The Client –
Global aerospace manufacturer
The Challenge –
Creating a test chamber capable of achieving extreme temperatures
The Solution –
Custom built solution, incorporating Aqua ProHeat heat pump technology
When our client set out to expand and upgrade their large-scale environmental test chamber facility, they looked to partner with a temperature control supplier who had the ability to design, build, and install a system that could overcome a number of technical challenges.
Situation
As a leading global manufacturer of components for the aerospace industry, they regularly undertake product testing at varying loads and temperatures. Due to the size of the parts under test, their test facility has a very large footprint and needs the ability to be able to test to extreme temperatures, from +70° right down to -54°C.
Solution
After a comprehensive site visit, our in-house team started work on designing a custom build temperature control system, which would include:
- 1 x Aqua ProHeat high temperature industrial heat pump
- 1 x ultra-low temperature Aqua Pro chiller unit
- 4 x temperature control units (TCUs)
- Pump skid, including high pressure pumps & integrally mounted tank
- Full mechanical installation, including specialist lagging
Because of the temperatures involved, we specified a chiller with a cascade refrigeration system. Essentially, it has two refrigeration circuits – one high temperature, one low temperature – which operate in a cascade arrangement. It runs on R290 (refrigerant grade propane) on the high stage and R170 at the low stage. The unit is water cooled from the site’s main cooling system and reaches -60°C with 100kW load.
The high temperature heat pump achieves 85C with 110kw output. For its heat source, the heat pump reclaims the waste heat from the facility’s cooling system, to boost the fluid from a temperature of 25/30°C to 80/85°C. This has the advantage of significantly decreasing energy usage, carbon footprint and operating costs.
Because of the application, the system requires a thermal transfer fluid that can both heat & cool the air within the test chamber. FRAGOLTHERM was chosen as the heat transfer medium and is supplied from a central buffer tank, with magnetically driven specialist pumps.
Both the cooling and heating lines feed directly to temperature control units (TCUs), which ensure the exact required temperature is supplied. This can be as low as -60°C, as high as +85°C or anywhere in between.
There are four individual TCUs deployed within the test facility. This ensures the customer can test components to their maximum operating envelopes.
The use of hydrocarbon and natural refrigerants, result in a more sustainable, environmentally friendly solution. Energy usage and operating costs are further improved by the chiller being inverter driven.
Results
“Energy saving and sustainability were at the heart of this project, from initial design and specification, right through to final installation” explains Aqua’s founder, Simon Davis.
“For our client, the efficiencies that have been gained allow them to remain highly competitive within their market, and they now have a test facility which future proofs their business and enables them to continue their cutting-edge product design & development programmes.
“A project of this magnitude and specialist nature takes a high level of engineering skill to deliver from start to finish. We’re immensely proud and it highlights the talent and engineering prowess of the team involved.”
If you’re looking for a support with a specialist heat pump, chiller or system application, chat with the team today on 0333 004 4433.
