Headquartered in Germany, LEONI is a global provider of products and solutions for energy and data management in the automotive sector and other industries. The company expertly offers traditional, special and custom developed wiring systems for automobiles. Present in 30+ countries, LEONI Wiring systems manufactures quality wires and harnesses in its production facilities across the globe. The company recently partnered with Thermax for a flexible cooling and heating solution for its plant in Tunisia – a partnership that offers the plant grid-independent comfort.
GOING GRID-FREE FOR COOLING AND HEATING
Situated in northernmost Africa, Tunisia has one of the hottest summers where the temperature exceeds 40°C and the coldest winters dropping to as less as 7°C. LEONI Wiring Systems was heavily relying on electricity to deliver comfort for the production facility. High electricity prices in the country remained a challenge for comfort cooling and heating at the plant. Hence, the company decided to upgrade the plant’s cooling and heating system in order to reduce its electricity expenditure.
GETTING THE MOST OUT OF GAS
With gas widely available in the country at a cheaper price, Thermax experts recommended natural gas driven solution for the plant, aiming to cut down the energy cost associated with cooling and heating. After a brief analysis of the site and its requirement, it was decided to replace the existing cooling and heating system with four natural gas driven absorption machines. The machines were to flexibly cater to the comfort cooling and heating demand of the company’s factory in Monastir, Tunisia.
ULTIMATE SOLUTION FOR YEAR ROUND COMFORT
Thermax with a history of delivering flexible cooling and heating solutions for industries replicated a similar model for the wire and harness manufacturing plant. Four direct fired absorption machines were commissioned at the plant. Driven by natural gas, the solution constitutes two chiller heaters (1410 TR and 1610 TR) and two evaporative heaters (1410 TR and 1610 TR)
In summer, the four machines altogether provide chilled water, catering to air conditioning in the plant production area, offices and canteen via the AHU (Air Handling Unit) and fan coil units. The two evaporative heaters deliver hot water at 55°C for the premises only during winter. Thus, the four machines offer the plant consistent cooling and partial heating as required with no pressure on the grid.
KEEPING UP DESPITE THE LOCKDOWN CHALLENGES
Tunisia’s pandemic regulations restricted the plant operation timings, thus affecting the pace of the installation process. Yet, the commissioning occurred steadily, enabling the hand-over exactly as scheduled. Within a few days of the commissioning, the plant was able to witness the exceptional performance of the machines and their energy benefits.
WHAT ARE THE BENEFITS?
Besides meeting the intended objective of grid-independence, Thermax’s solutions have offered the following benefits to LEONI’s plant, • Low operational costs • Low maintenance • High reliability • Flexibility in catering to the requirement
Owing to its initial venture into absorption technology, the commissioning has been a game changer for LEONI Wiring Systems, especially considering the significant reduction in the plant’s electricity consumption. In the company’s journey towards energy-efficient cooling and heating, the results achieved are beyond energy optimisation – uninterrupted comfort and productivity.
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