Tailor made and process optimised. Perfect Cooling and Temperature Control for the chemical and pharmaceutical industry

Transcription

1 Tailor made and process optimised Perfect Cooling and Temperature Control for the chemical and pharmaceutical industry

2 For more than 40 years Perfect cooling and perfect temperature control For over 40 years Gesellschaft Wärme Kältetechnik mbh has been manufacturing high-quality temperature control and cooling equipment and supplying this equipment worldwide. Today more than 360 employees design, produce and install complete process solutions for heating and cooling in customer specific designs. More than 33 sales and service locations worldwide represent the global character of our work and guarantee our permanent success. In addition to a huge product range of serial products we also offer tailor-made solutions for challenging applications. These individually designed units are available for a temperature range between 40 C and +400 C, and are developed and produced in Meinerzhagen according to the customers demands. As one-stop manufacturer of compact units, cooling plants and temperature control units, up to water treatment and heat recovery systems and complete container systems, gwk is a competent and innovative partner. Headquarters in Meinerzhagen, Germany 2

3 Technical advance through innovation Misc. test-field arrangements Production Worldwide unique we do not only design our shell & tube heat exchangers, but do also manufacture them in-house. They can be used as heating or cooling heat exchangers in temperature control units as well as evaporators or condensers in our chillers. The shell can be carbon or stainless steel, the pipes can be either made by copper or stainless steel. Quality test After completion each unit will be tested in one of our three test-fields which are located right next to our production lines. Customers are welcome to witness FATs. A special air-treatment system looks after proper air exchange rates. It also prevents odour nuisance in test-field and production area. Our own transformer station supplies our test-fields with three-phase AC up to 500 V. Therefore we can also test big units under full load. We especially look after energy-saving testing. Cooling loads can be used to cool down the site cooling water system. Waste heat caused by the testing can be used as simulated heat load again. Shell & Tube heat exchanger production Perfect Cooling and Temperature Control 3

4 Schematic P&ID Vacuum steam heaters for process engineering tests In chemical and pharmaceutical engineering more and more so called mini plants replace costly kilo labs. The gwk vacuum steam heater is a compact unit for heating of pressure sensitive devices with steam of organic fluids. The fluid is chosen according to the desired steam temperature. The maximum admissible outlet temperature is +300 C. The heating temperature is adjusted by variation of the operating pressure between 100 and 1000 mbar. Vacuum steam heater Vacutherm VT 24 This new, patented system is characterised by: High heat flow density (i.e. high heat surface load) Small temperature difference between product and steam Steady heat distribution within thermal fluid Safe operation due to low pressure, especially within glass devices Electrical capacity measurement Control via steam temperature (temperature, differential pressure) Determination of transferred heat via volume/time measurement of condensate quantity at evaporator pipe For small units: selection of max. heating capacity below 6 kw Fast heating/cooling due to small contents within system Highly improved heat transfer with metal consumers Can be used for cleaning tanks and other devices with disinfecting solvents; afterwards vacuum drying Modular design: units with heating capacities up to 60 kw 4

5 Tailor-made temperature control units Multi circuit temperature control systems Whenever there are high requirements, gwk are the right partner. A wide production range as well as our willpower ensure that we can individually design a unit for your application. High capacities at high temperatures are our speciality. Due to our longstanding experience gwk are the privileged partner of many end users for applications with water up to +220 C and with thermal oil up to +400 C. Heating can be realised via electrical heaters or via steam heat exchangers. For cooling several fluids can be used as cooling medium in combination with a heat exchanger. For applications with high capacities and many consumers it might be reasonable to combine several temperature control units to one economic system there is no upper limit. Design of all temperature control units is based on DIN Do not be afraid of hazardous atmosphere. Trust our longstanding experience with Ex design. Ask gwk project managers for advice to find the best solution for your application. Temperature control unit in Ex design Temperature control unit for +400 C Perfect Cooling and Temperature Control 5

6 Chiller in Ex design Tailor-made chillers Water-cooled chiller for temperatures down to -25 C In addition to a standardized series program of chillers gwk also offer tailor-made compact chillers for special heating and cooling tasks of chemical and pharmaceutical industry. Hereby gwk can supply solutions for challenging applications within an operating temperature range of 100 C up to +350 C. Our production facilities are equipped with state-of-the-art CNC systems to produce metal frames and covers. We do design and build the evaporators in-house. Air-cooled and water-cooled condensers are designed in a way they save energy and can be used in extreme ambient as well. Design of all chillers is based on EN 378 and 2006/842 F gases directive. On request, we also offer units in Ex design. We recommend to talk to our project managers to specify the design suitable for your application. Central chiller system 6

7 Container with cooling tower Container systems a success story for almost 30 years For almost 30 years gwk container help to reduce investment, operation and maintenance costs. Basically the following systems are available: Central heating & cooling system water chillers with environmentally friendly refrigerant R 134a heat pump systems for heat recovery cooling tower in combination with KU system as a closed, clean circuit Heat exchangers for direct heat recovery hermeticool principle hybrid coolers for energy saving cooling water conditioning units There are almost unlimited options for container systems regarding capacity and combination varieties. Each unit is designed and built as result of an individual energy assessment from gwk project managers. Contact them. Perfect cooling and perfect temperature control Energy saving cooler hermeticool Container interior with chillers Perfect Cooling and Temperature Control 7

