In a demanding industrial environment, thermal comfort is far more than a luxury – it’s a fundamental driver of worker well-being, productivity, and operational efficiency. At TERAO, we recently partnered with a leading automotive manufacturer in Southeast Asia to transform their challenging production workspace into a cooler, safer, and more efficient environment.
The Challenge: Overheating, Discomfort, and Inefficient Operations
Our client’s large automotive factory faced significant issues with excessive heat, especially around machinery and active production lines. This wasn’t just about discomfort; it directly led to:
- Worker heat stress and fatigue, impacting morale and raising safety concerns.
- Reduced productivity as employees struggled to maintain focus in uncomfortable conditions.
- High energy bills from inefficient cooling systems are attempting to combat the intense heat generated by industrial processes.
The factory needed a precise, impactful solution that could manage heat effectively without disrupting operations or incurring excessive costs.
TERAO’s Approach: Advanced CFD Modeling and Strategic Interventions
To accurately diagnose the problem and propose effective solutions, TERAO conducted a comprehensive thermal comfort study utilizing advanced Computational Fluid Dynamics (CFD) modeling. Our methodology involved:
1. Detailed Data Collection: We gathered extensive on-site data, including ambient temperatures, surface temperatures of the building envelope (e.g., roof temperatures reaching up to 58°C on skylights and non-insulated areas), and accurate heat loads from machinery. We also incorporated local weather data, including wind direction and outdoor temperatures (averaging around 33.4°C).
2. CFD Model Development: Using advanced software such as industry-standard simulation tools, we created a detailed 3D model of the factory. This allowed us to simulate current airflow patterns, temperature distribution, and how heat from operations impacted the indoor environment.
3. Performance Evaluation: Our CFD analysis revealed that the working space temperatures ranged from 34°C to 36.5°C, with some roof areas exceeding 40°C. Existing fans created high air velocities (up to 4.3 m/s), causing drafts and uneven comfort.
4. Optimization Strategy Development: Based on the simulations, we proposed two key strategies to improve thermal conditions:
- Installing Roof Extraction Fans: To efficiently remove hot air, increase air change rates, and improve overall air quality. We calculated the required airflow and identified suitable industrial fans.
- Combining Extraction Fans with Louver Blocking: To eliminate unintended air leakage through wall and roof louvers, ensuring that the extraction fans could more effectively control ventilation and direct airflow for targeted and consistent air exchange.
Solutions & Impact: A Cooler, Safer, and More Efficient Factory
The CFD simulations demonstrated the significant positive impact of our proposed interventions:
Temperature Reduction: Both optimization strategies consistently lowered working space temperatures by approximately 1°C to 1.5°C. While this might seem small, in a natural ventilation industrial setting, this is a substantial improvement for worker comfort and heat stress reduction. Importantly, the roof area no longer showed air volumes above 40°C.
Improved Airflow Uniformity: The optimized fan placement and louver management resulted in more controlled and balanced air velocities (ranging from 0.3 m/s to 3.8 m/s), significantly reducing uncomfortable drafts and ensuring more consistent air movement throughout the space.
Enhanced Productivity & Safety: A cooler and more comfortable environment directly leads to reduced heat stress, improved concentration, and a safer workplace for employees.
Increased Energy Efficiency: By strategically managing hot air extraction and optimizing natural ventilation, the factory can achieve better thermal conditions without relying on energy-intensive air conditioning, leading to potential energy savings.
Conclusion: Driving Industrial Performance Through Optimized Environments
This case study highlights TERAO’s capability to deliver precise, data-driven solutions for complex industrial thermal challenges. By leveraging advanced CFD modeling and targeted interventions, we help manufacturing clients enhance worker well-being, improve operational efficiency, and achieve their sustainability goals. Investing in optimal thermal comfort is a strategic decision that drives both human and operational performance.
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