Faurecia Jelcz Laskowice PL

Chilled Water for Manufacturing and Air Conditioning

Process cooling system for new car seats manufacturing facility.

Technology of polyurethane foam production requires that metal forms are cooled with chilled water. Continuity of the chilled water delivery is paramount for the manufacturing process and therefore redundancy was required.

Chilled water system included two chillers with air cooled condensers and air cooled free cooling system for shoulder season and winter. Mechanical compressor cooling was intended for warmer periods.

HVAC system was DDC controlled and ready for future addition of the centralized computer graphics.

New system featured:

  • Variable speed fan for air cooled condensers
  • Variable speed fans for the free cooling glycol dry cooler (fluid cooler)
  • Efficient air cooled chillers with practically zero maintenance
  • 100% redundancy for water delivery to the manufacturing

Explosion Proof Mechanical Ventilation, Heating and Heat Recovery

HVAC system for new car seats manufacturing facility (production lines relocated from France to Poland).

Technology of polyurethane foam production required intense ventilation, with explosion proof exhaust (by products of the technology are highly combustive vapours). Due to the nature of the process occasionally emission of highly toxic poisoning gases was possible thus high number of air changes per hour (ACH) required at working stations.

HVAC system was based on heat recovery ventilation units with explosion proof fans on the exhaust and glycol loop for heat recovery. Total air volume approx 310,000 m3/h (approx 190,000 CFM) with warm air being exhausted above production lines, thus attractive efficiency of the air to air heat recovery.

Supply air is filtered to EU7 standard (approx NEMA 11) with long bag filters thus lower pressure drop and reduced fan power consumption. Exhaust air was also filtrated for heat recovery coil protection, similarly long bag filters with lower pressure drop were used.

Displacement ventilation air diffusers were designed to direct ventilation air to the working zones. Low location of the general supply diffusers is noticeable on the photos. Gaseous by-products of the manufacturing process were mostly lighter than the air, therefore supply was located relatively low, while exhaust high above production lines. This approach allowed relative air flow reduction comparing to traditional “all mixing” approach.

HVAC system was DDC controlled and ready for future addition of the centralized computer graphics.

New system featured:

  • Explosion Proof construction for the exhaust
  • Efficient glycol loop heat recovery (note that glycol loop was the only system to ensure full separation of the exhaust from the supply – absolutely critical from the explosion protection perspective)
  • All fans and their motors were energy efficient; fans were selected at correct point of their characteristic to ensure low energy consumption
  • Innovative air delivery with displacement ventilation minimized volume of air in the system
  • Low pressure drop, long bag filters
  • Iterative approach for system selection was exercised – we prepared two alternatives (refer to drawings and description indicating “A” and