Schwämmle Manufactures

Special Cooling Systems

WWH ECO Special Cooling System

WWH ECO Special Cooling System

With the WWH ECO series SCHWÄMMLE Industrial Cooling Systems presents you with a real innovation. Energy-saving modular cooling – tailor-made to fulfil your requirements. The cooling systems of series WWH have been developed for processes that are very function-critical and cannot be shut down, if possible. The design is extremely space-saving and thus energy-optimized.

We can manufacture and run in the systems of this series in a turnkey manner in our factory which results in an extremely short installation and commissioning time.

The WWH ECO is equipped with the ECO control system and specializes in energy-efficient and intelligent cooling. Our WWH Eco systems save energy costs thus reducing the CO2 emission. As a pleasant side effect, the service life of the plant will be prolonged. Sounds interesting?

How To Achieve Efficiency

The ECO control system activates the individual modules according to the cooling capacity that is required. This successive switching on of modules also saves energy since only those modules that are really needed are in operation and the system can very well react to the various loading conditions. The fans of the dry cooler are controlled the same way. As the capacities of the fans have been rated for high temperatures, the speed is reduced accordingly when the temperatures are low thus saving a lot of energy. Additionally, the control system monitors various flows, filling levels, feeding etc.

If one of the cooling modules goes into operation, one of the pumps for the dry cooler circuit will be switched on. The temperature in the dry cooler circuit is controlled via the speed control of the fans. A temperature sensor is installed outside. Depending on the ambient temperature, the control system decides whether the cooling modules are required or whether free cooling is sufficient. In Stuttgart, Germany, for example, the temperature throughout the year is statistically under +10 °C  during 5,300 h and under +12 °C during 6,040 h.

With ambient temperatures of under approx. +12 °C, the complete cooling can be effected via free cooling. Therefore, only the fans must be driven and not the cooling units. As soon as the temperature falls below 12 °C, the speed of the fans will be reduced. Since the power consumption of the fans rises or drops approx. ex cube with the speed, this effect can be used for great energy savings. As you can see, a large dimensioning of the dry cooler and heat exchanger is definitely worth it!

Structure and Function

Hydraulic System

The hydraulic unit is mounted in a complete frame and comprises the double-pump station for the consumer and for the cooling circuit via the dry cooler, the heat exchanger between the dry cooler circuit and the consumer circuit, the heat recovery as well as the entire hydraulic piping.

Cooling Module

The cooling module is also mounted in a frame and is connected with the hydraulic unit. It consists of a container which – depending on its design - can take in up to 8 individual cooling modules. The water distribution in container 1-8 generates individual cooling modules which are completely independent of each other. The cooling modules can be maintained or exchanged without an interruption of the overall system. Likewise, the cooling capacity can be increased by adding modules.

Dry Cooler

The dry cooler can be delivered as a desktop version (flat) or as a V-shaped version to save space. It is installed outdoors. The size depends on its capacity and the maximum permitted noise level. It consists primarily of one or several large-dimensioned heat exchangers and a number of fans. The fans are speed-controlled depending on the cooling load and the ambient temperature. If dimensioned accordingly, the entire cooling can be achieved without any cooling unit by means of heat recovery on condition that temperatures are low!

Control System

The entire system is controlled via PLC. – Visualization of all processes, flow charts, parameters, faults and warnings – Recording of up to 16 different parameters like pressures, temperatures, flows – Data transfer to external users is possible.

ECO Control System

A cooling unit is operated by means of a compressor. Roughly calculated, one can say that the compressor requires approx. 1/3 of the cooling capacity for its drive capacity. With the ECO control system in the WWH ECO, the compressors of the cooling units can be switched off when the ambient temperature is low so that cooling can be effected directly via the dry cooler. This requires a sophisticated system for measurement and control reducing the temperature of the glycol circuit and cooling the water via a heat exchanger. The cooling modules are only switched on in peak-load cases. Thus, it is possible to operate the system solely via the dry cooler for two thirds of the year depending on where the factory is located.

The benefits of this system are perfectly obvious: – Prolongued service life of the cooling modules through low utilization – Saving energy costs and reducing CO2 emission.

Example: 200 kW cooling capacity require approx. 130 kW electrical energy if conventional cooling modules are used. The fans of the dry cooler require only 20 kW electrical energy input for the same cooling capacity!

Download data sheet (PDF)

Technical details, performance calculation etc. at a glance

Download sample quotation

Dimensioning example and quotation of a WWH Eco system