8 Tailor-made solutions Example 1 Heating/Cooling system type teco Operating temperature range: 0 C up to +160 C Thermal fluid: water (Electrical) heating capacity: 24 kw Cooling capacity: 32 kw/+15 C 2 Expansion tank 5 Pump 7 Electrical heater 10 Cooling heat exchanger 12 Level switch 16 Safety valve 18 Temperature switch 20 Pressure switch 36 Temperature probe 37 Temperature controller K U Cooling water Thermal fluid Example 2 Heating /Cooling system type tecma wi Operating temperature range: -25 C up to +20 C Thermal fluid: water/ glycol Cooling capacity: 100 KW/-15 C with water / glycol / brine-heat exchanger Thermal fluid for temperature below 0 C can be water/glycol or brine. Reactor heating & cooling 8

9 Example 3 Combined Heating/Cooling system Two options: either use a gwk temperature control unit type tecma and plug into primary energies on site. Or use a chiller unit type weco for more flexible requirements. Chiller weco W Operating temperature range: -40 C up to +150 C Thermal fluid: oil Cooling capacity 1: 5 kw/-40 C Cooling capacity 2: 60 kw/+20 C with water heat exchanger Heating capacity: 80 kw/+150 C with steam heat exchanger Water-cooled condenser Units with air-cooled condenser do have a compact design like the water-cooled units. You could also use a split design with chiller unit inside and condenser outside the building. Example 4 Secondary circuit units use primary energies available on site. By feeding different temperature levels into the unit, you get a combined heating & cooling system type tecma. Operating temperature range: -100 C up to +200 C Thermal fluid: oil Electrical heating capacity: 180 kw Cooling capacity: 500 kw/+20 C with water heat exchanger Chilling capacity: 300 kw/-80 C with brine heat exchanger Perfect Cooling and Temperature Control 9

10 All gwk units are equipped with the reliable compact controller Logotherm as standard. Precise microprocessor control Digital alpha-numeric display with set points and actual values Membrane type keyboard Optional connection for external thermocouple (Fe-CuNi or Pt 100) Optional interfaces (analogue 0-10 V, 0/4-20 ma; serial RS 232, RS 422, RS 485, TTY; CAN-Bus; Profibus) Optional ramp functions Safety functions, e.g. set point limitation, flow and level control Installation in control cabinet, protection class IP 54 Microprocessor controlled compact controller Logotherm A Set-point B First set-point C Dwell time gwk Logotherm: The perfect controller for your application For more complex control systems we use Siemens PLC systems with operator panels such as the OP 73. We use PLC systems with Multi Panel to control complete systems that combine several chillers and temperature control units. In addition to this we offer the option of remote maintenance. PLC operator panels Malfunctions and production stops can be more or less prevented or easily fixed by continuous gwk service and evaluation of operation data via telecommunication devices. 10

11 Service worldwide and around the clock Requirements in pharmaceutical and chemical industry regarding production processes are demanding. gwk therefore define service as assistance throughout your whole process from the beginning on. Preventive inspections of your heating and cooling systems eliminate potential production stops in advance. New directives such as pressure equipment directive or F-gas regulation require inspections on a regular basis. Project planning Infrared analysis Performance measurement Project studies Mould design Contracting Second hand units Contracts Financing Support Maintenance In-house service inspection Teleservice Mould cleaning/system cleaning Training Spare parts Optimization Retrofitting / redesigning Advice / support Water analysis Perfect Cooling and Temperature Control 11

12 Perfect Cooling and Temperature Control Production costs Cost reduction Increased productivity In many areas of the industry, cooling and temperature control provides a great potential for increasing productivity and thus for lowering costs. Many factors serve to improve productivity: Reduction of cooling time, therefore savings in required machine hours Improvement of product quality Increasing availability of production plants Decreasing running cost Reduction of maintenance cost gwk teco cw Most economic system to extract heat from consumers at very low temperatures by patented cold water temperature control. gwk-tecma High process stability with customised temperature control solutions for all applications with high performance requirements up to 400 C. gwk KU-plants The simplest and cheapest solution to increase the availability and to decrease the maintenance cost of open cooling systems. gwk-weco Controllable production in variable climatic conditions and high flexibility with compact, energy saving water chillers using environmentally friendly refrigerant. gwk hermeticool hybrid Innovative cooling system to decrease the running and maintenance cost in comparison to conventional cooling systems. gwk SKL/SKW Reliable and economic supply of cooling water in the low temperature range, even under the toughest ambient conditions. gwk HSW Cost reduction by means of advanced heat recovery systems. gwk container-plants Highest flexibility and lowest expenses for planning, in stallation and relocation of a centralised cooling plant. gwk active Adjusting and maintaining optimum capacity by means of constantly clean water, supplied by a fully automatic water treatment system. gwk service Decreasing the maintenance cost and protection of company owned resources through professional execution of installation and maintenance works incl. cooling water treatment. CHemie_GB_06/2014 Subject to technical modification without notice. Gesellschaft Wärme Kältetechnik mbh Scherl 10 D Meinerzhagen Tel Fax info@gwk.com