Solutions
Commercial & Industrial Heat Pump
Heat pumps play a vital role in achieving net zero emissions as commercial and industrial heating accounts more than 20% of the total global CO2 emissions. We consider the following principles to design and build most efficient heat pump systems customised for the facility.
Efficiency and Performance Optimization
- Sizing: Properly size the heat pump system based on the facility’s heating and cooling demands. Oversized or undersized systems can lead to inefficiencies.
- Heat Source Selection: Choose the most suitable heat source (air, ground, water) based on availability, temperature, and efficiency.
- Heat Exchangers: Optimize heat exchanger design for efficient heat transfer between the heat pump and the facility.
Integration with Existing Systems
- Integration: Seamlessly integrate the heat pump system with existing infrastructure (e.g., boilers, chillers).
- Hybrid Systems: Consider hybrid solutions that combine heat pumps with other technologies for optimal performance.
Refrigerant Selection and Environmental Impact
- Low-GWP Refrigerants: Choose refrigerants with low global warming potential (GWP) to minimize environmental impact.
- Safety and Efficiency: Balance safety, efficiency, and environmental concerns when selecting refrigerants.
Controls and Automation
- Smart Controls: Implement advanced control systems to optimize heat pump operation based on real-time conditions.
- Load Management: Integrate load management strategies to balance heating and cooling demands efficiently.
Maintenance and Monitoring
- Regular Maintenance: Establish a maintenance schedule for heat pump components (compressors, coils, valves).
- Monitoring: Install monitoring systems to track performance, detect anomalies, and ensure optimal operation.
Energy Efficient Utilities
Many buildings—office blocks, shopping centers, hospitals, hotels and industrial facilities were constructed between 20 and 40 years ago. These structures often have outdated heating and cooling systems that consume excessive energy. Simply replacing ageing equipment with like-for-like components is not the right solution. Molen Technic adopts new, energy efficient smarter technologies and practices to reduce utility bill and decarbonize heat. Our holistic solutions encompass all critical elements of utilities, ensuring comprehensive and efficient system design. These components include:”
Chillers
- Chillers form the core of cooling systems. They efficiently remove heat from buildings and industrial processes.
- Our chiller solutions prioritize energy efficiency, reliability, and customization to meet specific requirements
Heat Recovery from Chillers and Cooling Towers for Heat Pumps
- Heat recovery technology captures waste heat from chillers and cooling towers.
- This recovered heat can be repurposed for space heating, domestic hot water, or other applications.
- By integrating heat recovery, we maximize energy utilization and reduce overall consumption
Pumps
- Energy-efficient pumps play a crucial role in circulating fluids within the system.
- Variable-speed pumps adapt to demand, minimizing energy waste and maintaining stable flow rates.
Control Valves
- Pressure-independent control valves ensure precise regulation of heating and cooling.
- Stable temperature control enhances occupant comfort while optimizing energy use.
Distribution System
- Properly designed distribution piping minimizes energy losses.
- Insulated pipes prevent heat transfer, improving overall system efficiency.
Demand Based HVAC
Poorly conditioned and ventilated buildings does not only impact occupant comfort but also their health. On the other hand, unnecessarily excessive heating, cooling and ventilation result in high energy cost and more carbon emissions. We design and implement demand based HVAC that adjusts heating, cooling and ventilation based on the actual occupancy and air quality rather than a fixed setpoint. Our solution dynamically responds to changing conditions and optimizes energy efficiency while ensuring a healty and comfortable indoor environment. Some of the key principles that we consider for demand based HVAC design is given below.
Occupancy Sensing
- DCV systems use occupancy sensors (such as motion detectors or infrared sensors) to detect the presence of people in different areas of the building.
- When a room is unoccupied, the system reduces ventilation rates to save energy.
Air Quality Monitoring
- Sensors measure indoor air quality parameters such as CO2 levels, humidity, and volatile organic compounds (VOCs).
- If air quality deteriorates (e.g., due to increased occupancy or pollutants), the system increases ventilation rates to maintain a healthy environment.
Variable Airflow Rates
- Unlike constant airflow ventilation (CAV), where the airflow remains fixed, DCV adjusts ventilation rates dynamically.
- When more fresh air is needed (e.g., during busy hours or events), the system increases airflow. Conversely, it reduces airflow during off-peak times.
Integration with HVAC Controls
- DCV systems communicate with HVAC controllers to modulate fans, dampers, and other components.
- The control logic ensures that ventilation aligns with real-time demand.
Energy Savings
- By avoiding over-ventilation in unoccupied areas, DCV significantly reduces energy consumption.
- It prevents unnecessary heating or cooling of fresh air, leading to cost savings.
Customization and Zoning
- DCV allows customization for different zones within a building.
- For example, conference rooms may have higher ventilation rates during meetings, while storage areas may have minimal airflow when empty.
Health and Comfort
- Proper ventilation improves indoor air quality, which positively impacts occupants’ health, productivity, and well-being.
