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Cooling system innovation saves Dyno Nobel thousands

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article image Summit Matsu Chillers presented a unique cooling concept designed for high ambient conditions

Summit Matsu Chillers completed a very challenging cooling system for Dyno Nobel’s new ammonium nitrate emulsion plant at Port Hedland.

Key challenges included the consistently high ambient air temperatures at Port Hedland and a dusty site. Accurate temperature control was critical since the ammonium nitrate produced by the plant was used to manufacture explosives. Additionally, being a remote location, there was a shortage of local trades and services, and a lack of accommodation and facilities.

Summit Matsu Chillers presented a unique cooling concept that was designed for high ambient conditions, allowed free cooling overnight and during most of winter to save on power, and pre-fabricated for fast and simple connection at site, saving Dyno Nobel considerable expense on the overall project.

Being a distributor for the Italian made Thermokey heat exchangers, Summit Matsu Chillers chose for the dry cooler, a Thermokey JGQ series 5.2 x 2.4 metres V-shape type model delivering 366kW of cooling. Rosenberg fans were factory fitted at Summit Matsu Chillers and the control system was set to monitor the water outlet temperature and turn fans on in groups with the changing ambient temperature.

The chiller delivered 250kW of refrigeration capacity at 45°C ambient air temperature and was fabricated into a 20’ shipping container together with a 5000-litre insulated thermal buffer storage tank. Grundfos pumps were used for both the chiller side and process side, and power distribution and electrical controls were factory wired using Eaton components.

Chiller compressors used in the system included Hanbell screw compressors with solenoid staged capacity control. The chiller controller was a Dixell iPro from Emerson and was set for the dry cooler to operate up until the ambient condition rose to a point where the chiller was required. The controller then staged the first chiller compressor, followed by the second compressor depending on demand.

Being a licensed electrical contractor, Summit Matsu Chillers also completed all the site wiring that could be done in-house to reduce site installation costs.

As a licensed refrigeration and air conditioning contractor, Summit Matsu Chillers was able to offer site commissioning and preventative maintenance through its national contractor network, ensuring reliable performance for the life of the chiller unit.

Summit Matsu Chillers manufactures a standard chiller range using components sourced from world-leading manufacturers and serves customers such as Hewlett Packard, Dyno Nobel, Modwood, ABB and Rockwell Automation.

Summit Matsu Chillers also manufactures containerised chillers, plant rooms and pump and tank modules for rapid deployment to remote sites. Customers include Fortescue Metals Group, BHP Billiton, Rio Tinto, Xstrata, Newcrest Mining, Millennium Minerals and Newmont Mining.

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