90% gas reduction with CO2 heat pump
CO2-NEUTRAL PRODUCTION
SBS Friction manufactures brake pads and friction solutions for motorcycles, scooters, motocross, and ATV’s worldwide with production facilities in Svendborg, Denmark.
The company aims to have CO2-neutral production and become free from fossil fuels by 2025. Part of the plan is also to provide excess heating from the production to the grid so the local community can benefit from it.
FACTS
End-user: SBS Friction
Contractor: PVN Køleteknik
Segment: Process cooling and heating
Background: Increase production capacity and have a CO2-neutral production by 2025
Products: SteelX MT only 3x0
Start up: February 2023
Specifications:
- 380 kW heating capacity at 35°C water inlet and 75°C water outlet temperature
- 370 kW cooling capacity
- Chiller Module for cooling down water used for process cooling
- Heat Recovery for increasing water temperature for comfort heating and hot tap water
- MODBUS/BACNET communication
- Permanent Magnet Motors for maximum energy efficiency
PRODUCTION EXPANSION with LARGER HEAT PUMP
To produce brake pads of highest quality, SBS Friction uses conductive sintering technology to heat up the friction material to 900°C by electrical current. This requires process cooling to cool down the ovens to maximum 50°C.
Since 2010, SBS has used heat pumps for process cooling, comfort heating, and hot tap water. SBS could have chosen a cooling solution, but instead choose a 380 kW heat pump to be able to use the excess cooling from the heating process for process cooling while also providing comfort heating and hot tap water for the office buildings.
In 2021, SBS Friction was acquired by Italian brake system manufacturer Brembo. Since then, SBS has rapidly expanded its production capacity. The increase in production capacity also increased the needed cooling capacity, and SBS Friction therefore needed a larger capacity heat pump.
150,000 KHW AND 50,000 M3 SAVED
The new CO2 heat pump was installed in February 2023, and from February to September 2023, SBS Friction has saved 150,000 kWh thanks to the heat pump.
SBS also expects to save 50,000 m3 gas yearly corresponding to 90% of their current gas consumption with the new heat pump. The remaining 10% covered by gas is used during weekends and holidays where production is closed, and no excess heat is generated from the heat pump.
CO2 emissions reduced by 51,935 kg
To meet the goal of a CO2-neutral production, it was important that the existing HFC heat pumps were replaced by a heat pump based on natural refrigerants.
The two existing heat pumps were based on HFC refrigerants R404a and R410a with a Global Warming Potential (GWP) of 3,911 and 2,088 respectively. In contrast, CO2 has a global warming potential of 1.
The two HFC heat pumps carried 23 and 8.6 kg of refrigerants with a total CO2 footprint of 51,935 kg. In comparison, the new CO2 heat pump has a CO2 footprint of 320 kg.
EXCESS HEAT TO THE GRID
SBS Friction is further expanding their production capacity and therefore plans to install an identical CO2 heat pump in January 2024 to cover the excess cooling capacity needed.
With the addition of a second CO2 heat pump, SBS intends to sell the excess heat to the grid.