GALAXY ENERGY SOLUTIONS LLP THE SAVING ANALYSIS REPORT

Transcription

1 GALAXY ENERGY SOLUTIONS LLP PRODUCT: THE SAVING ANALYSIS REPORT COMPANY: SITE: DATE: 24 TH - 25 TH September, 2016

2 CIPET- A PREMIER NATIONAL INSTITUTE IN PLASTICS: JAIPUR CENTRE EXECUTIVE SUMMARY: The report presents the findings and analysis relating to application of Hydromx as heat transfer medium in Mellcon air cooled water chiller of 3TR capacity. This water chiller is required for the cooling of dies used on injection moulding machine ELECTRON-155 (215 gm). The machine is used to make plastic parts by injection moulding process. This machine is used at CIPET, Jaipur Centre for training as well as for contract production facility to customers.

3 The replacement of water by Hydromx as a medium of heat transfer, in the closed loop cooling system between the chiller and the dies on the machine, has resulted in performance improvement of the system. It is observed that the overall improvement in the system performance is around 30% and the direct saving in the consumption of Input power is of the order of 24%. INTRODUCTION: ABOUT INSTITUTE: CENTRAL INSTITUTE OF PLASTICS ENGINEERING TECHNOLOGY (CIPET) The institute has its centres spread all over India for research, academic, learning and training purposes. There are 5 centres of high learning, 14 centres for learning and training. It has vocational training centres as well. JAIPUR CENTRE in the state of Rajasthan was established in the year 2006 under the XIth Five year plan of Govt. of India The centre is located in the "Pink City" Jaipur in "Sitapura Industrial Area" and is spread in an area of acres with all the necessary infrastructural facilities. CIPET-Jaipur Centre is ISO 9001:2008 certified for Training and Technical Services. Its Plastics Testing Centre is accredited by NABL for ISO 17025:2005 QMS & ISO and recognized by Bureau of Indian Standards (BIS). Technical Support Services (TSS) is an integral part of the activities of CIPET. CIPET renders quality services to its customers in Tooling, Precision Machining on CNC machines, Design and Manufacturing of Moulds for Plastic and allied products, Plastics product manufacturing through Injection Moulding Machines, Blow Moulding and Rotational Moulding etc.

4 PROCESSING UNIT: ABOUT INJECTION MOULDING MACHINE: CIPET workshop consists of various types of plastic moulding machines. CIPET also offers these machines to the customers for production of their plastic parts on commercial basis. This activity provides real life training to their students as well. Injection Moulding Machine In Operation The injection moulding machine consists of moulding zone where dies are mounted, the heating zone where plastic material is heated to a semi liquid state so that it acquire fluidity to flow into the mould-dies. The injection of heated material is carried out under pressure through injection system. The heat of injected material in the mould dies gets transferred to environment through mould die parts. If this heat transfer from injected material is faster; then quicker is the cooling of moulded part and hence faster is its ejection from the die. Thus the rate of heat removal puts a limit on the rate of production of moulded parts. A cooling system has been adopted to cool the mould die faster so as to increase the productivity of the machine. A chiller has been installed with the machine. A closed loop system is created between the chiller and the mould die on the machine so that heat is carried away by circulating water, which is acting as medium of heat transfer.

5 The problems faced by the cooling system are: 1. The excessive heat of injected material received in the die parts poses a great problem. This heat creates higher working temperature in the die, which hampers the continuous operation of the machine, i.e. frequent slowdown or breakdowns. This means loss of productivity. 2. This problem is resolved to some extent by installation of a industrial water chiller unit with the machine. The purpose of this chiller is to remove the heat through water from die parts, so that the working of machine is not hampered. 3. However, the use of water as heat transfer medium has not solved the problem satisfactorily. Though the application of chiller reduced the temperature of die parts to certain level, but the circulation of water in the spindle has posed another problems namely; a. Scaling, corrosion and calcification in the system (die parts and chiller system) and piping unit connecting the chiller with the die parts for circulation of water as medium of heat transfer. b. The result of scaling, corrosion and calcification in the system results into overheating of die parts and clogging of the chilled water piping, demanding the stoppage of the machine for servicing. c. The stoppage of machine means loss of production. d. If the evaporator side temperature in the chiller is set very low, it will further increase the energy consumption. These problems are practically being faced by users of injection moulding machines in their production shop. Galaxy Energy Solutions propose a remedy for the problems faced by injection moulding machine users. The remedy is the use of Hydromx as medium of heat transfer in place of

6 water in the closed loop system between the chiller and the mould die on the machine. Management at CIPET agreed upon and we did the pilot project to demonstrate the advantages of use of Hydromx as the medium of heat transfer in place of water in the closed loop system between the chiller and the die parts. Hydromx as a heat transfer medium will resolve the problems faced on the injection moulding as demonstrated in the pilot exercise. a. by faster heat removal from the chiller and maintaining lower temperature among the die parts b. Eliminating problems of scaling, corrosion and calcification. c. problem of production hamper resolved as frequent daily, weekly breakdown problems disappeared with teh use of Hydromx d. reduced energy consumption by the chiller and e. lowered maintenance cost of the machine PRODUCT: Hydromx is a patented energy saving, advanced heat transfer fluid that makes use of nano-thermo technology. Hydromx uses nano-particles to increase the speed of energy transfer, by cooling / heating up the fluid and transferring the energy in a shorter amount of time, thereby requiring significantly less energy. It is used with water (Hydromx : water as 50:50). Hydromx provides great benefits on environmental impacts calculated when compared to water and ethylene glycol systems due to energy savings achieved during the use phase. The Hydromx provides the multiple benefits mentioned in the table given below; in addition to the fact that it is a better heat transfer medium in comparison to water.

