Application Examples

1. Application in Energy Consulting

Task

Validation and optimization of refrigerators of an automotive supplier

Solution

  • Creation of a new TOP-Energy® component “compression chiller”
  • Development, simulation and valuation of different variants

Result

The acquisition of new refrigerating machines was not reasonable

  • Reduction of the supply temperature in the cold water system (- 17%)
  • Changing the hydraulic systems (-6%)
  • Changing of the operational mode (-12%)

Total energy savings of more than 30%

2. Milk Production

Task

Examination of the potential for savings in the manufacturing process of dairy products

Solution

Modelling and analysis of the production process from different views; mass flow, energy, costs, ecology

Result

  • Microfiltration required a huge amount of electric energy
  • In pasteurization a possibility for heat recovery became apparent
  • Standardization showed a large loss of energy and exergy
  • Visualization was realized by using combined energy and process flow diagrams

3. Energy Supply System of a Hospital

Task

Economic evaluation of different variants of energy supply systems to replace the broken CHP

Solution

Modeling of the actual condition and creation of different variants for the system (Refurbishment of the CHP, purchase of a new CHP, use of storages)

Result

  • The purchase of a new CHP showed the best economical result
  • The payback period amounted to 2 years
  • Major factor in this was the CHP funding
  • The use of storage is not economically feasible

4. Optimizing the Use of a Cooling Water System of a Plastic Manufacturer

Task

Analysis and optimization of cooling water system at a plastic processing company

Solution

Three different ways of saving were simulated and both, the relevant and the total energy savings were calculated

Result

The costs of the optimized cooling can be calculated and compared with the actual condition

Total energy savings for the cooling water system up to 70%

5. Manufacturer of adsorption-type refrigeration systems

Task

  • Profitability of the facilities was difficult to prove
  • Complexity of the simulations was at a high level

Solution

Implementation of the individualized application

6. Manufacturer of electrolysis membranes and large producer of chlorine as a base chemical

  • Bayer developed a new procedure for chlorine-alkali electrolysis
  • This process was evaluated ecologically and economically
  • The degree in which hydrogen is used for chemicals, is crucial for the economy
  • It became apparent that the efficiency of chlorine production is highly dependent on external conditions

Solution

25 % of CO2 savings potential became apparent in a reference scenario