- DCV ensures that fresh air supply meets actual needs without wasting energy.
BMS Optimisation
A poorly operating BMS not only impacts building performance but also affects energy efficiency, occupant satisfaction, and overall cost-effectiveness. We have surveyed and improved BMS of over 100 industrial and commercial facility. Some of the following faults are quite common on Building Management Systems. Faulty sensors, damper and valve actuators temporary open heating and cooling valves that has become permanent Heating and cooling valve hunting due to poorly functioning PID loops Passing heating and cooling valves Single temperature setpoints with no or very narrow headband Unnecessarily low or high temperature and humiditiy setpoints Over humidification or dehumidification due to wrong humidity setpoints.
Our specialist BMS optimisation team survey BMS and address all the issues and improves not only building management system performance but also improves energy efficiency and occupant comfort; and reduces cost and carbon emissions.
Metering & Monitoring
Energy Metering & Monitoring: We design and build tailored energy metering and monitoring systems that provide actionable insights, support sustainability goals and contributes efficient resource management. We consider the following key principles.
- Standard Equipment and Adaptation
- User Expectations
- Reliability and Simplicity
- Maximizing Return on Investment
- Data Completeness and Quality
Energy Efficient Fan Retrofit
In many buildings, AHU fans are the largest energy consumers within the HVAC system. Inefficient fans not only waste energy but also impact overall system performance.
Our energy-efficient fan experts surveyed, designed, and retrofitted dozens of fans in industrial and commercial buildings. We are independent fan experts who do not represent any brand. As a result, we design and install the most appropriate fan for the purpose. Technical surveys and site tests are essential for proper design and installation.
A new energy efficient fan can save up to 50% of energy with an average payback of 2-5 years.
Energy Efficient Pump Retrofit
In the pursuit of energy efficiency and sustainability, upgrading to Energy-Efficient Heating and Cooling Circulation Pumps is a smart move. Pumps account for 20-50% of overall energy consumption, depending on building type and utilities. As such, replacing obsolete pumps with energy-efficient pumps saves cost and reduces carbon emissions significantly. Our specialised team surveys current pumps, performs site testing to calculate pump efficiency, and chooses a new energy efficient pump from a wide range of high-quality pumps.
We have a coating option for big, pricey pumps too. Because the payback time is so long, it’s not always a good idea to replace an old pump with a new one. This solution improves performance and efficiency by 3% to 25% with a much better payback time.
Heating and Cooling Control Valves
Pressure independent control valves(PICVs) enhance system stability, simplify design, improve energy efficiency, and provide precise temperature regulation. Their reliability and proven performance make them a valuable choice for modern HVAC systems.
PICVs maintain a constant flow rate, even with pressure fluctuations. This stability prevents overflows, underflows, and wasted energy, resulting in a more comfortable space for occupants.
PICVs optimize flow regardless of pressure changes. This leads to better energy efficiency by minimizing unnecessary flow and reducing energy consumption. PICVs ensure that each device receives the required heat transfer. This precise control enhances comfort and system performance. We also provide energy valves option which combine flow control, energy efficiency, and monitoring in one device, making it a valuable choice for modern HVAC systems.
Integrating PICV/Energy valves with variable speed pump control enhances system performance, reduces energy waste, and ensures a comfortable indoor environment.
Following an extensive survey, we design an optimal heating and cooling distribution system that includes new Pressure Independent Control Valves (PICVs) and pumps. This system is set to significantly improve performance, reduce expenses, and minimize carbon emissions.
Heat Recovery
Heat recovery in commercial and industrial ventilation systems is essential for energy-efficient, healthy indoor environments. Whether you’re designing a new building or upgrading an existing one, consider integrating AHUs with heat recovery to reap the benefits of improved air quality and reduced energy consumption.
A well-designed AHU operating with a heat recovery system can recover upwards of 73% of the thermal energy from the extract air stream. This recovered heat is then input directly back into the fresh air supply before distribution via the building’s ventilation system.
- Commercial Buildings: Offices, retail spaces, hotels, and restaurants benefit from AHUs with heat recovery.
- Industrial Facilities: Factories, warehouses, and production facilities can maintain optimal air quality and temperature with heat recovery.
Pharmaceutical Industry Solutions
Molen Technic, a trusted partner of leading pharmaceutical firms worldwide, specializes in crafting and executing carbon and cost reduction plans without compromising quality or compliance. Since 2017, we’ve identified numerous carbon optimization initiatives spanning hundreds of pharmaceutical facilities, benefiting a diverse array of life science clients. Our proven solutions were implemented at 100+ pharmaceutical manufacturing sites. We follow science and risk based approach for our solutions.
Residential Solutions
As a division of the Molen Technic Group, the Higreen brand is well-known for its high-quality residential heating products and services. Higreen offers heat pumps, efficient boilers, and smart heating systems for residential and small commercial buildings with a focus on sustainability and Net-Zero energy.
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