Tag Archive for: ventilation system

Ventilation system with flame tubes and heat shields from LK Metallwaren

Successful model “Made by LK”: overseas with flame tube and heat shield

Wherever surfaces need to dry as quickly and evenly as possible, particularly powerful and highly reliable ventilation units are required: this also applies to systems used in the furniture construction and furniture processing sector.

In May 2023, LK Metallwaren produced two ventilation systems at its main site in Schwabach.
ventilation systems
to a Westphalian company that specializes in plant engineering for furniture production. The components that LK Metallwaren supplied to the customer were intended for use in wood processing, specifically for drying furniture components after surface treatment. The process air used for this process air is heated in a temperature range between 60 and 80 degrees Celsius.

In this way, the applied coatings can dry much more quickly, packaging and shipping of the parts can be carried out faster and delivery times can be shortened. To achieve this with maximum efficiency and effectiveness, LK Metallwaren has equipped the newly designed ventilation systems with flame tubes and heat shields. Both systems were integrated by the customer into their systems and then shipped to their own customers overseas, in this case to Canada and the USA.

Two further deliveries in September and November 2023 as well as two current orders for next spring from the same customer not only show that the systems have been “well received”, but have also been successfully put into operation by the end customers The two current orders finalized with the customer were also delivered to companies overseas: one to a furniture manufacturer and the other to an instrument maker from the United States. Of the ventilation units ordered for delivery in spring 2024, one will be sent from the customer to Canada and a second to a furniture manufacturer in Baden-Württemberg.

The delivered or ordered systems differ fundamentally only in the means by which the process air is heated. Gas is generally preferred in the plants that were delivered overseas. In the domestically supplied system, a pumped hot water coil is used for the volume flow of 20,000 cubic meters of air per hour to be generated.

Further orders for this current successful model “Made by LK” are expected to follow soon. Customer-specific modifications are possible here, in addition to the type of heat generation, especially in the dimensioning and performance of the units.

Hybrid heating

LK "Green-Climate-System (GCS)" Warm Air Heater

The Climate Protection Act has been in force since August 2021.
The German government has tightened climate protection targets and enshrined the goal of greenhouse gas neutrality by 2045. By 2030, emissions are already to be reduced by 65 percent compared with 1990.

Warm air heater RBW
LK Warm air heater RBW

LK Metallwaren offers three innovative solutions for the heating, ventilation and air conditioning of production, logistics and industrial halls. In order to achieve the climate protection targets in non-residential buildings, LK Metall has combined the RBW warm air heater and the REKU ventilation system with heat pump technology , as well as developing the new “Green Climate System”, which heats industrial halls without using gas as a fuel.

LK Warm air heater RBW with condensing boiler and heat pump technology
LK Warm air heater RBW with condensing boiler and heat pump technology

The hybrid heating system with gas and heat pump technology

The very efficient RBW warm air heater with condensing technology is extended with a heat pump package. The combination of gas as a fuel and heat pumps for heat exchange creates the hybrid heating system. Here, the heat pump takes over the heat generation mainly in the transitional period, i.e. in autumn and spring. In winter, on the other hand, the gas heating only switches on when the outside temperatures are too low to heat mainly with the heat pump.

With the air-to-air heat pump, the air is used as a heat source and thus an efficient and environmentally friendly operation is realized. The heaters in the warm air heater are piped to the heat pump and filled with R32 refrigerant. Additional fan units make independent operation of warm air heater and heat pumps possible. The air-to-air heat pumps used with the new R32 refrigerant significantly improve energy efficiency.

Comparison of the greenhouse potential of refrigerants
Graphic - Global Warming Potential (GWP) over 100 years
Graphic – Global Warming Potential (GWP) over 100 years
Source: IPCC Fourth Assessment Report. Global Warming Potential (GWP) over 100 years.

Compared: 2,088 (R410A) vs. 675 (R32). The advantages of hybrid heating are obvious. Hybrid heating reduces CO2 emissions by up to 30%, significantly reducing the need to burn fossil fuels. Another advantage of hybrid heating is the cooling function, which is provided by the heat pumps at all times. Especially in summer, this additionally improves the hall climate for the staff. LK hybrid heating is used in production and logistics halls. In the case of renovation, a gas hybrid heating system is subsidized by BAFA with up to 30 %.

The ventilation system REKU combined with heat pump technology

The LK ventilation systems REKU are often used in aerosol polluted production areas such as machining fabrications, welding shops and areas with high process waste heat. Filtrations up to class F7 ( New: ISO ePM 2.5) can be used in supply and exhaust air. The filter class can be adjusted depending on the application. With the integrated heat recovery system, up to 84% of the thermal energy contained in the exhaust air is transferred to the supply air via a plate heat exchanger using the counterflow principle. The outside air drawn in is thus heated and fed into the hall. With this technology, the supply air and exhaust air flow is separated from each other. Thus, heat from polluted air can also be used.

LK Ventilation system REKU with heat pump package
LK Ventilation system REKU with heat pump package

In summer, the process waste heat is discharged directly to the outside. The heat recovery is bypassed via a bypass to avoid unnecessary heating. A combination of the LK ventilation system REKU and an air-to-air heat pump does not require fossil fuels. As with the other system combinations with heat pumps from LK Metallwaren, the heating element can be operated for heating (direct condenser) or for cooling (direct evaporator). This added value helps to significantly improve the hall climate. Another advantage is that this combination is also subsidized by up to 35%.

