Specialists from EPMICS-Engineering have successfully completed a comprehensive upgrade of the industrial and process cooling systems at the ABFC production site.
EPMICS | BLOG
EPMICS-Engineering Optimizes Cooling Infrastructure at ABFC Basalt Plant
As the operator of the region’s largest newly constructed continuous basalt fiber plant, Arab Basalt Fiber Company (ABFC) is currently undergoing the ambitious process of scaling up to its full design capacity. To support this transition, ABFC’s engineering team identified several complex challenges regarding the integration of cooling systems. The objective was to ensure seamless reliability during the initial ramp-up phase and future full-scale operations, while maintaining maximum flexibility, precision tuning for technological needs, emergency resilience, and energy efficiency across all operating modes.
Innovation in Energy Efficiency
The ABFC facility is a pioneer in the industry, featuring an innovative energy-saving cooling scheme. The system utilizes absorption chillers to generate cold by recovering “waste” heat from furnace exhaust gases. While this system offers undeniable advantages—essentially eliminating electricity consumption and providing constant savings of hundreds of kilowatts—it requires the majority of the basalt melting furnaces to be operational. During the phased commissioning and fine-tuning of core production processes, such continuous operation is not always feasible. To bridge this gap, the design allows for the integration of temporary compression chillers to maintain air conditioning and heat removal from critical furnace components.
Innovation in Energy Efficiency
The ABFC facility is a pioneer in the industry, featuring an innovative energy-saving cooling scheme. The system utilizes absorption chillers to generate cold by recovering “waste” heat from furnace exhaust gases. While this system offers undeniable advantages—essentially eliminating electricity consumption and providing constant savings of hundreds of kilowatts—it requires the majority of the basalt melting furnaces to be operational. During the phased commissioning and fine-tuning of core production processes, such continuous operation is not always feasible. To bridge this gap, the design allows for the integration of temporary compression chillers to maintain air conditioning and heat removal from critical furnace components.
Engineering Excellence and Results
EPMICS-Engineering spearheaded the technical realization of this upgrade. As Engineering Consultant our team performed complex engineering calculations, developed the necessary documentation, selected specialized equipment, and provided rigorous oversight of the installation work carried out by the contractor, Expert Co.
As a result of these improvements:
Hybrid Operation: Absorption chillers can now operate independently or in tandem with temporary chillers.
Dynamic Adaptation: Process water supply temperatures can be flexibly adjusted to meet specific technological requirements in any mode of operation.
Emergency Reliability:
The system now features an automated mode that ensures uninterrupted cooling of furnace components – critical for the protection of high- value equipment – even during a complete power failure.
EPMICS-Engineering spearheaded the technical realization of this upgrade. As Engineering Consultant our team performed complex engineering calculations, developed the necessary documentation, selected specialized equipment, and provided rigorous oversight of the installation work carried out by the contractor, Expert Co.
As a result of these improvements:
Hybrid Operation: Absorption chillers can now operate independently or in tandem with temporary chillers.
Dynamic Adaptation: Process water supply temperatures can be flexibly adjusted to meet specific technological requirements in any mode of operation.
Emergency Reliability:
The system now features an automated mode that ensures uninterrupted cooling of furnace components – critical for the protection of high- value equipment – even during a complete power failure.
Solving Complex Challenges
To achieve these results, EPMICS engineers performed detailed thermodynamic calculations of LPG combustion within the furnaces. We identified specific operating modes that maximize the efficiency of the Absorption Chiller Machines (ABM) with a limited number of furnaces active, all while ensuring no negative impact on the fiber production process or the integrity of heat exchangers.
Additionally, a comprehensive water chemistry program was implemented: Full-scale flushing and treatment of the water circuits to preserve the longevity of piping and cooled equipment. Based on site-specific water analysis, EPMICS selected the optimal chemical treatments and calculated the required water-chemical regime for ongoing maintenance.
To achieve these results, EPMICS engineers performed detailed thermodynamic calculations of LPG combustion within the furnaces. We identified specific operating modes that maximize the efficiency of the Absorption Chiller Machines (ABM) with a limited number of furnaces active, all while ensuring no negative impact on the fiber production process or the integrity of heat exchangers.
Additionally, a comprehensive water chemistry program was implemented: Full-scale flushing and treatment of the water circuits to preserve the longevity of piping and cooled equipment. Based on site-specific water analysis, EPMICS selected the optimal chemical treatments and calculated the required water-chemical regime for ongoing maintenance.
Arab Basalt Fiber Company is the Middle East and North Africa region’s largest basalt fiber and composite manufacturing facility, located in Fujairah, UAE. Through newest state-of-the-art production facility, company deliver advanced material solutions across industries – from construction and automotive to renewable energy and defense applications, with planned expansion into North America and Western Europe. See more…
Expert Co is a contracting company located in Fujairah, UAE, specializing in ventilation and cooling systems.
EPMICS-Engineering is a multidisciplinary, full-cycle engineering company. Its specialists possess extensive expertise in establishing continuous basalt fiber production facilities. Among others, one of core competencies include the design, optimization, and implementation of projects focused on energy-saving cooling technologies – for both industrial and infrastructure applications—as well as all forms of water treatment, including chemical processing.
Expert Co is a contracting company located in Fujairah, UAE, specializing in ventilation and cooling systems.
EPMICS-Engineering is a multidisciplinary, full-cycle engineering company. Its specialists possess extensive expertise in establishing continuous basalt fiber production facilities. Among others, one of core competencies include the design, optimization, and implementation of projects focused on energy-saving cooling technologies – for both industrial and infrastructure applications—as well as all forms of water treatment, including chemical processing.