Planning and simulation of a ventilation system in an existing building at an aluminum foundry

Overview

Location: Germany, Saxony
Project duration: 9 months
Production area: approx. 3.500 sqm

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out the planning and simulation of a ventilation system for an existing aluminum foundry. The aim of this project was to design the ventilation capacity in line with demand, efficiently dissipate waste heat and sustainably improve the air quality at the workplaces.

Project content

Actual analysis and waste heat quantities

Evaluation of the current framework conditions in the existing hall, including documentation of the waste heat and relevant process data. Among other things, a required supply air volume of approx. 184,000 m³/h and a heat output of approx. 900,000 kW were determined.

Design parameters and air changes

Calculation of the required framework parameters for the ventilation technology, including defined air change rates and volume flows. Basis for a safe and efficient design of the technical building equipment (TBE).

Ventilation and system concepts in existing buildings

Development of ventilation and system concepts based on preliminary planning, tailored precisely to the hall geometry and workstations. Consideration of material flow, heat input and structural restrictions.

Computational Fluid Dynamics (CFD) / flow simulation

Validation of concepts using flow simulations, visualization of temperature and air distribution as well as critical zones. Simulation results as a decision-making aid for variant selection and design.

Design planning of the simulated concept

Deepening of the selected concept for design planning including 3D planning. Specification of components, cable routing and installation areas for smooth implementation.

Measurement, control and regulation technology (MSR) and electrical supply

Development of a control and regulation concept and planning of the new electrical supply. Ensuring energy-efficient and reliable plant operation.

Construction planning, interfaces and project management

Coordination of construction requirements and interfaces, including cost estimates and scheduling. Transparent approach for plannable implementation.

Advantages of our solution

• Comprehensive general planning: Integrated consideration of ventilation technology, technical building equipment (TBE), measurement and control technology (MCR), electrical engineering and construction minimizes interface risks.
• Reliable design: Well-founded calculations and clearly defined framework parameters (e.g. air change) ensure needs-based dimensioning.
• Transparency through simulation: Computational Fluid Dynamics (CFD) makes flow and temperature fields visible and reduces iteration loops.
• Cost and schedule certainty: Early cost estimation and reliable scheduling create decision-making certainty for implementation.
   

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