Customer:
Glenmark Pharmaceuticals Ltd., Sikkim
Project Category:
HVAC Products
Customer Requirement:
Client: Glenmark Pharmaceuticals Ltd. Site: Sikkim manufacturing plant (formulation division). Application: AHU hot-water circuit (air-handling heating loop). Process Pattern: 24-hour operation, 10 000 L/hr water flow. Water Source for Heat Pump: Chiller return line (approx. 25–30 °C). Objective: Integrate a chiller-source heat-pump system without disturbing the existing steam network, retaining it as backup.
Project Result:
Successful completion of Solar Water Heating Project
What we did:
The chiller-source heat pump captures heat from the chilled-water return line via a coaxial or BPHE evaporator, upgrades it through a Bitzer scroll compressor, and transfers it to the AHU hot-water line using a BPHE condenser. Integration Logic Heat-pump pipeline connected in parallel with the existing boiler-steam PHE line via T-joint. Both circuits isolated by valves to allow easy switchover. Existing circulation pumps reused; PLC controller manages sequencing and safety interlocks. IoT module logs flow, ΔT, power, and calculated savings in real time. Major Components -Bitzer scroll compressor (with overload protection) -Selec PLC controller -BPHE / coaxial heat exchangers -SS 316/304 multistage pumps (Shakti make) -Schneider / L&T electricals with overload and single-phase protection -Dixell temperature sensors -Emerson / Danfoss / Sanhua expansion valves and HP-LP switches -Wikka SS 316 flow meter -3 mm MS frame with anti-corrosive coating --------------------------------------------------------------------------------------------------------------- -Elimination of diesel/LDO for AHU hot-water generation. -Continuous hot-water supply at 55 °C using renewable electrical energy. -Average COP ≈ 2.4, achieving substantial operating cost reduction. -ROI achieved within ~6 months under HeatRay’s performance-linked model. ------------------------------------------------------------------------------------------------------------------
Project Description
Glenmark’s Sikkim facility required a more efficient and cleaner solution for heating process water used in its AHU system. Previously, steam generated from LDO-fired boilers was used to heat 10 m³ of water per hour from 45 °C to 55 °C — an energy-intensive and carbon-emitting process. HeatRay Solar implemented a 140 kW chiller-source heat pump system that captures waste heat from the chilled-water line and re-uses it to heat the AHU hot-water loop. The result is a dual benefit: reduced heating fuel cost and lowered chiller load on the cooling side. Replace fossil-fuel-based heating (LDO steam) with a high-efficiency electric heat-pump system. Utilize existing chiller water as the heat source, thereby recovering waste energy. Reduce both heating cost and cooling power consumption simultaneously. Integrate seamlessly with the existing AHU circuit using T-joint and isolation valves, allowing dual-mode operation. Enable automated control through a PLC-based system with IoT monitoring and real-time performance tracking.
Project Budget:
NA
Completion Date:
2024-04-16T00:00:00
