Reduction in carbon footprint with the use of a commercial bivalent system

The Buhler Group, a Swiss company renowned for its innovative solutions in the grain and food industry, also specialises in the production of advanced materials that enhance the energy efficiency of vehicles and buildings. Their facility in East London encompasses factory floors, research and development spaces, and administrative offices.

In 2007, the existing heating system of the building relied on radiators and rooftop air handling units equipped with heating coils, powered by an Ideal IMAX Plus F240 condensing appliance, which featured six cast aluminium sections and individual burners. Over time, the system experienced recurrent component failures, and the appliance neared the end of its operational life, prompting the site services manager to investigate replacement or alternative solutions. Independent Heating & Cooling (IHC) was commissioned to identify the most efficient and cost-effective option.

Initially, the plan involved replacing the boiler with a more efficient model integrated into the existing system. However, the Buhler Group’s commitment to reducing carbon emissions led them to pursue a more environmentally friendly alternative: air-to-water heat pump technology. Consequently, a bespoke bivalent system was designed to fulfil the client’s heating requirements while minimising the carbon footprint.

The newly designed system incorporated three Mitsubishi Electric CAHV air source heat pumps arranged in a cascade configuration, providing up to 120 kW of heating capacity with an outlet temperature of 70°C, even under ambient conditions of -20°C. Complementing the heat pumps was an Ideal Evomax2 120 kW fully condensing boiler, equipped with a manufacturer’s plate heat exchanger, both of which fed into a 1000-liter buffer tank. The obsolete Ideal IMAX Plus boiler was decommissioned, a small plinth was constructed to accommodate the new boiler plant, with new piping and associated valves, pumps, and fittings connected directly to the buffer vessel.

The heat pump cascade was positioned approximately 60 meters from the plant room on an adjacent section of the roof. Stainless steel piping was installed between the CAHV units and the buffer, inclusive of all necessary pumps, valves, and fittings. The existing system underwent comprehensive cleaning and flushing prior to the connection of the new buffer vessel and plant.

Upon commissioning the Ideal Evomax2 boiler and Mitsubishi Electric CAHV units, the system was activated. The primary heating load for the buffer was provided by the cascaded CAHV units, while the boiler served as a supplementary heat source during periods when ambient temperatures fell below -5°C. The entire system was managed through a web-based Covert control management system, which further enhanced efficiency and aligned with the Buhler Group’s carbon footprint objectives.

In conclusion, the Buhler Group sought a more sustainable heating solution to mitigate their carbon footprint. IHC facilitated the implementation of air-to-water heat pump technology, integrated with efficient boilers and an advanced control system. This initiative enabled the company to achieve its environmental goals without sacrificing reliable and effective heating for their facility. This innovative approach serves as a valuable example for other organisations aiming to enhance energy efficiency and progress toward a more sustainable future.

Client feedback on completion of project:

We have been using IHC for a few years and during that time have become aware of how professional and competent their engineers are, especially in solving problems with a HWS Boiler that had baffled previous contractors.

When the decision to replace the old gas boiler was made, a cost comparison for a like for like gas solution was sought by looking at a few contractors, and IHC were competitively priced. It was then logical to ask IHC to propose an Air-Source Heat Pump solution, allowing us to move further away from gas and utilising green electricity. The initial location of the heat pumps was not ideal for a variety of reasons, but IHC were always prepared to listen to suggestions, and ultimately, they delivered a system that is not visible to staff or the general public and provides no sound or air pollution for the residential neighbours.

The removal of the old equipment, and installation of the heat pumps, buffer vessel, pipework and ancillary equipment was carried very professionally and in a timely manner. When finished, the bare pipework was like a work of art and so well thought through but now fully insulated to the highest standards.

We opted for the Covert control system as the cost of modifying our existing BMS was too much, but this gives us the ability to remotely log in to the controls to both make operational changes where needed, or view alarms. Shortly after commissioning, we did see an alarm, and within an hour and one email IHC saw the alarm, responded with an engineer who knew what the fix was, and the fault was fixed the same day.

Whilst the project overall involved considerably more expense than a simple like-for-like gas boiler swap, we have reduced our CO2 emissions and our reliance on non-renewable natural gas energy.

I wouldn’t hesitate to recommend IHC to anyone and will look to partner with them on a solution for our ageing HWS gas boilers in the near future.

John Deans

Site Services Manager

Buhler UK Ltd

For further information on how IHC can assist you in achieving similar objectives, or assist with any of your heating or cooling installations, maintenance or repair, please do not hesitate to contact us to visit our website.

Website: www.ihc-uk.com

Email: sales@ihc-uk.com

Telephone: 01323 449000