Optimization of theEnergy Optimizationat Systec Plastics in Eisfeld

Key Technical Data:
  • Optimized cooling supply with 1,300 kW of cooling capacity and 1,000 kW of free-cooling capacity
  • Efficient waste heat utilization through two buffer tanks with capacities of 5 m³ (heating) and 3 m³ (domestic hot water)
  • Energy-efficient compressed air station with 18 m³/min and refrigerated drying to 3 °C; automated switching of compressor stations via an intelligent control system

To ensure the long-term energy efficiency of the Systec Plastics Eisfeld GmbH recycling site, pbe energietechnik developed a holistic supply concept as part of an initial consultancy provided by RheinEnergie. The goal was to optimize the heating, cooling, and compressed air supply with a strong focus on energy efficiency and operational reliability. The implementation and system integration were carried out during ongoing production operations.

Key Project Measures

  • Heating supply: Conversion from fossil fuel-based heat generation using heating oil to waste heat recovery from compressed air generation; installation of a buffer tank for heating and domestic hot water, as well as a new heating circuit control system.
  • Compressed air supply: Renewal of both compressed air stations; primary supply via a 75 kW variable-speed compressor, supplemented by a 55 kW unit and an existing machine; energy-optimized refrigerated drying to a pressure dew point of 3 °C; integration of all compressed air components into a central control system for fully automatic, demand-oriented operation.
  • Cooling supply: Replacement of two air-cooled chillers with a liquid-cooled turbo chiller providing 1,300 kW of cooling capacity; integration of existing system components into the new plant configuration; installation of a water-glycol cooling circuit with free-cooling capability and connection of existing table coolers; central control system for the cooling and heat-rejection systems.
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Optimization of the heating, cooling, and ventilation systems at Diehl Metal Applications GmbH