Agro-industry | Iraq

Lail Al-Tariq” as a production leader in Iraq’s HVAC sector

Lail Al–Tariq for Contracting & Trade Refrigerator & Freezers & Chillers Equipments LTD is an engineering and contracting company based in Baghdad, operating in conditions where cooling capacity calculations are directly linked to the sustainability of agro-industrial and food chains. With outdoor temperatures of 42–48 °C and continuous cycles of 20–24 hours per day, even a 4–6% deviation in cooling capacity leads to an increase in specific energy consumption of 0.08–0.12 kW/h per kW of cooling and accelerated equipment wear. Therefore, the company builds projects around accurate thermal models from EVROPROM.

The Lail Al-Tariq engineering portfolio was formed as a universal platform for different types of facilities, from growing and fermentation chambers to cold stores and processing lines. In the 2024–2026 investment cycle, the company purchased TRANE RTWB 210 water-cooled chillers with a capacity of 320 kW, CARRIER 30GX with a capacity of 450 kW, as well as two CARRIER 30HXC models with a capacity of 374 kW and 414 kW. 

All units are equipped with screw compressors, shell-and-tube heat exchangers, and two independent refrigeration circuits, which is critical for facilities with a continuity factor above 0.85.

The total installed capacity of the water-cooled segment exceeds 1.55–1.60 MW, which allows for flexible load distribution in the range of 55–90% without entering inefficient COP zones. At design conditions of 12/7 °C and condensation of 30–35 °C, the system maintains a seasonal EER of 3.2–3.9, even with heat flow fluctuations of ±25%. Equipment operating hours — from 4,000 to 85,000 h — were taken into account in the calculations of residual life and service intervals, which reduces the risk of unplanned shutdowns during peak months of agricultural load.

At the same time, the company invested in ammonia technology, purchasing two GEA GRASSO RC912 compressor stations, each with a capacity of 572 kW, running on R717. These units cover the base loads of agricultural facilities with high cooling density and provide a working COP of 5.4 at temperatures of 5/40 °C. 

In combination with water-cooled chillers, this forms a total cooling capacity of around 2.7–3.0 MW with the possibility of 35–45% redundancy without duplication.

Lail Al-Tariq’s engineering calculations are based on specific heat loads of 85–130 W/m², simultaneity factors of 0.65–0.78 and a seasonal load increase of up to 30%. Thanks to screw compressors, correct hydraulics and the elimination of overload modes, the company achieves a reduction in specific consumption of 0.11–0.19 kW/h per kW of cooling. With an annual output of 1.9–2.4 million kW/h, this is equivalent to a reduction in operating costs of 180,000–320,000 USD per year, depending on tariffs and the potential load profile of the enterprise.

As a result, the company is not creating a set of disparate machines, but rather a reproducible HVAC architecture, where each subsequent project is based on proven calculations, standardised components and predictable economics. Reusing solutions reduces commissioning time by 12–18 days, lowers capital and operational risks by 20–30%, and allows cooling to be scaled without rebuilding the system, even with a 25–40% increase in production capacity in a single cycle.

Initial HVAC conditions

The agro-industrial facilities covered by the project form dynamic thermal profiles, where cooling operates not at nominal values, but in a real load fluctuation range of ±0.5–1.0 °C, pressure drops of ΔP 1.5–2.5 bar, refrigerant flow rates of 8–20 kg/min, heat transfer fluid consumption of 80–160 m³/h per section, heat transfer fluid ΔT of 4–6 K, indoor air temperature of 16–22 °C, and relative humidity of 75–95% RH.

— Growing and storage chambers: basic cooling load 120–280 kW per zone, density 1.5–2.2 kg/m², air exchange 4–8 ACH; peak loads during transplanting and watering 180–320 kW; ΔP difference per section 0.4–0.6 bar; compressor start frequency 6–10 times/hour.

Heat transfer fluid inlet temperature 8–12 °C, outlet temperature 14–16 °C; chiller fan air flow 350,000–420,000 m³/h; EER 3.4–3.8 at partial load 55–75%.

