An industrial chiller is a cooling system that works like a fridge but for industrial purposes. It takes heat from water and moves it somewhere else, usually into the air or another body of water. It’s made up of a few parts:
- A compressor (like what you’d find in an air conditioner).
- A temperature controller.
- A pump.
- A tank for the liquid being cooled.
To use it, you fill the tank with water or a special mix, connect it to whatever needs cooling, and power it up. The controller helps set the right temperature, flow, and pressure. It’s flexible and comes in different sizes for various jobs, like grain chilling, concrete batching, injection moulding, food processing, and more.
Types of Chillers:
- Portable Chiller: It’s like a movable cooling system on wheels. You can use it to cool down machines or devices in different places.
- Air-cooled Chiller: These chillers take heat from water and release it into the air around them. They’re good when extra heat in the air isn’t a problem. They’re easy to maintain and don’t need additional equipment like a cooling tower.
- Water-cooled Chiller: These chillers also take heat from water, but they transfer it to another water source like a river or cooling tower. They’re great for big jobs or when getting rid of extra heat is a concern. They need some extra care to prevent mineral build-up that can make them less efficient.
| Water | Air |
| 1. Adequate water supply available from tower or well source | 1. Adequate water supply not available from tower or well sources. |
| 2. Water supply is of good quality. | 2. Water supply is not of good quality. |
| 3. Heat recovery is not practical or unimportant. | 3. Heat recovery is practical and important. |
| 4. Plant ambient temperatures consistently exceed 95º F. | 4. Plant ambient temperatures will not consistently exceed 95º F. |
| 5. Ambient air is polluted with large dust and dirt particles. | 5. Ambient air is not polluted with large dust and dirt particles. |
Investing in a chiller offers numerous benefits for various industries:
Equipment Protection: A chiller safeguards expensive processing equipment, ensuring its longevity and reliability, which outweighs its cost.
Increased Production: Maintaining consistent cooling temperatures enhances production speed and accuracy, reducing part rejections and boosting hourly output.
Precise Temperature Control: Industrial chillers ensure stable temperatures, which is crucial for flawless industrial processes, scientific experiments, and medical applications, preventing defects and equipment damage.
Improved Efficiency: By preventing overheating, chillers keep machinery operating optimally, reducing breakdowns, lowering energy consumption, and cutting maintenance costs.
Enhanced Product Quality: Proper temperatures maintained by chillers are vital in preserving product quality in various industries, reducing waste, improving customer satisfaction, and bolstering brand reputation.
Industrial chillers aren’t one-size-fits-all. Consider your temperature needs, the type of chiller, required refrigerant, safety aspects, and your budget. Each chiller is designed for specific temperatures and fluid flow rates. Also, factor in the type of fluid being cooled—different chillers are needed for distilled water versus tap water due to their corrosive effects on certain materials. For more information, refer to our industrial solutions buying guide.
Industrial process chillers find various applications in different industries:
Plastics Industry: Chillers cool hot plastic used in moulding processes and equipment.
Laser Technology: They cool lasers and power supplies to maintain optimal temperatures.
Printing: Chillers remove heat from printing rollers and excellent printed materials after ink drying.
EDM (Electrical Discharge Machining): They maintain ambient temperature in machinery during cutting processes.
Machine Tooling: Chillers have perfect machine spindles and the liquid used in part manufacturing.
Medical Imaging: Chillers cool electronics in MRI and PET scans to ensure diagnostic equipment functions smoothly.
The refrigeration process in industrial chillers involves four main components: compressor, condenser, metering device, and evaporator. Here’s how it works:
Compressor: This device increases the pressure of a gas (refrigerant).
Condenser: Converts the high-pressure gas into a lower-pressure liquid by removing heat.
Metering Device: Controls and regulates refrigerant flow to a heat exchanger.
Evaporator: This heat exchanger cools water, water/glycol, or air by transferring heat to the refrigerant, turning it into a gas.
The cycle begins as the compressor pumps the refrigerant gas to the condenser, where heat is removed, causing it to condense into a liquid. The metering device then lowers the pressure of the liquid refrigerant, making it easier to evaporate. When it disappears in the evaporator, it absorbs heat from the surroundings, which cools the targeted area. The refrigerant is then directed back to the compressor, and the process repeats continuously. This cycle effectively removes heat from one place and relocates it to another, achieving refrigeration.
In essence, refrigeration involves manipulating the state of a refrigerant to absorb and release heat, allowing for controlled cooling in industrial settings.
