The modular AmbiHeat® heat pump plant delivered by Calefa to Orion in Espoo is an important part of the factory’s production process. The heat pump plant efficiently uses waste heat from the production process and outdoor energy, providing an environmentally friendly solution for the Orion factory’s heating and cooling needs.
“Since the summer of 2024, the 2 MW cooling requirement of the tablet production line has been met completely CO2-free with five heat pumps in the heat pump plant. The previously commissioned heat pump plant provided the factory area with emission-free heating from outdoor air, reducing the need for purchased energy for heating by more than 50%,” notes Mikko Rantanen, supply chain manager at Calefa.
“The waste heat generated from the factory processes is used through the district heating network of the factory area in the heating of properties. The plant’s total heating capacity from waste heat and outdoor air is 3 MW, which means up to 19,300 MWh of completely carbon-neutral heating energy per year. The AmbiHeat® heat pump plant reduces CO₂ emissions from heating at Orion's Espoo plant by 2,200 tonnes per year,” shares HVAC engineer Jaakko Valkama from Orion.
Reliable operation of heat pumps and quality of electricity
The quality of electricity is important for the energy-efficient and reliable operation of heat production. Disruptions in the quality of electricity, such as harmonics, can cause equipment to overheat, in addition to premature wear and tear and damage. Good electricity quality ensures that the heat pumps operate stably in all conditions. This is especially important in cold climates, such as Finland, where the reliable operation of heat pumps is critical, during the winter months in particular. Heat pumps running on optimal power are energy efficient and, thanks to their long maintenance intervals, also cost-effective.
“At the core of the success of the cooperation project between Orion, Calefa and ABB was comprehensive planning started at an early stage. Challenges caused by harmonics were identified in time, meaning that the design and the equipment selections were carried out specifically from the point of view of electricity quality and the adequacy of transformer power,” recalls Pyry-Pekka Lehto, sales manager at ABB.
ABB ACH580 ULH drives: Efficiency and reliability for industrial heat pumps
ABB ACH580 ULH drives are ideal for industrial heat pump applications. ULH drives with AFE (Active Front End) technology keep the voltage of the motors stable, and their good power factor reduces energy costs and improves performance. They improve the energy efficiency of the power grid because all the power supplied is used as active power without the consumption of reactive power. In addition, the harmonic levels of ULH drives are up to 97% lower than those of conventional frequency converters. ULH drives reduce the need to overdimension power grid components, ensure trouble-free power grid operation, minimize energy losses, improve equipment durability and eliminate the risk of network overload. More efficient energy use and lower losses in the power grid reduce carbon dioxide emissions, contributing to sustainable development. ABB’s ULH drives are also easily integrated into existing systems and support a wide range of fieldbus protocols, making them flexible and versatile.
*AFE (Active Front End) technology is an advanced method to reduce harmonics in drives. AFE technology ensures less than 3% THDi, and nominal voltage is maintained in the power supply. THDi describes the number of harmonics of current in relation to the base frequency. A high THDi value can cause problems in electrical systems, such as the overheating of equipment, disruptions and energy losses. It is important to keep the THDi as low as possible, especially in sensitive and critical applications. For six-pulse standard drives with chokes, the Total Harmonic Distortion of current (THDi) is 40%, which means 16% higher losses in the electrical system.
