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Technical systems are often expanded, adapted, or combined with other systems over many years of operation. As a result, complex plant infrastructures develop in which individual components were originally designed for specific energy-related and economic conditions. However, these conditions change over time: energy prices rise and fall, technical requirements evolve, and environmental objectives become increasingly important.

As part of a current project, KB KälteBeratung has been commissioned to carry out a feasibility study for the future refrigeration supply of a large production and logistics site.

Initial Assessment as a Basis

The first step involved a comprehensive inspection of the existing technical areas. The large-scale refrigeration systems, together with their associated components and supply systems, were initially recorded and assessed at a general level.

The main areas of focus included:

• the technical condition of the existing systems,
• their current operating modes,
• the interaction between the individual systems,
• potential energy-related dependencies,
• identifiable potential for optimisation and modernisation.

This initial assessment provides the basis for the subsequent detailed evaluation. After all, it is not only the age or condition of an individual system that matters. Equally important is the question of how effectively the entire system still works together under today’s conditions.

What Made Sense Ten Years Ago May No Longer Be the Best Solution Today

Even if the basic plant configuration has remained largely unchanged over the years, the economic conditions surrounding its operation may have shifted significantly.

One example is the integration of a combined heat and power unit (CHP). Such a system generates electricity and heat simultaneously by burning gas. The heat produced can then be used to supply an absorption refrigeration system.

Whether this interaction is still economically viable today depends on a number of factors:

• How have gas and electricity prices developed?
• What are the current heating and cooling requirements?
• How efficiently are the individual components operating?
• Is the electricity generated on site more cost-effective than purchasing electricity from the grid?
• Could the required refrigeration capacity be provided more efficiently by other systems?
• Would continued operation, conversion, or decommissioning be the more appropriate solution?

A system may still be technically functional while no longer representing the most economical or energy-efficient solution.