Chiller
- Considered for larger industrial type applications; floor model (AutoAnalyzer, Electron Microscope, Lasers, EDM, Injection Molding)
- Narrow temperature band of –15ºC to 40ºC (Heating available to 80C)
- Limited stability of ±0.5ºC
- Significant heat removal of up to 2850 Watts at 1 HP
- On board reservoir is to provide thermal mass and cannot be used as a circulating bath.
Chiller– How to Choose
What is the Application?Knowledge of the application may allow you to skip several steps
What is the Temperature Range?
< 30°C? Think refrigeration >30°C? Think Heating only
What Temperature Stability is Required?
±0.01°C? Think circulator ±0.5°C? Think chiller
Closed Loop or Open Bath Application?
If closed loop, think anything but immersion circulator
How Much Cooling Power is Required?
Modest (100 – 700 watts) Strong (750 & up) Think circulator Think chiller
What are the Pumping Requirements:
| Chillers |
| Magnetic Drive Centrifugal – fixed flow/ fixed pressure |
| Positive Displacement – fixed flow/adjustable pressure |
| Turbine – adjustable flow or pressure |
Other Requirements?
Remote probe
RS232 port
Expanded programming capabilities
Special fluids – watch compatibility and safety
Overall
Select chillers to provide best cooling power / heat removal
Chillers have many applications. For industrial use:
- Determine and match your specific cooling requirements with the chiller’s capacity and efficiency.
- Consider factors like cooling capacity, operating conditions, and any special needs for your application.
- Contact our Customer Service, Sales, or Engineering teams for further guidance or customization options.
For laboratory use:
- Assess your cooling needs based on the equipment and experiments being conducted.
- Look for chillers that fit the temperature range and precision required for your lab work.
- Don’t hesitate to contact us for additional information or to address any unique requirements you may have.
Choosing the right size recirculating chiller adds to the economies of its use. The optimum size needed is based on the amount of heat your application is generating, plus additional power to maintain temperature under varying loads.
Normally the manufacturer of the equipment you are cooling will supply heat removal information, which will include BTU/hr or watts to be removed along with flow rate and desired and inlet and outlet temperatures for the equipment.
If information isn’t available, here’s how to calculate the heat load of your system:
BTU/hr = (T1-T2) x gpm x 60 min/hr x 8.33 lb/gal x Cp
T1 = temperature of coolant leaving the equipment, deg F
T2 = temperature of coolant entering the equipment, deg F
gpm = gallons per minute of coolant flowing through the equipment
Cp = specific heat of coolant; Water = 1.0
Measure temperature with the same thermometer if possible of with two thermometers of known accuracy. Measure gpm using a flowmeter of by collecting the coolant in a known volume for a given period of time.
Additional Considerations:
1. If ambient temperature of the cooling location is above 68°F, add 1% to the calculated BTU/hr for each 0.9°F above 68°F.
2. If operating at 50Hz, add 20% to the calculated BTU/hr.
3. If line voltage is consistently below rated voltage, or if you work at high altitude, add 10% to the calculated wattage.
4. Future growth cooling needs or variability of heat output of existing unit.
Conversions:
Watts = BTU/hr / 3.413
Tons = (BTU’s / hr) / 12,000
To determine the cooling required for your plastic processing, use this formula: [(Pounds per hour being processed) / Material Factor] * 3519 = Watts of cooling required.
For example, if you’re injection moulding Nylon at a rate of 220 lb/hr and Nylon’s material factor is 40:
(220/40) * 3519 = 19355 Watts
For conversions:
BTU/hr = Watts * 3.41
Tons = BTU/hr / 12000
Refer to the cooling capacity chart for models like DCA750 or DCW750 from DuraChill based on your calculated cooling needs.
