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IEA Implementing Agreements Heat Pump Programme – Annex 35 Industrial Energy-related Systems and Technologies – Annex 13 Examples of existing Installations Heat pump in Food and Beverage industry - Combine heating and cooling in chocolate manufacturing (UK) The chocolate manufacturing process also requires cooling capacity for certain steps of the process. These simultaneous demands for cooling capacity and heating capacity allowed the replacement of the heating and the cooling system by a combined cooling and heating installation. The idea was to install a Single Screw compressor Heat Pump combining Heating and cooling. The Heat source consists in cooling process glycol from 5°C down to 0°C this evaporates Ammonia at - 5°C and the heat pump lifts it to 61°C in one stage for heating. Process water is finally heated from 10°C to 60°C. Based on the clients previously measured heating and cooling load profiles the analysis showed that to meet the projected hot water heating demands from the ‘Total Loss’ and Closed Loop’ circuits, the selected heat pump compressors would have to produce 1.25 MW of high grade heat. To achieve this demand the equipment selected offers 914 kW of refrigeration capacity with an absorbed power rating of 346 kW. The combined heating and cooling COP, COPhc, is calculated to be a modest 6.25. For an uplift of 17 K in discharge pressure the increase in absorbed power was 108 kW boosting the COPhi to an impressive 11.57. The initial thinking for the customer was to get a 90°C hot water heat pump. Indeed, some application demand required 90°C. However the total demand for this temperature level was around 10% of the whole hot water consumption. Designing a heat pump installation for such temperature would not be interesting in terms of performances and efficiencies. It was decided to install the heat pump producing 60°C hot water. When the small amount of 90°C water is required, the incremental heat is supplied now by a small gas boiler heating up the water from 60°C up to 90°C. In parallel, other alternatives for the heating were assessed like a central gas fired boiler, combined heat power or geothermal heat pump. Qualitative and quantitative assessments (cost, required existing installation upgrade, future site growth...) defined that the best alternative solution for this project was the heat pump. So a correct analysis and understanding of the real need for the installation allow installing the right answer to the real Nestle needs. Nestlé can save an estimated £143,000 per year (166,000 € per year) in heating costs, and around 120,000 kg in carbon emissions by using a Star Neatpump. Despite the new refrigeration plant providing both heating and cooling, it consumes £120,000 (140,000 €) less electricity per year than the previous cooling only plant. Another impact of the complete project (combined heating and cooling, additional gas boiler for the 90°C water peak demand, etc.) decreased the total water consumption from 52,000 m3/day down to 34,000 m3/day. The Nestlé system recently won the Industrial and Commercial Project of the Year title at the 2010 RAC awards. IEA Heat Pump Programme 3 www.heatpumpcentre.orgPDF Image | Industrial Heat Pumps
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