664 518Height [mm] 712 652 487Weight [kg] 860 735 120*Sound Pressure Level [dB(A)] 64,1 66,1 53,5

Table 1 – Comparison between compressors that having a cooling capacity of about 290kW for the 100% of load, condensing temperature of 40°C and evaporating temperature of 3°C. *Sound pressure level referred to measures according to normative ISO3744, pressure level at distance of 10m, referred to free field on reflecting surface.

Figure 5 – Comparison between three air-cooled chillers: Hitema model EET.750 with twin semi-hermetic screw compressors; Hitema model ITC.770 with twin semi-hermetic screw inverter driven compressors; Hitema model AHA.760 with Turbocor compressors. Each models are equipped with economizer and condenser with cooper tubes and aluminum finned core. The models EET.750 and ITC.770 have fitted shell & tube evaporator and AC fans regulated with fan speed regulator (cut phase). The model AHA.760 have fitted flooded evaporator and EC fans. The refrigerant for all models is R134a.ÅÅ

Figure 6 – Comparison between three water-cooled chillers: Hitema model ECWH.630 with twin semi-hermetic screw compressors; Hitema model ECWH.630 with twin semi-hermetic screw inverter driven compressors; Hitema model AHW.630 with Turbocor compressors. Each models are equipped with shell & tube condenser. The models ECWH.630 have fitted shell & tube evaporator and the model AHA.760 have fitted flooded evaporator. The refrigerant for all models is R134a.

From these two figures it can be seen that the use of compressors with inverter technology leads to an increase in the efficiency of chillers especially at partial loads with a consequent reduction in power consumption. This is especially true for models fitted with Turbocor compressors. Also you can see a higher EER for the water cooled chillers in comparison of air-cooled chillers due to the lower condensing temperature and the absence of energy consumption by the fans mounted in the air-cooled models.

For chillers with screw compressors installed with inverter control and variable Vi compressors, the increase achieved in ESEER is around 14% for air cooled chillers and 17% for water cooled chillers. For chillers with Turbocor compressors and EC condenser fans, compared with chillers that have fitted standard screw compressors without inverter and AC fans, the increase achieved in ESEER is around 36% for air cooled chillers and 63% for water cooled chillers. If we compare chillers with inverter driven screw compressors and chillers with Turbocor compressors, the increase achieved in ESEER is around 20% for air cooled chillers and 40% for water cooled chillers.

Axial Fans for Condenser with inverterTo reduce the yield gap that exists between the chillers that have screw compressors, with or without

installed with fans operating from a variable frequency drive, significant noise reductions up to 6 dBA for the same chiller unit are possible (ISO3744).

Hitema also uses another innovative application around the air fans, by the use of a special diffuser on top of the fans, that allows:

• Energy Saving of 22%.• Noise reduction of 6 dB(A).

Centrifugal process pump (2-4 poles) with InverterHitema has continued the use of inverters to their circulating pumps in order to obtain a non-dissipative regulation of power with variation of the pump speed, depending on the heat load required. Agin we obtain significant results in energy savings as you trace the actual load energy requirements without any effect on the process.To understand how the non-dissipative adjustment is able to

act in this method, we can consider the operating curve of a centrifugal pump. (Figure 7). The intersection of the characteristic operating range for centrifugal pump with the typical flow-pressure curve can be used to identify the point of working regime (point A for 100% of load). If the load in the system requires a flow of 75% of the maximum by the regulation by the classic choke valve installed after the pump then an additional pressure drop is artificially introduces and the system must overcame a higher pressure drop (kPa or m.w.c.) than is actually required by load (point B). Furthermore by moving the operating flow point, the pump efficiency is also changed, which then introduces a further efficiency loss.

By adjusting inverter frequency instead, it follows the real load demand by altering the pump curve. (Figure 8). Varying the speed of the pump changes its actual operating curve, which will move vertically downwards and thus we reach into the new operating point (point C) without any adjustment valve introduction. This results in a real energy saving of 30%.

The process pumps when installed with an inverter can effectively have zero starting current if the water flow can be gradually increased up to the maximum

AHA SERIES from 245 to 1140 kW Big Evolution Chiller SERIES like EET and ITC up to 1.5MW

Figure 7 - Operating curve of a centrifugal pump.

inverters, and chillers that have Turbocor compressors, Hitema also offer the use of inverters applicable to the standard axial fans. To control the volume of air circulated through the condenser in the air cooled chillers simple fan speed regulators to cut the phase applied to the fan motor are currently widely used. With this method, it is possible to decrease the rotation of the motor intervening directly on the supply voltage. However, with the use of inverters, which modulate the frequency from 20 to 50 Hz it is possible to reduce steadily the air flow and achieve improved condensing control.

Benefits obtained by the use of frequency variation with respect to voltage variation are the following:

• Lower energy consumption

For low-medium speed (rpm) the frequency variation allows reduced power consumption. However the motor efficiency is completely utilized with all cooling load. A cut phase adjustable fan-motor has an efficiency ratio between 72−74% whereas the same motor with frequency driver has a performance ratio of 80%.

