Sep. 02, 2024
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Chiller systems are essential for temperature control and cooling in several industries. Choosing the right industrial chiller for process and space cooling can lower cooling costs, minimize downtime, and improve operational efficiency.
This article will cover the different types of chillers for commercial and industrial applications and the pros and cons of each. The aim is to help you make an informed buying decision.
The three major types of industrial chillers in use today are air-cooled chillers, water-cooled chillers, and evaporative condensed chillers. Let&#;s take a closer look at all three:
The most common types of water chillers use water from an external tower to cool the gaseous refrigerant in the condenser. After expelling its heat, the refrigerant undergoes a phase change into a liquid and is recirculated into the system.
Explore portable, stationary, central, and custom water-cooled chillers from Cold Shot Chillers here.
Air-cooled chillers use ambient air to reject heat from the refrigerant in the condenser before condensation and recirculation. Additionally, air fans attached to the unit help speed up the cooling process.
Air-cooled chillers are suitable for applications where the discharged heat will not be an issue, as they tend to produce considerable warmth at the site.
While the components of air-cooled and water-cooled chillers are mostly the same (condenser, expansion valve, evaporator, and compressor), the main difference is how the refrigerant is cooled.
In an air-cooled chiller, hot refrigerant entering the condenser is exposed to atmospheric air, rejecting the heat before it condenses to its liquid state. On the other hand, in a water-cooled chiller, hot refrigerant gas is sent to a water-cooled heat exchanger or condenser, and the refrigerant is cooled using water from a cooling tower. For a better understanding, learn how cooling towers and chillers work together.
Industrial chillers can be further grouped as &#;vapor compression&#; or &#;vapor absorption&#; types based on how the refrigerant is transported within the system. Take a closer look at how a chiller works in these different system types.
Vapor compressor chillers use a compressor to pump refrigerant, which extracts unwanted heat from a process. The components of the system are the same as in the absorption type &#; we have an evaporator, a condenser, and an expansion unit. However, there is no absorbent medium in the unit.
Unlike vapor compressor systems, vapor absorption chillers use a heat source to transport the refrigerant around the system for cooling. The components of the system are the same as in vapor compressor-type chillers, but in place of the compressor, there is an absorber, a pump, and a generator.
The heat source can be heated by water or steam; the refrigerant can be a low Global Warming Potential (GWP) type like R-134a or Rze, and the absorption medium can be a solution of Lithium Bromide or ammonia. The heated water or steam helps regenerate the adsorption solution.
Centrifugal chillers are dependable vapor compression cycle chillers ideal for medium to large-scale cooling operations (from 150 &#; tons of refrigeration). They consist of the usual evaporator, compressor, condenser, and expansion device set-up but with additional rotating impellers, which compress the refrigerant and transport it around the system.
Screw Chillers are vapor compressor chillers that use a screw compressor to transport the coolant through the system. Some key benefits are compact installation, quiet operation, lower maintenance costs, and high energy efficiency. They are also ideal for high-rise buildings.
Both chiller types offer efficient cooling for facilities. However, Cold Shot Chillers recommends using centrifugal chillers for high-volume cooling and screw chillers for dependable operation in facilities with space constraints. To better determine your needs, use our chiller sizing calculator.
Maintaining optimal temperatures for food and beverage products is critical to ensure their safety and quality. Food and beverage chillers are used in the industry to achieve this, whether it&#;s to cool liquids like milk or juice or to keep food products fresh. Different types of chillers are available, including air-cooled and water-cooled units, with the size of the chiller depending on the amount of product being cooled and temperature requirements.
Medical chillers designed for healthcare applications play a vital role in maintaining optimal temperature levels, particularly when it comes to sensitive medical equipment like MRI machines and CT scanners. With precise temperature control, these chillers ensure consistent performance and prevent overheating, which can impair equipment and patient safety. Chillers also help maintain sterile environments by precisely controlling humidity levels.
HVAC chillers are critical components of various industrial and commercial applications, including hospitals, data centers, and manufacturing plants. These chillers help to cool water or other fluids to provide air conditioning or process cooling. These chillers can range in size from small units that fit under a desk to large systems requiring an entire room. Choosing an appropriate chiller size and type can help businesses improve efficiency and reduce energy costs while extending the life of their HVAC mechanical systems.
Industrial chillers for metal finishing ensure high-quality metal plating and chemical processes. The precise control of temperature provided by these chillers is necessary to avoid corrosion, pitting, and other defects resulting from incorrect temperature regulation. Therefore, when selecting an industrial chiller for metal finishing, it&#;s important to consider factors such as the size of the application, the required temperature range, and the type of chemicals being used.
Contact us to discuss your requirements of Types of Water Cooled Chillers. Our experienced sales team can help you identify the options that best suit your needs.
Industrial chillers are applicable in a wide range of commercial and industrial operations where they can be used to cool large-scale machinery and equipment to ensure optimal performance. Different industrial chillers are available, including air-cooled, water-cooled, and evaporative cooling systems. With proper planning and adequate maintenance, industrial chillers can provide reliable cooling for several years.