— Processing and fermentation lines: pulsed operation with load fluctuations of ±30–45% over 24 hours; heat inputs 250–370 kW; stabilisation time Δt 8–12 min; starting currents 280–340 A; peak condensation pressure 6.2–6.8 bar; product ΔT 4.5–5.5 K; R134a/ammonia consumption 12–18 kg/min; compressor start frequency 8–12 times/hour.

Number of compressor operating cycles 1800–2200/year per machine; specific energy consumption of old systems 0.85–0.95 kW/h per 1 kW of cooling; COP of modern screw units 4.8–5.2.

— Cooling sections before packaging: ΔT 4–6 K, deviations of ±0.5 K lead to 3–7% rejects; water consumption 90–110 m³/h; ΔP 0.35–0.45 bar; heat transfer fluid inlet/outlet temperature 8–12 °C / 14–16 °C; air velocity in ducts 4.2–5.0 m/s.

Load on downstream processes 15–25 kW/hour; pump shutdown frequency 2–4/day; power reserve 10–15%.

— Seasonal peaks and extreme conditions: outdoor temperature 32… 48 °C; heat gains through enclosures 120–160 kW/zone; load from ventilation and personnel 15–22 kW/zone.

The zone simultaneity factor shifts from 0.65–0.7 to 0.8–0.9; ΔP in condensers 1.8–2.2 bar above nominal; partial load of chillers 55–95%; air flow 420,000–480,000 m³/h; heat transfer fluid ΔT amplitude at peak sections ±1.2 K.

— Facility operating mode: 24/7, local night-time drops of 40–50%; compressors withstand 210–260 kW without overheating; ΔT of condensers 4.5–5.5 K; number of starts 6–12/hour; total refrigerant consumption 32–45 kg/hour.

Suction pressure 2.5–3.2 bar; refrigerant temperature at the evaporator outlet 2–4 °C; energy efficiency EER on old systems 3.0–3.2, COP of new screw compressors 4.8–5.4; hydraulic losses ΔP 0.3–0.6 bar.

— Previously used solutions: water chillers had a reserve of 10–15%, power consumption of 0.85–0.95 kW/h per 1 kW of cooling; peak power losses of up to 25–30 kW; hydraulics required recalculation when changing zones ±2–3.

Pump groups 2×50–80 kW; automation control ±2–3% FS; pressure drops ΔP 0.6–0.8 bar; maintenance frequency 3–5 times/year; total annual consumption 1.8–2.2 million kW/h.

— Introduction of new units: water-cooled chillers 374 kW and 414 kW, air-cooled 450 kW and 320 kW, GEA ammonia stations 572 kW ×2; total installed cooling capacity 2.7–3.0 MW; EER 3.6–4.0; COP of ammonia 4.8–5.4.

Working temperature of the coolant 8–16 °C; air flow rate 350,000–480,000 m³/h; ΔT 4–6 K; compressor outlet pressure 2.5–6.8 bar; annual energy consumption 1.9–2.3 million kW/h; power reserve 30–45%.

Together, this creates an engineering load of 142–276 kW on the chambers, 18–24 m³/h liquid flow rate on the fermentation line, ΔT 4.2–5.8 K, pressure of 7.5–8.9 bar, vibrations of 0.7–1.3 mm/s, currents of 42–56 A, fan speed of 1,050–1,250 rpm, start frequency of 6–11 times/hour, and energy efficiency of 0.59–0.71 kW/h per 1 kW of cooling.

The system adapts to peaks of 33–46 °C, a simultaneity factor of 0.66–0.88, and a power reserve of 32–48%, allowing loads to be scaled by 28–52% without changes to hydraulics and automation, minimising downtime costs of up to €13,500–19,000 per day.

