Feasibility study for the renewal of a refrigeration system

Location: Rüsselsheim, Germany

Services: As-built status and data recording, Solution development / Feasibility studies

Industry Branch/Type of Plant: Green Energy

Client: Opel Automobile GmbH

Activity period: 2025

Project description

As part of the renewal of the refrigeration supply at the production plant in Rüsselsheim, INP got the order for this feasibility study. The aim of the study was to develop four technical variants of future refrigeration systems for the production plant and compare them in regard to economic efficiency, operational reliability, energy efficiency, space availability and safety-related requirements (e.g., incident management, occupational safety, fire protection). The study covered a modulation cooling capacity up to 5MW designed to cover base-load, part-load, and peak-load conditions. The results provide the basis to find the decision for implementation a future-proof solution.

INP developed a robust decision framework for the future cooling generation of the painting facility at the Rüsselsheim production plant. First, the existing system was systematically documented, current load profiles were evaluated, and future demand was estimated. Based on this, four technical variants were developed:

a) refurbishment of the existing system

b) construction of a new building on the same site as the old system

c) construction of a new building in an adjoining room

d) an innovative system with ice storage and a new CHP unit.