• Reduced noise levels

This is a key point when using axial fans for refrigeration in the air conditioning sector, as air cooled chillers are widely used in residential applications; when

Figure 8 - Operating curve with speed pump variation.

Figure 9 – Electrical panel for Big Evolution chillers product by Hitema

HITEMA SRL Via Mons. G. Babolin 14, Z.I. San Gabriele 35024 Bovolenta (Padua)Tel. 049 5386344 R.a. 12 linee, Fax. 049 5386300, info@hitema.it, www.hitema.it

For more information, please contact:

flow, which again avoids potential water hammer. The correct management of the inverter location completes the full system optimization.

ConclusionToday there are many applications that require effective and innovative solutions to reduce the absorbed power requirements of the refrigeration hardware in process cooling industries, commercial air conditioning and data centres facilities. The optimum operation of the refrigeration equipment at partial loads is especially significant when average annual ambient air temperatures are between +5°C and +20°C, typical for the vast majority of European countries. For even lower ambient temperatures, the combination of inverter technology coupled with that of free-cooling, whereby chilled water can be produce by using fan energy only, can also be effectively used to produce chiller units with even greater efficiencies than previously considered possible.

New ECWH SERIES from 260 to 1500 KW

New AHW SERIES from 260 to 1560 kW

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FROM MARCH 2015

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NEW PRODUCTS SERIESStarting from today, Hitema is offering a more advanced products range

for your cooling needs.

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We strive to reduce the electrical consumption Problems viewing? Click to view online

HOW TO IMPROVE REFRIGERATION SYSTEM EFFICIENCIESIn the last 10 years awareness in energy saving has continuously increased in both industrialand  HVAC  applications,  at  Hitema  we  strive  to  reduce  the  electrical  consumption  ofcooling  equipment  using  the  most  effective,  innovative  and  efficient  techniques.  In  therefrigeration  and  heat  pump  sectors  European  standards  and  directives  are  now  applied  toincrease  the  standard  of  materials  used,  increase  innovation  and  in  the  application  of  newtechnologies to improve refrigeration system efficiencies.

The ENR/ENRF and SBS/SBSF are chillers from our Cooling Plus Energy series with air cooledcondensers operating on R­410A, which can also come with complete "Free­cooling" sections(only for models ENRF and SBSF) to guarantee energy savings.

ENR/ENRF unitsThe  ENR/ENRF  units  are  equipped  with  either  stainlesssteel  plate  type,  self­cleaning  coaxial  or  shell  &  tubeevaporator, aluminum finned copper condenser, axial fansand  rotary  compressor  (mod.  001÷005)  or  scrollcompressors  (mod.  008  ÷480,  up  to  4  compressors)installed  on  one  refrigeration  circuit  (mod.  001÷100)  ortwo independent refrigeration circuits (mod. 130÷480).

 

SBS/SBSF unitsThe  SBS/SBSF models  are  all  equipped  with  shell  &  tubeevaporator,  modular  aluminum  finned  copper  coilcondensers,  mounted  in  V  configuration,  axial  fans  andscroll compressors.

CALL US TODAY+39 049 538 63 44 r.a.

Via Mons.G.Babolin, 1435024 ­ Bovolenta (PD) ­ Italy

info@hitema.itwww.hitema.com

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NEW TURBOCOR CHILLERS LINE

Arctic Cool Chillers Limited and Hitema SRL are pleased to announcethat they have collaborated efforts to launch the Arctic Cool magneticBearing Chiller offering to the European and surrounding markets. The

products will be offered through the current Hitema representativenetwork and will carry both the Arctic Cool and Hitema brand.

DISCOVER NOW

A WORLDWIDE MARKETING CAMPAIGNHitema has launched a new marketing campaign on most important online magazines of

the field. You can find us on La RPF (France), RAC (UK), Die Kälte, Extrusion (Germany),

Termoklima (Turkey), Apic (Russia) and refripro.eu.

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COOLING SOLUTIONS BY INDUSTRY SECTORS

 

 

 

 

 

CHILLERS AVAILABLE IN STOCK! CONTACT US!

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Chiller for chemical plant, installed in UK, 320kW @ -22°C

LWT, ambient temperature 37°C

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HITEMA SRL Via Mons. G. Babolin 14, Z.I. San Gabriele 35024 Bovolenta (Padua)Tel. +39 (0

Partnership with HITEMA Guarantee of Success!!!

Thank you for your kind cooperation

HITEMA SRL Via Mons. G. Babolin 14, Z.I. San Gabriele 35024 Bovolenta (Padua)

0)49 5386344 R.a. 12 lines, Fax. +39 (0)49 5386300info@hitema.it www.hitema.com

Partnership with HITEMA Guarantee of Success!!!

Thank you for your kind cooperation

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HITEMA SRL Via Mons. G. Babolin 14, Z.I. San Gabriele 35024 Bovolenta (Padua) 5386300

Partnership with HITEMA Guarantee of Success!!!

Thank you for your kind cooperation