System HVAC architecture for cooling in a project with a high risk zone, industrial reporting and savings from EVROPROM

The Lail Al-Tariq project began with an analysis of actual heat flows and load dynamics: growing and storage chambers generate a cooling demand of 120–280 kW per zone, processing lines experience pulsating fluctuations of ±30–45%, packaging areas require a stable ΔT of 4–6 K, and summer outdoor air peaks reach 32–48 °C. Based on this data, a pool of four chillers was formed, each designed for its own load range — base, average, peak and reserve — with a total nominal cooling capacity of 2.7–3.0 MW, ensuringthe facility operates 20–24 hours a dayday without re-assembling the hydraulics and automation.

“WATERCOOLED CHILLER TRANE RTWB210 320 KW”:

— Cooling capacity 320 kW at 12/7 °C, ΔT heat transfer fluid 4.5–5.5 K, COP 4.1–4.5, specific energy consumption 0.62–0.68 kW/h per 1 kW of cooling;

— Two TRANE screw compressors, service life 30,000–35,000 h;

— Shell-and-tube heat exchanger, pressure drop ΔP ≤0.35 bar, water flow rate 80–100 m³/h;

— Start frequency 6–8 times/hour, temperature stabilisation time 180–220 s.

The unit is designed for basic and round-the-clock operation of growing chambers, withstands seasonal load fluctuations of ±18–22%, maintains stability of ΔT ±0.4–0.6 K and ensures repeatability of operating modes with an accuracy of ±0.5 °C, ensuring the coordinated operation of all hydraulic and cooling circuits.

AIRCOOLED CHILLER CARRIER 30GX–132 450 KW:

— Power 450 kW, COP 3.3–3.7, partial load 50–70%;

— Two CARLYLE screw compressors, starting currents 350–420 A, operating hours 68,080/84,520 h;

— Six fans create a flow of 420,000–480,000 m³/h, maintaining a condensation pressure 1.8–2.2 bar below peak values;

— ΔT air in the zone is stabilised at ±0.6 K, transient processes 200–350 s.

The chiller is activated at peak load times, unloads the water circuits by 12–18%, reduces hydraulic losses by 15–20% at a flow rate of 95–110 m³/h and a pressure drop of 1.8–2.2 bar, and minimises the frequency of emergency shutdowns to 0–2 events per month, ensuring stable operation of the entire system at a load of ±35–50%.

“WATERCOOLED CHILLER CARRIER 30HXC110 374 KW”:

— Cooling capacity 374 kW at 12/7–30/35 °C, ΔT heat transfer medium 4.2–5.0 K, EER 3.3–3.9;

— Two R134a refrigeration circuits, two CARLYLE screw compressors, partial load 55–75%;

— Water consumption 75–95 m³/h, pressure drop ΔP ≤0.32 bar;

—Stabilisation time 150–200 s, start frequency 5–7 times/hour, ΔT ±0.4 K.

The unit covers the average load range, withstands daily and seasonal fluctuations of up to ±30%, maintains ΔT 4.8–5.3 K at the outlet, provides COP 3.3–3.9 at partial load 55–75%, water consumption of 85–110 m³/h and circuit pressure of 6.2–7.4 bar, minimising temperature fluctuations and ensuring process stability within ±0.5 K.

WATERCOOLED CHILLER CARRIER 30HXC120 414 KW:

— Power 414 kW at 12/7–30/35 °C, COP 3.4–3.8, partial load 60–80%;

— Two refrigeration circuits, two CARLYLE screw compressors, operating time 4,362/4,359 h;

— Heat transfer fluid flow rate 82–110 m³/h, pressure drop ΔP ≤0.34 bar;

— Stabilisation time 160–210 s, start frequency 6–9 times/hour, ΔT ±0.5 K.

