Choosing The Right Industrial Chiller For Your Application
Industrial chillers are essential to maintaining production efficiency and safe operation across various industries, especially in sectors where temperature control is vital.
These robust refrigeration systems effectively manage heat dissipation by removing excess heat and preventing costly production downtime caused by excessive thermal energy.
By maintaining optimal temperatures in machinery and industrial processes, chillers help protect product integrity, prevent equipment from overheating due to excess heat, and contribute to process reliability.
Choosing the right industrial chiller is a critical decision that can significantly impact your operation’s success.
Evolution and Innovation in Chiller Design
Over the years, industrial chiller systems have evolved significantly. Early models were large, inefficient, and unreliable. But today’s process cooling systems offer superior performance with reduced energy consumption, enhancing overall operational efficiency.
Technological advancements have also led to chillers with improved controls for precise process water temperature regulation and system monitoring. These innovations have increased equipment longevity, reliability, and energy cost savings, highlighting the continuous evolution in chiller performance and, potentially, overall operational efficiency.
Understanding the Basics of Industrial Chillers
Industrial chillers absorb heat from processes or equipment and dissipate it to maintain optimal operating conditions. Doing so prevents overheating, which can damage the chiller unit, process machinery and components. Effective cooling is vital in various sectors, such as manufacturing, chemical processing, and food and beverage industries.
Air-Cooled vs. Water-Cooled Chillers
Industrial chillers come in two main types: air-cooled and water-cooled. Each type has its unique applications and benefits.
Air-cooled chillers use air to remove heat from the system. They offer lower upfront costs and require less maintenance compared to water-cooled chillers, making them an excellent choice for industries with limited water availability or high water costs. They are well-suited for small to medium-sized applications.
On the other hand, water-cooled chillers dissipate heat using water or other fluids. They are generally more energy-efficient, especially in closed systems where they can take advantage of water’s high heat capacity and rapid heat absorption. Although industrial water chillers require more maintenance due to their complex cooling systems, they are highly efficient and perfect for large-scale industrial applications, even in hot conditions.
Ensure that you select the right product to meet your specific needs to optimise the benefits it brings to your operations. Control Gear can of course help guide you through the process.
Key Factors to Consider When Choosing The Right Industrial Chiller For Your Application
Chiller Size and Capacity
The size and capacity of the chiller directly affect its effectiveness. Selecting a correctly sized chiller that meets your specific needs is vital to avoid inadequate cooling or inefficiencies.
Industry standards and the cooling application should guide the sizing process. For example, data centres may require larger chillers than smaller manufacturing units.
To calculate the appropriate chiller size needed for an application, it is crucial to consider the flow rate and the heat energy added by the process equipment to the cooling medium. The heat energy is represented by the change in temperature (∆T) or the temperature differential between the inlet and outlet water.
Avoid choosing an undersized chiller
An undersized chiller may be unable to meet the cooling demands of your facility, resulting in insufficient cooling and potential equipment failure. Using an undersized pump will decrease the fluid flow rate in the entire cooling loop, and if liquid ceases to flow, excess heat may result.
Chillers equipped with internal pressure relief will redirect the flow back into the chiller, bypassing the process. Without internal pressure relief, the pump will operate at dead-head pressure or reach its limit while trying to maintain the required pressure.
Avoid choosing an oversized chiller
An oversized chiller can also have negative consequences. It can lead to inefficiencies and result in higher energy consumption and increased operating costs. Additionally, an oversized chiller can take up more space and require a larger initial investment.
Process Fluid Performance
The type of process fluid used in the chilling process also affects the chiller’s performance. Consider properties like specific heat, viscosity, and freezing/boiling points. It’s also essential to ensure compatibility between the coolant fluid and the chiller’s materials to prevent corrosion and seal degradation, which can impact the chiller’s lifespan.