7 Table: Multiple Benefits of Hydromx Hydromx is best suited for closed loop heating and cooling systems. The efficiency of the system increases due to diminishing run-time of associated equipments. Hence drastic increase in equipment life is achieved along with lesser maintenance cost. Hydromx when used with water in the ratio of 50:50 enhances the capacity of water to transfer heat, thus making it more efficient in terms of energy consumption. The Schematic diagram showing the working of Hydromx in the chiller is presented in the figure given below. Schematic diagram showing the working of Hydromx in the chiller

8 Other Additonal Advantages: 1. Anti-corrosive and Anti-calcification: protects the system from corrosion and scaling; thereby life cycle increases, 2. Anti-freeze: protects the system against freezing 3. Faster heat removal: This will keep CNC head at lower temperature during its working, thereby reducing wear & tear of the unit. 4. Life cycle: Thus product has years life cycle for its 1 st use. 5. No shut down is required: The equipment does not need any frequent shut-downs for dosing of inhibitors, which were otherwise happening when water was used as heat transfer medium. 6. No inhibitor is required: Hydromx itself also acts as an inhibitor. 7. No retrofit is required: Hydromx can be used in the system without any rectification or modification in the equipments. 8. Can be reused again and again: Hydromx used in one system can be reused / transferred on another system, if required. This product is ready for reuse after its life cycle by processing it through recycling. Galaxy Energy Solutions (GES) is the exclusive distributor of Hydromx, - an Energy saving Solutions in close loop hydronic systems - in India. STUDY: The pilot project study is carried out on the chiller used for the injection moulding machine as listed below: Injection Moulding Machine: ELECTRON 155 (215 gms) It is fully automated injection type equipment for moulding plastic parts. It consists of an automatic raw material feeding system, a unit for heating the raw material before injection to the mould system, the moulding unit consisting of die set, injection of raw material, ejection of moulded part system and a chiller unit.

9 The chiller unit with the equipment: Air cooled Water chiller Make Mellcon Capacity- 3 TR The water chiller continuously extract heat from the water circulating through the die set so as to maintain the desired temperature on the die surface for the uninterrupted quality production of the plastic parts on the machine. Injection Moulding Machine replacement of dies

10 Injection Moulding Machine under trial test GES approached CIPET for performance evaluation of Hydromx in their production processing unit with the aim of making a case study in India. The object of this study was to compare the performance of Hydromxas against water in identical conditions in a production processing system. The superior heat transfer quality of Hydromx, as envisaged, against water will help Indian industries to adopt Hydromxas a heat transfer fluid which will result in energy savings. CIPET agreed to allow the use of Hydromx in their highly automated production processing unit under the same identical production conditions. The same product will be processed with same production parameters using both the Hydromx and water to ensure fair and accurate performance. CIPET management was enthusiast about the idea of energy savings, however, they were apprehensive about the method of assessment on this highly automated equipment.

11 GES explained them about the Logger system that is an automated data recording system, which can record the measured data at a regular interval on such automated working units. The Logger system: The system consists of a control unit with temperature logger and energy meter for recording, on line / off line, the measured temperature, volts, amps, run time, watts and energy consumptionetc. through the use of appropriate sensors. Recording of data is on-line and in SD card as well with an interval of one minute. Temperature Sensors: These are RTD sensors (calibrated) and highly sensitive. Operating conditions: Starting room temperature: 35 0 C Part Description: Name : Material: Weight : of part produced during performance period Cover (Lid) polypropylene 6.5 gm per piece Production rate: 1440 per hour (cycle time = 5 sec. per two pieces) RESULTS: Performance test period: The machine was set for regular production of the part Cover weighing 6.5 gms per piece and after sufficient run time, the various parameters for chiller operation were collected on 24/09/2016 from AM to 5.30 PM. Similar parameters were collected after replacement of water by Hydromx in the cooling loop for the die set for the same product under identical manufacturing environment on 25/09/2016 from AM to 5.30 PM.

12 AIR-COOLED CHILLER DATASHEET: The data of the air-cooled chiller recorded with the help of Logger system installed on the machine were analysed. The results so obtained are presented in the table below. It indicates an increase in cooling capacity and Energy Efficiency Ratio. Sr.no. 3 TR AIRCOOLED CHILLER DATA SHEET Description Electrical Power With water With Hydromx loading % 100% 100% Ambient date 24/9/16 25/9/16 1 Voltage V Current A Frequency Hz Input power KW Evaporator 5 Entering water temperature ⁰C Leaving water temperature ⁰C Water flow rate USGPM Water side pressure drop kg/cm Air cooled Condenser(ACC) 9 Entering dry bulb temperature System Suction Pressure PSIG Discharge Pressure PSIG Suction Temperature ⁰C Compressor 13 buffer tank cut temp. ⁰C buffer tank temp. ⁰C condenser 15 temperature ⁰C Calculated Parameters 15 Unit Evaporator Capacity TR Energy Efficeincy Ratio CKW/EKW Input power/evaporator Capacity KW/TR % increase in cooling capacity % % increase in EER % 29.3

13 CONCLUSION: The replacement of water by Hydromx as a medium of heat transfer in the closed loop of the cooling system has resulted in performance improvement of the system. Direct saving in input power per unit TR (IkW/TR) 23.6% The increase in the energy efficiency ratio (EER) 29.3% It is observed that the overall improvement in the system performance is around 30% and the direct saving in the consumption of Input power is of the order of 24%.