At the Komsomolsk-on-Amur Aircraft Plant named after Y.A. Gagarin (KNAAZ), engineers in the electroplating shop have successfully implemented an economical solution for cooling production tanks. This new system utilizes ambient winter air, replacing traditional energy-intensive methods. The United Aircraft Corporation (UAC) press service confirmed this development.
The electroplating process mandates strict adherence to specific operating temperatures for electrolytes. Anodizing tanks, in particular, require maintaining temperatures ranging from -7°C to +16°C (19.4°F to 60.8°F). Previously, meeting these requirements consumed 412,080 kWh of electricity over just 101 winter days.
The integrated cooling system installed at KNAAZ features an outdoor cooling tower positioned six meters (approximately 20 feet) above ground. A 200-meter (approximately 656 feet) pipeline filled with antifreeze transfers the cold winter air directly to the tanks. To ensure consistent temperature control when outdoor temperatures are above freezing, KNAAZ engineers integrated a backup chiller unit into the system. Six fan-assisted radiators facilitate rapid heat extraction and ensure uniform cooling across all tanks.
Calculations performed by the plant indicate a significant reduction in energy consumption for electrolyte cooling, dropping from 100% to just 7%. Additionally, the tank cooling time has been halved, decreasing from six hours to three hours. Based on electricity costs, KNAAZ estimates savings of several million rubles per winter season. Plant officials project the project will achieve full payback within two operational seasons.
The system’s design carefully considered heat transfer dynamics, the chemical properties of the solutions, and stringent safety requirements. By integrating the cooling tower, pipeline, radiators, and backup chiller, KNAAZ can maintain stable temperatures, minimize the load on the electrical grid, and accelerate the technological cycle without compromising coating quality. This application of natural frigid air demonstrates the potential for scaling KNAAZ’s innovative solutions to other enterprises with similar technological processes.
By significantly reducing energy consumption and stabilizing electrolyte temperatures, this innovative cooling system directly enhances the efficiency and reliability of KNAAZ’s anodizing processes, which are critical for aircraft component production. Faster and more consistent coating cycles contribute to higher throughput, improved quality of structural and surface treatments, and ultimately support timely delivery of aircraft assemblies. This demonstrates how industrial process innovations can have a tangible impact on overall aviation manufacturing performance.
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