The LK Warm Air Generator Green Climate System
The LK Warm Air Generator Green Climate System

The new LK “Green-Climate-System” (GCS) warm air heater

In order to conserve finite resources, the LK design engineers have developed the new CO2-neutral LK “Green-Climate-System (GCS)” Warm Air Heater developed for industrial halls from 4 m hall height. The “Green Climate System” does not use fossil fuels. The LK warm air heater is installed under the hall roof and draws in either hall air or outside air. Ventilation is provided by highly efficient radial impellers with EC motor technology. The passing air is heated via a heating coil connected to the heat pump. An upstream filter cleans the fresh and hall air supply from impurities. In case of very cold outdoor temperatures, it is possible to use an electric reheating coil. This covers peak loads without having to resort to a fossil fuel.

The system behaves similarly to the heating element in the heat pump in the domestic sector. Here, as in the systems already mentioned above, a heat pump with R32 coolant is used. The new system can thus heat and ventilate the hall during the winter months. In summer, ventilation and cooling is possible. With the new LK warm air heater “Green-Climate-System”, LK Metall relies 100% on the medium electricity and thus on regenerative energy sources. This makes the new plant system particularly eligible for subsidies.

Conclusion: LK Metall relies on energy efficiency and resource-saving systems with its entire plant technology in hall heating.

 

The new office building of mister*lady GmbH in Schwabach (photo source: LK Metall)

Dust-free feel-good climate without drafts on 4,500 sqm

The German fashion retailer mister*lady relies on energy-efficient heating without dust and drafts. LK Metall installed an innovative heating and ventilation system as part of a new construction of a logistics center for the German fashion retailer mister*lady in Schwabach. An investment that has already proven itself in many ways, emphasizes mister*lady managing director, Rudolf Kempter.

Background: mister*lady GmbH moved its headquarters from Nuremberg to Schwabach. In addition to the new central administration with an area of 6,000 m², two logistics halls with an area of 4,500m² each were built. Each hall has 10 gates, a room height of about 7.50 m and a room volume of about 75,000 m³.

In particular, the climate-friendly heating and ventilation of the logistics halls posed a challenge. Managing Director Kempter was faced with a choice. “The architect, general contractor and other consultants recommended different solutions,” he recalls, “so with new construction, it’s important to find out exactly what the requirements are.” Of course, the warehouse activities had to be taken into account: The approximately 22 mister*lady employees moved about 15 million parts in about one million packages per year in single-shift operation. Around 3,600 arrivals and departures took place at the 10 loading stations.

Since the production halls employ the company’s own staff, Kempter is particularly concerned about their well-being: “A modern and energy-efficient solution was important. To achieve a good indoor climate for our people, the temperature distribution must be even and free of dust and drafts. Rudolf Kempter deliberately decided against using gas-fired dark radiators.

Technical structure of the hot air generators
The warm air generators installed under the ceiling draw in waste heat rising from the hall – such as heat generated by lighting or solar radiation – and filter it. In addition, fresh outside air can be drawn in. The air passes a stainless steel combustion chamber to bring it to the desired room temperature. Turbulent flow of the exhaust gases is generated inside the heat exchange tubes arranged on the left and right, thus ensuring optimized heat exchange. Special air outlets and return air ceiling fans distribute the air flow draught-free in the hall. The hot air distribution is controlled automatically by means of PI differential temperature control via measuring sensors in the working area and on the ceiling.

A control system regulates the temperature of the system intelligently and adapted to the wishes of mister*lady: The hall is heated individually as required. The desired room temperature is freely programmable. After an installation period of only one week, mister*lady was able to put the systems into operation.

Costs in view
Looking back, after a first winter heating season, the managing director’s expectations have been met: “The employees are satisfied. The air layering is super, as promised. The air is distributed evenly. There are no cold or warm corners, no trace of drafts.” The energy consumption is also convincing: “On normal working days, we need an average of 320 m³ of gas during the cold season, which corresponds to a cost of about €80,” says Rudolf Kempter.

Especially in the transitional period, the system does not require the burner to be switched on. Then the accumulated heat under the hall roof is already enough. The return air ceiling fans then distribute it evenly back to where it is needed. Great climate should also prevail in the summer at mister*lady. Here, the good hall insulation and the ventilation system play the supporting role. At night, the system draws in the cold outside air and has already ensured pleasantly cool temperatures in the logistics hall by the time the shift begins in the morning. This makes extra air conditioning superfluous.

Advantage: less space required for hall expansion
Another advantage of the plant will only come into play in the future. Rudolf Kempter has further plans for the expansion of the hall. He would like to add a lattice mezzanine at mid-hall height for administration. No problem thanks to the intelligent air distribution of the RBW 125. “With our heating solution, even the employees on the first floor still get warm feet. In addition, there is no need to maintain a minimum distance, as is required for radiant heaters. The space consumption would have been enormous with probably up to 70 radiant heaters needed in the logistics area,” he concludes.