In the realm of sustainable technology, Absorption Chillers stand out as remarkable inventions, offering a solution to the challenge of waste heat by converting it into valuable resources like cold or hot water. Among these, the BROAD Absorption Chiller series showcases a versatile range of types, each meticulously designed to suit specific applications, whether it’s cooling or heating. These chillers ingeniously harness various heat sources, including residual hot water from production processes, hot air exhausts, or steam discharges emanating from power plants or boilers. Now, let’s embark on a detailed exploration of these classifications and types, which are intricately linked to temperature and heat source considerations.
1. Utilizing High-Temperature Waste Heat (Above 70°C):
The BROAD Single Stage Absorption Chiller comes into play when waste heat exceeds 70°C, sourced from hot water or low-pressure steam below 0.3 MPa. This particular chiller is primarily engineered for cooling purposes. Medium temperature water, a common occurrence in both natural and industrial settings, serves as an abundant source for this application. It includes thermal drainage like steam condensate, by-products of chemical reactions, or even water from power plant generators. Medium temperature water arrives with a predefined temperature, making it readily applicable for cooling, heating, or steam production needs. Operating within this setup, the chiller achieves a commendable Coefficient of Performance (COP) ranging from 0.5 to 0.8, effectively transforming waste heat into viable cooling solutions.
Utilization Mode
Hot water temperatures exceeding 70°C are ideal for operating a hot water absorption chiller for cooling purposes. Higher hot water temperatures not only increase the efficiency of the chiller but also reduce investment costs. The specific chiller model and its cooling capacity can be determined based on a detailed analysis, often outlined in a corresponding table for easy reference and decision-making.
The cooling capacity of a hot water absorption chiller can be calculated based on the rate at which medium temperature water is cooled. For instance, for every ton of medium temperature water cooled by 1℃, a certain amount of cooling capacity is generated. Let’s consider an example: if 100 tons of water at 100℃ are cooled to 55℃, the cooling capacity can be determined using a formula like this: 100 * (100 – 55) * 0.7 = 3,150 kW. Alternatively, the cooling capacity can also be estimated using the Coefficient of Performance (COP). For the same scenario, the calculation might look like this: 100 * (100 – 55) * 1.163 * 0.6 = 3,140 kW. This calculation is based on the fact that the heat output of 1 ton of water, with a temperature drop of 1℃, is approximately 1.163 kW.
Application
a. BROAD Single Stage Hot Water
Hankook Tires, Factory, Tennessee
The facility ingeniously utilizes waste steam, a byproduct of the tire curing process, by repurposing it to recover condensate for heat exchange at a cozy temperature of 185°F (85°C). Furthermore, they incorporate the state-of-the-art BROAD BDH250 Double Section chiller to convert this reclaimed hot water into a refreshing cooling supply for both the factory floors and office spaces. Imagine a tranquil oasis of chilled water flowing at a refreshing 43°F (5.6°C), offering a welcome relief amidst the bustling activity. But the innovation doesn’t stop there; this system efficiently reduces the heat source temperature to a comfortable 131°F (55°C), ensuring that every bit of waste heat is utilized effectively.
Application Value
By harnessing recovered residual heat from steam condensate, the facility adeptly addresses the challenge of waste heat treatment, particularly for process cooling purposes. They achieve this feat through the utilization of BROAD Triple Generation chiller technology, which not only provides cooling services for both process and office buildings but also significantly reduces the plant’s overall power consumption. The consistent and reliable operation of these chillers throughout the year yields substantial environmental benefits, equivalent to saving 1,060 tons of standard coal annually. This translates to a remarkable reduction in carbon emissions by 2,642 tons, a feat comparable to planting 144,000 trees.
b. BROAD Single Stage Hot Water Chiller from condensate Steam
Yangzi Petrochemical-BASF Co. Ltd.
Yangzi Petrochemical-BASF Co. Ltd. emerges as a striking example of collaboration between two industry giants, Sinopec and BASF, operating in a perfectly balanced 50:50 partnership. Situated in the bustling Nanjing Chemical Industry Park, this company specializes in the production of ethylene oxide and ethylene glycol, compounds renowned for their flammable and explosive properties. Given the inherent risks, stringent safety measures are paramount, mandating rigorous chemical safety training and the donning of protective gear for all personnel entering the premises.
In their pursuit of top-notch refrigeration equipment, Yangzi Petrochemical-BASF Co. Ltd. embarked on a global quest to identify the best suppliers. After exhaustive technical evaluations and meticulous site inspections, BASF’s adept technical experts from Germany were captivated by BROAD’s unmatched research and manufacturing capabilities, coupled with its stellar product performance. Consequently, the decision was made to entrust BROAD with the critical task at hand.