Here are material factors for different processes:
INJECTION MOLDING
30 lbs/hour HDPE
35 lbs/hour LDPE
35 lbs/hour Acrylic
35 lbs/hour Polyproplene
40 lbs/hour Nylon
40 lbs/hour Delrin
40 lbs/hour Urethane
45 lbs/hour PET
50 lbs/hour Polystyrene
50 lbs/hour ABS
50 lbs/hour Polycarbonate
50 lbs/hour Acetal
70 lbs/hour PVC
BLOW MOLDING
40 lbs/hour HDPE
40 lbs/hour PET
40 lbs/hour PVC
SHEET CALENDERING EXTRUSION
35 lbs/hour PE
60 lbs/hour ABS
60 lbs/hour PS
PROFILE EXTRUSION
50 lbs/hour HDPE
50 lbs/hour LDPE
50 lbs/hour PP
50 lbs/hour PET
60 lbs/hour ABS
60 lbs/hour PVC
VACUUM FORMING
70 lbs/hour HDPE & LDPE
70 lbs/hour PP
200 lbs/hour PS
250 lbs/hour PVC
Calculating process heat loads for industrial applications involves various formulas and definitions. Here are some essential methods and definitions:
Refrigeration Ton: 12,000 Btu per Hour or 3,025 kg calories per Hour equals one ton of refrigeration.
Water: For water systems, use Btu/hr = GPM (Gallons per Minute) x 500 x Delta-T (Temperature Difference).
Other Fluids: For fluids other than water, use Btu/hr = Lbs. Per Hour x Specific Heat x Specific Gravity x Delta-T.
Solids: Calculate heat for solids using Btu/hr = Lbs. Per Hour x Specific Heat x Delta-T.
Conversion Formulas: Btu/hr = kW x 3,413, Btu/hr = HP x 2,544, and kW = Btu/hr / 1000 x .293, among others.
PSIA: PSIA (absolute pressure) equals PSIG (gauge pressure) plus 14.7.
Here are heat rejection estimates for standard industrial machinery:
Air Compressors: 1,500 Btu/hr per HP
Air Compressor Aftercooler: 1,500 Btu/hr per HP
Vacuum Pump Cooling: 1,500 Btu/hr per HP
Hydraulic Cooling: 2,544 Btu/hr per HP x 0.6
Hot Runner: 3,420 Btu/hr per kW
When specific component heat loads aren’t available, multiply the total input HP or kW by the relevant conversion factor to estimate the maximum potential heat load.
These calculations are crucial for understanding and managing heat-related aspects in industrial processes, ensuring efficient operations and equipment performance.
Industrial chillers are vital for cooling heavy machinery and processes in factories. They circulate cooled liquid through equipment to maintain efficiency and productivity by preventing overheating caused by friction and heaters. This helps extend the lifespan of heavy-duty equipment, ensuring smoother operations in industrial settings.
These chillers are crucial in chemical processing, food production, pharmaceuticals, power generation, HVAC systems, concrete mixing, agriculture, medical facilities, and more. Their role is to cool down machinery, ensuring optimal performance and prolonging equipment lifespan.
Industrial chillers offer various benefits:Accurate Temperature Control: They maintain desired temperatures effectively.Preventing Overheating: Ensures machinery and processes don’t overheat, averting damage.Enhanced Efficiency: Improves productivity in industrial processes.Energy Savings: Operate efficiently, saving on energy costs.Flexibility and Scalability: Adaptable to varying industry needs and growth.Extended Product Shelf Life: Helps preserve product quality.Enhanced Worker Comfort: Provides a more comfortable working environment.
There are three main types of industrial chillers: air-cooled, water-cooled, and evaporative condensed chillers. These systems are crucial for controlling temperatures in various industries, aiding in process cooling and space temperature regulation. Each type offers specific advantages, helping to minimize downtime, enhance operational efficiency, and reduce energy costs over time.
Water-Cooled Chiller:
Needs: Requires a separate cooling tower.
Efficiency: Higher heat exchange efficiency.
Air-Cooled Chiller:
Needs: No separate cooling tower is required.
Efficiency: Lower heat exchange efficiency.
In simple terms, water-cooled chillers are more efficient but need an extra cooling tower, while air-cooled ones are easier to set up but are less efficient in exchanging heat.
When you buy a chiller from Tempcon, you’ll receive comprehensive support every step of the way. Our team of experts is committed to guiding, educating, and providing top-notch after-sales support for quality and long-term satisfaction.
When selecting an industrial chiller, apart from ensuring it meets your cooling needs, consider the following:
Power Supply: Check the required phase (single or three), voltage, and frequency.
Refrigerant: Know the specific refrigerant needed for the chiller.
Our chillers can be customized for various applications, catering to specific requirements.
If you need more clarification about the ideal chiller system for your business, TEMPCON is here to help. Our skilled technicians, boasting 25+ years of experience, will guide you in selecting the perfect chiller tailored to your process cooling requirements. Additionally, we provide installation and maintenance services to ensure seamless operations. Contact us for personalized assistance!