This chiller provides a power reserve of 30–45%, maintains operation at a partial load of 25–100%, provides fault tolerance of up to 55–60% of cooling capacity when one circuit is shut down, reduces specific energy consumption by 0.12–0.16 kW/h per 1 kW of cooling

The combined architecture of four chillers covers a load range of 320–450 kW for base and peak modes and 374–414 kW for average modes, providing a COP of 3.3–4.5 at partial loads of 25–100%. ΔT stability is maintained at ±0.5–0.6 K, water consumption varies between 85–115 m³/h, heat transfer fluid outlet pressure is 6.8–7.6 bar, compressor start frequency does not exceed 6–10 starts per hour, and the temperature reserve reaches 30–45%. The system is ready for round-the-clock operation 20–24 hours a day, withstands summer peaks of 32–48 °C and dynamic load fluctuations of ±45%, reduces specific energy consumption by 0.12–0.18 kW/h per kW of cooling and minimises unscheduled downtime by 40–60%. This type of HVAC infrastructure transforms cooling from an auxiliary engineering system into a manageable investment resource, allowing production to be scaled up again without rebuilding hydraulics, automation and distribution schemes, ensuring predictable energy efficiency and fault tolerance throughout the entire cycle.

Strategic application of R717. Cost optimisation, minimisation of specific kW/h and stable integration into complex HVAC integrations

Two GEA GRASSO RC912 ammonia compressor stations, each with a capacity of 572 kW, became a key element of the new concept:

— Total cooling capacity of 1,144 kW on R717;

— GRASSO piston compressors with a service life of 25,000–30,000 hours;

— Operating range 5 / 40 °C, ΔT ≤0.5 K;

— Weight of one station 1,390 kg, compact dimensions 1.82 × 1.17 × 0.93 m, installation without foundation reinforcement.

Ammonia stations are designed and implemented based on strict HVAC engineering calculations and the requirements of the agro-industrial facility:

— Specific energy consumption is 0.11–0.17 kW/h per 1 kW of cooling, which provides savings of up to 22% compared to similar HFC systems with an annual output of 2.1–2.7 million kW/h;

— The operating temperature range of the heat transfer fluid is 5–40 °C and the ambient temperature is up to 48 °C, ensuring stable operation in the extreme conditions of Iraq, including summer peaks with solar radiation of up to 950 W/m²;

— Compatibility with agro-industrial chambers – 120–280 kW/zone, fermenters – load 150–320 kW per cycle, blast freezing lines and packaging zones ΔT 4–6 K ensures continuity of the technological process without loss of product quality;

— High fault tolerance at loads of 55–90% and partial loads of 50–80% allows for the simultaneous shutdown of one circuit without reducing cooling capacity by more than 8–12%;

— Each station is tested at a pressure of 29–31 bar, a flow rate of 18–22 m³/h, ΔT 5–6 °C, suction 7.5–8.4 bar and discharge 28–32 bar, vibrations 0.8–1.2 mm/s, which confirms compliance with strict operating parameters;

— Can be connected to existing water and electrical networks with a flow rate of 25–28 m³/h, currents up to 68–72 A and a working COP of 4.8–5.4 at loads of 60–100%;

— Annual energy savings from the introduction of ammonia amount to €45,000–90,000 per year, with additional reductions in service and maintenance costs of up to 20–30% and a 40–60% reduction in the frequency of unscheduled downtime;

— The stations provide the possibility of integration with future modules, power reserve of up to 50%, and project scalability up to 3.5–4 MW without complete reconstruction of hydraulics and automation.

With an annual output of 2.1–2.6 million kW/h, the energy savings from R717 alone are estimated at €45,000–90,000 per year.

Maximum efficiency and reliability of HVAC infrastructure for an agro-industrial facility from EVROPROM for a contractor from Iraq

Before the system was commissioned, the key factors were load stability and minimisation of downtime during round-the-clock operation. In the agricultural sector, every kilowatt of cooling directly affects product quality and income: heat flows of 120–280 kW per chamber, ±35% daily fluctuations, seasonal peaks of up to 38–48 °C, local temperature differences ΔT ±0.7 K, water consumption 82–118 m³/h, air consumption 425,000–485,000 m³/h, pressure drop 0.13–0.27 bar, start frequency 5–13/hour, which helps to avoid losses;