The project’s ingenious design harnesses 98°C steam condensate from the production process to power a BROAD single-stage hot water chiller, producing an impressive 7MW of 16°C chilled water to meet the process cooling requirements of the EOEG unit. Positioned within an explosion-proof zone, the chiller boasts ExdeibⅡBT4 and IP55 electrical protection ratings, ensuring full compliance with stringent safety standards.
Reliability takes precedence in this continuous operation, with the chiller tirelessly functioning 24/7, 365 days a year, pausing only during plant-wide overhauls. Its compact design necessitates installation close to production equipment, leaving no margin for backup units. With a potential daily loss exceeding $1 million in the event of a shutdown, reliability is non-negotiable.
Furthermore, the chiller’s resilience shines through as it withstands the elements, operating outdoors in temperatures ranging from -14°C to 43°C. Despite variations in heat source and cooling water temperatures, it maintains a consistent performance, with deviations not exceeding 4%.
The construction of the chiller adheres meticulously to the stringent “Made in Germany” standards, meticulously detailed across nearly 1,000 pages by BASF. Each aspect undergoes thorough scrutiny, from welding precision to material composition and performance testing. Renowned third-party firms oversee this process to ensure unparalleled quality and precision.
BROAD’s commitment transcends manufacturing excellence; its comprehensive after-sales service, inclusive of a global monitoring system, guarantees swift intervention in the event of any issues, thus ensuring uninterrupted operation.
Since its inception in 2011, the chiller has maintained an impeccable record, never experiencing a single downtime, which stands as a significant milestone in the absorption chiller industry. It not only delivers substantial energy cost savings of over $1.6 million annually but also serves as a testament to BROAD’s unparalleled capabilities in meeting the most rigorous standards. The unwavering trust placed by Yangzi Petrochemical-BASF Co. Ltd. in BROAD stems from the chiller’s consistent ability to exceed expectations, reaffirming its position as the undisputed choice in the industry.
2. Harnessing Moderate-Temperature Waste Heat (160-200°C)
The BROAD Double Stage Absorption Chiller steps in to utilize waste heat within the temperature range of 160 to 200°C, sourced from hot water or steam under 1 MPa pressure. This sophisticated chiller serves a multi-faceted role, functioning as a cooling system, a heating mechanism, and a hot water generator all in one. With a commendable Coefficient of Performance (COP) ranging from 1.4 to 1.5, it demonstrates an elevated level of efficiency in the utilization of resources.
Application
BROAD Steam Absorption Chiller from condensate steam
PT. Indorama Synthetics Tbk
As the foremost textile manufacturer in Indonesia, PT. Indorama Synthetics relies on coal-fired boilers to generate steam for electricity. Embracing the global shift towards sustainable energy practices, PT. Indorama collaborates with PT. PLN Persero to establish a power plant capable of producing 1 x 60 MW of electricity, evenly distributed between PT. Indorama Polychem and PT. Indorama Synthetics Tbk. The latter entity receives 1 x 30 MW of this capacity.
Utilizing condensate steam at a pressure of 7 bar from the power plant’s steam turbine, PT. Indorama Synthetics Tbk. repurposes it through a BROAD absorption chiller to produce chilled water with an impressive cooling capacity of 1570 kW (447 RT). This strategic initiative not only underscores the company’s dedication to renewable energy sources but also significantly enhances overall energy efficiency. Moreover, it marks the replacement of an aging absorption chiller sourced from a Korean brand, further elevating the company’s commitment to innovation and sustainability.
3. Tapping into High-Temperature Exhausts (250-600°C):
High-Temperature Absorption Chillers capitalize on exhausts with temperatures ranging from 250 to 600°C, offering a valuable heat source for various applications such as cooling, room heating, or hot water generation. Efficiency levels fluctuate depending on the temperature range, with an optimal Coefficient of Performance (COP) of 1.5 achieved at 500°C and 0.8 attained at 300°C. This makes 500°C the ideal temperature for maximizing efficiency, ensuring optimal utilization of the available heat source.
Application
BROAD Exhaust Absorption Chiller for cooling in factory
Glass Factory : Sisecam Pasabahce, Turkey
The company recovers heat from low-temperature exhaust gas (450°C) emitted by the glass melting furnace to power a single unit of BROAD exhaust chiller. This chiller boasts a substantial cooling capacity of 4,210 kW, generating chilled water essential for process cooling purposes. This innovative approach allows the company to achieve significant environmental benefits, including an annual reduction in CO2 emissions by 4,724 tons, savings of 1,830 tons of standard coal, and an environmental impact equivalent to planting 262,444 trees annually.
Conclusion:
Absorption Chillers, epitomized by the versatile BROAD series, play a pivotal role in enhancing energy efficiency and utilizing waste heat effectively. Their ability to seamlessly integrate with a variety of heat sources and provide multiple functionalities underscores their significance. These chillers serve as a cornerstone for sustainable cooling, heating, and hot water solutions in a wide array of industrial and commercial settings.