Maintaining precise temperature control is crucial in the plastics industry, which is why chiller systems play an essential role. The right chiller system can improve productivity and enhance product quality while reducing energy costs. Air-cooled and water-cooled chillers are available to meet various application-specific requirements.
For over 30 years, Cold Shot Chillers has manufactured the best industrial chiller systems to meet the process cooling needs in industrial and commercial applications nationwide.
Cold Shot Chillers offers ruggedly dependable and efficient water-cooled and air-cooled industrial chillers with close tolerances for any application as well as parts and accessories. For inquiries, please contact us online today or call us at 1.800.473..
Several types of chillers differ in their design, operation and benefits. Before choosing a chiller for your equipment, consider the following types:
A water-cooled chiller pulls water into an evaporator through a primary return. The evaporator transfers heat from the water to a refrigerant, chilling the water before sending it through the primary supply to the system&#;s water tank. A water pump then distributes chilled water to climate-controlled spaces.
As the chilled water flows through each space and reaches the air handler, it absorbs ambient heat. The second law of thermodynamics, which states that heat naturally flows from higher-temperature regions to lower-temperature regions, makes this heat transfer possible.
If this is an air conditioning application, after the heat transfers to the chilled water, the air inside the air handler cools down. A fan forces the air through ductwork and into each space, cooling the equipment&#;s climate-controlled areas. When the warm water returns to the system&#;s chiller, it cools again and repeats the process.
In order for the refrigerant to absorb more heat from the water in each cycle, it must transfer the heat it absorbed during the previous cycle. The evaporator moves the heated, low-pressure refrigerant to a motor-operated compressor. The compressor increases the temperature and pressure before sending the refrigerant to the condenser.
Inside the shell & tube condenser, the water surrounding the refrigerant pipes absorbs heat from the refrigerant. The water inside the condenser is pumped to a cooling tower where it releases its absorbed heat. As the refrigerant continues through its cycle, an expansion valve (much like a water spray bottle nozzle) reduces the refrigerant&#;s temperature and pressure as it flows through on its way back to the evaporator where it restarts the process.
Water-cooled chillers provide the following benefits:
An air-cooled chiller operates similarly to a water-cooled chiller. The only difference between and Air Cooled & Water Cooled chiller is in the condenser section of the units. And air cooled chiller utilizes an air-over condenser coil to remove heat from the refrigerant while the water cooled chiller uses a water to refrigerant condenser coil. The way each chiller removes heat from the process remains the same.
The refrigerant then increases its temperature and pressure by moving through the compressor until it reaches the condenser where outside air circulates from a fan. The condenser absorbs the refrigerant&#;s heat and expels it into the surrounding air. Finally, the refrigerant returns to the evaporator through the expansion valve to begin the process again.
Air-cooled chillers offer the following benefits:
A scroll chiller compresses refrigerant using a scroll compressor. It contains a stationary scroll plate and an orbiting scroll plate, which rotates around the stationary component and compresses the refrigerant to raise its temperature and pressure (Link: https://youtu.be/yNgqI4XPUZc). This process prepares the refrigerant for the rest of the cooling process.
Scroll chillers have the following benefits:
It&#;s best to avoid choosing a tandem scroll compressor chiller unit. It&#;s much better to choose a scroll compressor that applies a single compressor to each refrigeration circuit &#; this eliminates the risk of burnouts damaging multiple compressors.
You can choose between industrial air-cooled scroll chillers, air-cooled portable scroll chillers and water-cooled portable scroll chillers for your applications.
When it comes to a scroll vs. a screw compressor, it&#;s important to note that screw compressors handle larger capacities than scroll compressors. While scroll chiller tonnages vary between 2 and 140 tons (60HP maximum single compressor size), screw chillers vary between 30 and 400 or more tons. The main difference between screw and scroll chillers is that screw chillers use one or two rotating screws to apply force and compress refrigerant. Screw compressors are most commonly found in industrial process and petrochemical applications.
Some industrial machinery is susceptible to explosions, requiring industrial explosion-proof chillers to maintain safety. Explosion-proof chillers are manufactured with a reinforced, specialized design and contain features that protect their components from flammable materials. This design prevents potential explosions to protect employees, equipment and facilities.
Few air-cooled chiller manufacturers have the expertise to provide reliable explosion-proof chillers. If your equipment operates in hazardous conditions, it&#;s crucial to select an explosion-proof chiller from a reputable manufacturer that follows National Fire Protection Agency standards and codes.
Some industrial operating conditions require the leaving fluid temperature to remain below 35 degrees Fahrenheit. Low-temperature chillers ensure equipment operates efficiently for applications such as petrochemical processes and ice rink cooling that require low leaving fluid temperatures. Some units can run down to as low as -40 degrees F leaving fluid temperature. At these conditions, special heat transfer fluid is required.
An industrial glycol chiller features a reliable digital temperature controller. This controller makes it possible to maintain ideal temperatures for food and drink products. Wineries and breweries often use glycol chillers for this reason.
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