Chiller Replacement & Energy Reduction Solution
Ano-Tech Metal Finishing’s daily operations revolved around a single 100-ton chiller that was essential to their anodizing and metal treatment process.
But Ano-Tech’s chiller was antiquated, and approximately 50% oversized for their current operations. This was causing the system to start-and-stop at a dangerous frequency; causing severe wear and tear on the unit. The customer couldn’t afford that mechanical risk, as all operations would come to a screeching halt should the unit fail.
Early discussions with their utility provider revealed that Ano-Tech may be eligible for an equipment rebate if they could meet the stringent energy reduction guidelines.
BMI collaborated directly with Ano-Tech and the utility company to quantify current energy consumption and design a replacement chiller system that meets all specifications. BMI also calculated the new system’s loads and energy requirements under varying conditions.
CHALLENGE
Design a replacement process chiller system to hit substantial energy reduction targets, and implement the solution with little to no impact on production.
SOLUTION
- Professional design and energy calculations to meet the needs of all parties.
- Replace 100-ton with energy-efficient 45-ton unit; with difficult demolition and extensive piping.
- Partner with equipment manufacturer’s representative following installation to complete a full factory start-up and inspection.
BENEFITS
- The utility rebate program covered 80% of the project cost.
- Following the utility program’s completion, customer will continue to benefit from energy savings of over 44,000 kWh per year.
- Zero impact to production by coordinating a flexible installation schedule.