— Repeat delivery and scaling: in 2025, Lail Al-Tariq reintroduced six units — two ammonia stations of 572 kW each, water chillers of 320 kW, 374 kW, 414 kW, and a 450 kW air chiller; the total cooling capacity of the portfolio was 2,982 kW, each unit was tested on 8 key parameters with connection to water and electricity, which eliminates unscheduled work; re-supply reduced CAPEX by 55–70%, reduced downtime risks by 40% and provided direct energy savings of €95,000–150,000 per year, confirming the strategic approach to reproducible engineering solutions in the agro-industrial segment;

— Cooling capacity and zones: 3,080 kW covers 12–16 zones, including chambers, fermenters, packaging and warehouses — 24 hours a day, 20–24 hours/day, night-time drops of up to 50%, ΔT 4–6 K, summer peaks 32… 48 °C;

— Energy consumption and savings: at 55–95% load, specific consumption is 0.48–0.72 kW/h per 1 kW of cooling, annual reduction is 1.2–1.8 million kW/h, savings are €125,000–190,000;

— Service and scaling: unscheduled visits −20–40%, commissioning 5–15 days, possibility of phased expansion without shutdown;

— Peak loads: up to 650 kW with heat inflows of 35–50% are automatically compensated, EER 3.0–3.5 is maintained;

— Reliability and control: compressors tested up to 85,000 hours, pressure drop 0.12–0.25 bar, water consumption 78–110 m³/h, air consumption 420,000–480,000 m³/h, ΔT ±0.6 K, start frequency 4–12/hour;

— Energy efficiency: 18–25% reduction in specific consumption thanks to ammonia and HFC, R717 savings of €45,000–90,000 for 2.1–2.6 million kW/h generated;

— Engineering modularity: each unit is tested on 8 parameters before integration, reduction of unscheduled interventions by 40%, prevention of downtime €25,000–35,000 per day;

— Overall efficiency: temperature reserve 50–55%, specific consumption 0.58–0.72 kW/h per 1 kW of cooling, load distribution 320–580 kW, economic return of €65,000–130,000 per cycle, stability in all zones.

After the system was commissioned, economic and operational efficiency reached a new level. A temperature reserve of 50–55%, a reduction in specific consumption to 0.58–0.72 kW/h per 1 kW of cooling, optimisation of heat load distribution 320–580 kW and control of all peak modes provide a direct economic return of €65,000–130,000 per cycle and guarantee the stability of all technological zones.

The end result. Measurable stability, increased HVAC capacity, and energy and financial benefits for Lail Al-Tariq from EVROPROM

The project implemented a comprehensive cooling architecture, including ammonia compressor stations with a capacity of 500–600 kW each, 320–414 kW water chillers and 450–500 kW air units, with a total cooling capacity of 2.7–3.1 MW. All units were delivered and prepared for operation within 5–12 days with 1 working day of service, tested on 8 key parameters with 30–45 measurements recorded – pressure 7–32 bar, flow rate 15–30 m³/h, ΔT 4.5–6 K, liquid temperature 36–43 °C, vibrations 0.8–1.6 mm/s, currents 70–140 A, fan speed 1,200–2,100 rpm, EER 3.3–5.5 and commissioned without stopping the technological zones. The system can withstand 24-hour operation, summer peaks of 32–48 °C, partial loads of 40–100% with a reserve of 30–55%, which reduces specific energy consumption by 0.11–0.19 kW/h per 1 kW of cooling, annual savings of €80,000–180,000, a 25–40% reduction in unscheduled service calls, elimination of downtime, temperature control of ±0.3 °C, stable ΔT of 4.5–5.8 K, even load distribution of 320–340 kW per section, the ability to restart similar stages without recalculating diagrams and engineering, as well as B2B discounts of up to 80% with payment of customs duties, fees, taxes and complete documentation on testing protocols, water and electricity connections. This system turns cold into a controllable investment asset, a reproducible technological tool and a financially predictable resource for scalable business growth.

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