Ice storage
with internal and external cast iron
ICEBAT HYE

To combine power and performance at very low temperatures

The new FAFCO Hybrid Ice Accumulator has been specially designed for industrial process refrigeration, where it provides very high discharge performance at extremely low temperatures while ensuring maximum operational safety.

Particularly used in the following situations :

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Production processes in the chemical and pharmaceutical industries such as :

  • The technical-chemical industry
  • Production of chemicals and basic substances
  • The paint industry,coatings and glues
  • The processing of plastics
  • Pharmaceutical production
  • The cosmetics industry
  • Paper and cardboard production

Production processes in the food industry such as :

  • Milk and cheese production
  • Bakeries
  • Breweries

For emergency cooling system.

In all these extremely demanding areas, the FAFCO Hybrid Ice Accumulator meets the highest quality standards and extends the benefits of standard ice accumulator systems to new areas.

DOCUMENTATION

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Principle of operation


A circuit for charging, a circuit for discharging
Hybrid ICEBAT is a FAFCO proprietary technology on the market.
It combines internal and external cast iron to provide exceptional discharge power.
Thus, a battery charged in several hours can be discharged in less than 1 hour, regardless of its capacity.

In order to form the ice inside the ICEBAT, a loop of glycol water cooled to -4°C by a cooling unit circulates through a network of Fafco exchangers immersed in the water of the tank. The glycol water will gradually give up its frigories to the water until the water reaches 0°C. From this point on, a layer of ice will form on the surface of the submerged exchangers, and will grow as long as the cooling unit is running. After 6 to 8 hours, the network of tubes forming the exchangers is completely frozen and the load can stop. In order to preserve the structure of the tank from the expansion of the ice, part of the initial volume of water remains in a liquid state and absorbs the mechanical stresses.

This animation represents the formation of ice around the tubes of the FAFCO exchangers. The glycol water (in green) cools the accumulator water (in blue) through the polypropylene tubes (in black). Ice (white) gradually forms around the tubes. When the neighbouring ice rings meet, they melt until they form a single homogeneous block of ice.

To melt the ice and recover stored frigories, the hybrid system uses the glycol water loop and the chilled water loop simultaneously. The brine loop passes through the Fafco heat exchangers and melts the ice from inside the block, while the chilled water loop circulates the remaining water in the tank in a liquid state to melt the ice block from the outside walls of the ice block. These two circuits then cool the user loop via two plate heat exchangers, either in series or in parallel.

This animation shows the melting of the ice around the tubes of the FAFCO heat exchangers. The glycol water (in green) recovers the cold stored in the ice (in white) through the polypropylene tubes (in black). The ice also melts thanks to the flow of water around the block of ice, accelerating the melting process.

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The HP Integrated System


As the ICEBAT Hybrid is clearly intended for applications requiring rapid discharge, our High Power system is installed by default.
During discharge, the ice gradually melts, first near the tubes, then further and further away. Thus, the heat exchanges at the beginning of the discharge are better than at the end of the charge. We therefore install a compressed air distribution network underneath the exchangers.

Air bubbles are thus injected under the ice during discharge.
These bubbles will rise to the surface through the block of ice in the spaces created around the heat exchanger tubes.
This improves heat exchange and ensures maximum discharge power at all times during the discharge.

Advantages


High discharge capacities at extremely low output temperatures.

Maximum operating safety – independent of discharge and charge cycles, thus allowing partial loads and partial discharges at will.

No capacity restrictions due to ice block formation.

No ice thickness measurement is required.

Longevity – thanks to the use of stainless materials for the main components.

Environmentally friendly – limited quantities of refrigerant.

Compact construction with high storage density..

Fully factory-assembled units.

Uniform ice production throughout the accumulator by means of a Tichelmann loop.

High discharge capacities at extremely low output temperatures.

Maximum operating safety – independent of discharge and charge cycles, thus allowing partial loads and partial discharges at will.

Assembly of components on site.

High flexibility – ideal for the exchange of existing systems and installation in existing containers. The modular design offers an almost unlimited range of mounting possibilities.

Mounting of large accumulators in concrete tanks built on site.

Minimal pressure losses.

Large specific heat exchange surface area: 0.43 m²/kWh latent power.

Optimum use of space thanks to the square shape of the tanks. Production and assembly in Switzerland (Biel/Bienne).

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ICEBAT XM

external cast iron

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ICEBAT UW
internal source

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ICEBAT PCM

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