Cooling by freecooler of working systems of injection molding machines, injection molding machines and PET blowing machines

The technology of production of quality plastic products on injection molding machines requires not only high-quality technological equipment, but also makes a number of requirements for meeting the requirements for removing heat from water and oil.

This section is devoted to optimizing the operation of thermal regimes of injection molding machines (injection molding machines, blow molding machines), namely, how to achieve particularly significant tasks:

• Reduce the cost of PET plastic products.
• Increase the durability of the chiller in the system: chiller-thermoplastic automaton.
• Increase the quality of plastic products.
• Maximally reduce energy costs in the cost of plastic products.

All of the above tasks are achievable with the use or integration into an already operating Freecooler system or Dry Cooling tower or Draycler Green Box and IBC chillers.

Traditional scheme: Thermoplastic automatic - Chiller.

The system has the following drawbacks during operation:

• Permanent consumption of electricity during the winter and summer periods.
• Large volume of heat transfer from the operation of the chiller compressors.
• Less chiller life.
• The expense item in the cost of the product is constant or growing in the summer.

Without Freecooling: General: 60 kW  Economy: 0% The fricycle is switched off.  Environment 18 ° С Chiller  Cooling capacity: 150 kW  Power consumption: 60 kW

Integrated scheme A in the off-season : Thermoplast - Chiller - Frickler (dry cooling tower or drycooler) allows the chiller to be partially excluded from the working scheme during the off-season. As a result, during production, you get substantial savings, and taking into account the factors that Russia is mainly in the zone of 8-9 months of the year, low temperatures and only 3-4 the warmest seasons.

• Electricity consumption is exclusively in summer.
• The heat transfer from the operation of the chiller compressors to the room is completely absent.
• The increased service life of the chiller is 3 times.
• The expense item in the cost of the product is the lowest.

C Freckling during the off-season:  General: 43 kW  Economy 43%  Frictory: 91 kW  Power consumption: 10,4 kW  Environment 15 ° С Chiller:  Cooling capacity: 59 kW  Power consumption: 60 kW

Integrated circuit A in winter: Thermoplast - Chiller - Frickler (dry cooling tower or drive cooler) allows the chiller to be completely eliminated from the working circuit in winter. As a result, during production, you completely exclude electricity costs.

The freezer is charged with a solution of ethylene or propylene glycol with a calculated freezing point.

• The electricity consumption is "0".
• The heat transfer from the operation of the chiller compressors to the room is completely absent.
• The increased service life of the chiller is 3 times.
• An expense item for electricity in the cost of the product is missing.
• The work of Friculer 2 (charging with water) allows working in thermal conditions of the environment up to 25 ° C with an irrigation system.

C Freezing in winter: Total: 10,4 kW  Economy 83% Friction: 150 kW  Power consumption: 10,4 kW  Ambient temperature 12 ° С Chiller:  Cooling capacity: 0 kW  Power consumption: 0 kW

Integrated scheme A1 in the winter and inter-seasonal period : Thermoplast - Chiller - 2 contour Friculer (dry cooling tower or drive cooler). Friculer2 is filled exclusively with water.

The freezer is equipped with a drainage system. It operates in automatic mode, when the ambient air is cold enough that it provides preliminary cooling of the coolant in the freezer and reduces the operating time of the chiller compressors. 

When the system does not work or a scheduled emergency stop, in the absence of a heat load, the freezer automatically drains the water from the heat exchanger into the reserve tank to prevent it from freezing when the system runs on clean water without the addition of glycol.

The integrated circuit B2 with the use of two contour Friculler:

Cooling water and oil at the same time) and its advantages:

These systems are most effective for providing two independent temperatures and types of liquids for different consumers:

• The first circuit for low temperature is a water-glycol coolant (for example, for molds);
• The second circuit for cooling the consumers with the medium-high temperature of the coolant (for example, the hydraulic system) with the help of freecoolers.

In each case, it is necessary to analyze the system in person, which requires cooling. For each case there is an optimal solution that allows to organize the optimization of the system taking into account energy saving and development.

To effectively cool industrial equipment, and in particular molds, freecooler is often used. In this case, the temperature of the coolant must be at least 30 degrees. Systems with freecooling at industrial enterprises are gaining momentum, as such measures significantly reduce the total energy costs. This becomes actual in the cold season, as such systems operate on the principle of replacing warm air indoors with cold from the environment.

Chillers equipped with a system of freecooling are monoblock refrigerators. Work with built-in air or water condenser.

Principles of the system:

• For air cooling, an integrated freecooling heat exchanger is used. In this operation, outdoor air is used to cool the equipment. Also, effective cooling can be realized by freon, which circulates through the heat exchanger circuit.
• Combined work of the system. In this case, compressor cooling operates and is gradually included in the freecooler process. At the same time, the efficiency of the refrigerating machine is significantly increased.
• Air cooling with freon, circulation of which is ensured by the operation of the pump. The built-in water and air cooling assumes the forced operation of the machine.

Advantages of using a freecooler:

• high performance;
• stable cooling mode;
• complete independence of the setting;
• simple and quick installation;
• Outstanding energy savings up to 60%;
• easy replacement of modules (in case of breakage);
• the system does not need complex pumping stations;
• minimum production downtime;
• payback period is less than a year (since the system will work 4-5 months, that is, in the cold period).

Friction is applied:

• At industrial plants for the production of plastics.
• In the chemical industry for cooling water.
• Oil refining industry.
• Mechanical engineering (cooling equipment, machines, oils and liquids for grinding).
• In the food industry (for cooling oil, milk and other products).