May. 13, 2024
Does your company need a new chiller for your plant's manufacturing process? Deciding on the right chiller can be overwhelming for any plant manager or engineer. Choosing the wrong one can lead to significant issues for your plant and your job prospects. Let's discuss some of the available options.
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An Industrial Chiller
The first decision you need to make is whether to opt for an air cooled or water cooled chiller. If you are simply replacing or upgrading an older piece of equipment, you will likely replace it with the same type of chiller. But if this is a new installation, you need to explore your options.
The two most popular types of chillers are Air Cooled or Water Cooled. The “Air” or “Water” cooled designation refers to the type of condenser the chiller uses to cool the refrigerant.
Air cooled chillers are the most commonly used because they are self-contained systems. No additional outside components are needed, making them popular for rental applications. While less efficient than water cooled chillers, their self-contained nature makes them very appealing. An air cooled scroll chiller is easy to install and start-up.
Water cooled chillers require an external cooling tower and cooling tower supply pump to cool the water cooled condenser. If you already have an existing cooling tower at your plant with excess capacity, then this might be your best option. Once you decide between air cooled or water cooled chillers, you will face more specific decisions.
If you need a relatively small chiller (under 30 tons), you will need a scroll chiller. For cooling requirements over 30 tons, you must choose between a scroll or a screw compressor. Consider several factors when making this decision while comparing screw and scroll chillers.
Scroll compressors are limited in size. Although technology is continuously improving, the largest available scroll compressor is currently 40HP. For larger cooling loads, multiple compressors are necessary. However, ensure you do not get multiple compressors on a single circuit, as that could lead to service nightmares later.
Screw compressors start at 30HP, but their capabilities extend well beyond that. At the higher end, they can exceed 500HP. At this size, an air cooled condenser would not be sufficient; it would only be installed on a water cooled chiller. Screw compressors are considered true industrial process options—"the right tool for the job."
Scroll compressors are excellent for smaller process applications, particularly when operating time is sporadic (< 24hrs/day). We classify our scroll units as medium duty process chillers. They can handle longer run times depending on the environment.
If you plan to run your unit 24/7 and meet the load requirement (over 30 tons), we always recommend the air cooled screw chiller over the scroll system. Screw compressor systems offer better capacity control options, are fully serviceable, and have a wider operating range.
Another consideration is your chiller's evaporator. For any application over 20 tons, we typically recommend using a DX shell & tube evaporator over a brazed plate. While brazed plate evaporators are stainless steel with copper brazing, they do not handle fouling well. Let's be honest, most manufacturing plants do not have clean water.
Using a shell & tube evaporator will provide a longer lifespan and better durability. They can be built with custom materials and thicker tube walls to handle direct cooling of corrosive or even caustic liquids.
We hope this overview has helped you make a decision for a new or replacement chiller. While one of our main goals is to sell and build premier cooling equipment, our priority is providing you, the customer, with enough information to make an informed decision. Our Chiller Genius can provide an immediate quote for your chiller requirements. At Smart Family, we believe an informed customer is a better customer. Thanks again for reading.
Chiller is a cooling system utilized in various industries, particularly in the food sector. Chillers can be classified into air-cooled and water-cooled types.
Contact us to discuss your requirements for a vertical chiller. Our experienced sales team is here to help you identify the best options to suit your needs.
Air-cooled systems are generally cheaper as they do not need expensive water pumps or condensers. However, they require more space for installation and maintenance. On the other hand, water-cooled systems are more expensive but offer advantages such as reliability, low noise levels, and lower energy consumption.
Air cooled chillers are the most common type and use a lot of energy, needing replacement every few years. However, they are more affordable than water cooled chillers.
Water cooled chillers are less common due to higher maintenance and installation costs. They can last up to 20 years but cost significantly more than air cooled chillers.
The two main types of chillers are air-cooled and water-cooled. Air-cooled chillers use air to cool the condenser coil, while water-cooled chillers use a liquid.
In air-cooled chillers, air cools the condenser coil. The compressor sends refrigerant through coils that are cooled by ambient air or cooling oil. The refrigerant absorbs heat and vaporizes, then turns back into liquid to begin the cycle again. This continues until all heat is removed from the refrigerant.
Water-cooled chillers use water to cool the condenser coil.
The four main components of a chiller system are:
Air conditioners and chillers are two types of cooling systems. Air conditioners are designed to cool rooms or buildings, while chillers cool specific areas like industrial plants.
Air conditioning units have been around since the late 1800s. They pull in hot air from inside and release it outside, creating cold air that circulates through the room or building.
Chillers receive heat from an external source to produce cold water, which is circulated through pipes to various points in the plant for cooling.
Compressor cooling systems are the most common and cost-effective chiller system. They are efficient but can be noisy and less effective in extremely cold environments.
Air-cooled chillers use a fan to blow air over a heat exchanger. They can be quieter but are more expensive and less energy-efficient than compressor chillers.
Evaporative chillers use water to reduce the temperature of refrigerant gas through evaporation. They are not as effective in hot and humid climates but can be used in dry climates. These chillers have lower operating costs but higher installation and maintenance expenses.
Contact us today for industrial cooling solutions that fit your needs and budget!
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