In addition to specific compressors used with cooling systems, some chillers have particular applications. Two types, explosion-proof and low-temp, are custom chillers used by petrochemical companies. But these types of industrial chillers also have utility in other industries, such as ice rink maintenance and pharmaceutical production:
An industrial chiller works by directing heat away from process equipment through two operational principles: heat absorption or vapor compression. By changing the state or pressure of refrigerant in the compressor, evaporator and condenser, the unit is able to cool equipment or an environment. Each component of an industrial chiller plays a role in transferring heat from the process away and taking chilled liquid back into the process. To understand how these systems work, we have to examine all the different elements involved.
The first step for any chiller starts with the refrigerant. This chemical holds more heat than water does, which allows for more efficient cooling. The coolant readily changes states from a liquid to a gas as it heats. When the refrigerant cools, it condenses back into a liquid. Switching between these states and from high to low pressure allows the coolant to cool air or water used for a process.
While the refrigerant is the heart of the chiller system, it may not be the liquid that passes through process cooler coils for chilling, anodizing or metal plating liquids, or food storage. Water or glycol is often used in chiller coils to cool fluid in tanks. (It can be challenging to regulate the tank temperature when trying to run refrigerant directly through the tank coils. It is not recommended.) To reduce the temperature of the glycol or water, you need an industrial glycol chiller that cools and circulates propylene glycol throughout the system.
Process chiller systems have three main components — compressors, evaporators and condensers. Each changes the state or pressure of the refrigerant during the cooling process:
Two types of systems exist — open-loop and closed-loop systems. Open-loop systems expose the water to the outside at a cooling tower or large water storage tank. This exposure to the elements can introduce contaminants into the system. Closed-loop systems have the liquid flowing through the pipes in a sealed system with less chance of contamination. Closed-loop systems are better suited for smaller applications, while open-loop designs are best for large-tonnage chiller systems.
Maintaining an industrial chiller keeps it running longer. Regular measurements should be part of the care schedule. Best practices for chiller maintenance include testing water, oil and refrigerant and analyzing vibrations of any rotating equipment. These tests look for any contaminants in the system and inefficiencies, which can shorten the life span of the unit. For best results, you may need to partner with a water testing company or a water chemist to ensure proper testing procedures.
While having a designated maintenance crew member to keep up the industrial cooling equipment is ideal, many companies don’t have that luxury. Neglecting expensive, complex industrial cooling units is not an option. Instead, consider a maintenance service, which will take care of any upkeep. You can even get services covered under warranty or aftermarket services. Getting an immediate response for equipment failure helps reduce downtime. A big part of keeping a chiller lasting for the long haul is choosing the best type at the start. We can help you find the perfect chiller for your needs. You can contact our Service Department to discuss our available PM (Parts/Maintenance) contracts available.
Each state will have different guidelines and requirements for the efficiency of process coolers. California has some of the strictest requirements in the nation for the energy efficiency of industrial chillers, as outlined in Title 24 from 2001 — Title 24 is also updated every few years. As efficient as these guidelines are, you can still select components of a system that will allow for even more energy savings. Choosing the most energy-efficient chiller could save you thousands of dollars in energy costs over the lifetime of your equipment. While the study examined HVAC systems, the same principles apply to process coolers. Higher energy efficiency saves you money.
Regardless of where you operate, industrial chillers have become more efficient over time. Older models run less efficiently than newer models. For instance, all our systems adhere to the ASHRAE 90.1 energy efficiency minimum requirements. These standards dictate energy efficiency standards for almost all buildings except small residences and have served as the basis behind worldwide building codes for 35 years. ASHRAE regularly updates these requirements as technology changes.
Tonnage requirements for process coolers require precision. You cannot use an undersized unit. You won’t get the needed cooling level. Oversizing a process chiller is just as bad because it will run inefficiently. You need to know the incoming and outgoing temperatures for your process in addition to the amount of water flowing in gallons per minute. Find the difference in temperatures and multiply by the number of gallons per minute and by 500 to find the tonnage (for water only):
Once you know the tonnage, you might want to add 20 percent to the number if you plan to increase operations soon. Otherwise, use the calculated capacity to purchase an industrial cooler that minimally meets the number. While too much tonnage is wasteful, a little over the required load is better than having an undersized unit that will never attain the cooling you need.
Chiller prices are as varied as the options available. The type of chiller, its tonnage and use all affect the purchase price. Cost factors for chillers include quality, longevity and efficiency in addition to the purchase price. Evaluate these as carefully as you do the price tag to make the best decision.
How well you maintain a process, the type of chiller and the materials in its design determine the equipment’s lifespan. Chillers with screw compressors last 20 years compared to only 8-15 for scroll compressors. Air-cooled condensers can last 20 years (when properly maintained), as well, but fiberglass cooling towers can operate up to 35 years. When selecting a process cooling system, consider its lifespan when comparing prices. It will help you make the wisest investment of your money.
If you have any questions on Qualified Oil Chiller, Portable Water Chiller, CNC Oil Cooler. We will give the professional answers to your questions.