Cooling Fluid Temperature
The setpoint temperature is a critical factor in a chiller’s cooling capacity. Lower setpoint temperatures generally result in higher cooling capacity. However, for any chiller you choose, consider the temperature to be set and its total cooling capacity based on your specific process requirements to optimise energy efficiency.
Process Cooling Temperature, Pressure and Flow Requirements
The efficiency and longevity of an industrial chiller depend on the process cooling temperature, pressure, and flow requirements. A comprehensive understanding of the process cooling temperature is pivotal, as it directly impacts the type of chiller selected because different chillers function optimally at different temperature ranges.
The size of the chiller’s pump is critical in determining system pressure loss and flow rate. Larger pumps allow higher flow rates but may cause increased pressure loss across a system. Insufficient flow through the process results in inadequate heat transfer, preventing the removal of the necessary heat for safe operation.
As the fluid temperature surpasses the setpoint, the surface/component temperatures will keep rising until a steady-state temperature higher than the initial setpoint is achieved. Accurate calculations are crucial to avoid pressure loss across the system, potential damage to the system and production downtime.
Determining the Optimal Flow Rate
To calculate the optimal flow rate, consider the differential pressures between the process’s inlet and outlet. You can measure these differential pressures using pressure gauges at the process’s inlet and outlet. The flow rate then can be determined using the formula below:
Heat energy per second (power) = mass flow rate × specific heat capacity × temperature differential (∆T)
Remember, the optimal flow rate is not necessarily the highest one. Instead, it should be set at a level that allows your chiller to operate efficiently while achieving the desired cooling in your process.
Chiller Operating Environment
The ambient air temperature at which the chiller operates also affects the efficiency of air-cooled and water-cooled chillers. There is a direct relationship between the temperature and the chiller’s properties at a given temperature.
Air-cooled chillers may be less efficient in hot environments, as it becomes challenging to maintain the proper ambient air temperature. Also, the location and availability of adequate air circulation space around the chiller can affect performance. Failure to ensure the proper ambient air temperature can lead to sub-standard performance and inefficiency.
Proper air circulation is essential to prevent overheating and maintain efficiency. Without proper airflow, the risk of decreased performance and potential system failures become a reality.
Generally, the typical ambient temperature for non-exterior rated chillers should not exceed 40°C.
Advanced Features and Innovations in Chiller Technology
Advancements in chiller technology focus on energy efficiency, reduced refrigerant charge, and improved heat exchangers.
- Control Gear supplies energy-efficient chillers from Atlas Copco with features like variable speed compressors that reduce energy consumption.
- Innovations in the design of refrigerant technology minimise environmental impact on municipal water supply and wastewater discharge, aligning with green initiatives and sustainable practices.
- Improved heat exchangers offer greater efficiency in industrial chiller installations and reduced maintenance.
Industrial Chiller Maintenance, Safety, and Control
When choosing a suitable chiller, it’s critical to prioritise easy maintenance access and safety features. These considerations not only extend the lifespan of the equipment but also enhance operational safety. Look for chillers with features such as pressure relief valves, high-temperature alarms, and flow switches to detect irregularities and prevent hazards.
In the era of Industry 4.0, intelligent control systems are essential for optimal chiller performance rather than just a luxury. Touchscreen controllers provide user-friendly interfaces, offering operators a comprehensive overview of system performance. They simplify troubleshooting, enabling quick identification and resolution of issues.
Additionally, remote monitoring capabilities allow real-time tracking of system performance, facilitating predictive maintenance and reducing the risk of unexpected breakdowns. This leads to increased system reliability, reduced downtime, and significant cost savings within production budgets.
Choose a model that prioritises easy maintenance and safety features for enhanced performance. When a chiller is introduced into the system with intelligent control systems and remote monitoring capabilities, you can optimise efficiency, reduce downtime, and save costs.
Choosing the Best Chiller for Your Application
Selecting the right industrial chiller that meets your specific requirements requires thoughtful consideration.
One crucial aspect to consider is the cooling capacity, which should be calculated based on factors like heat load, ambient temperature, and coolant type to determine the correct equipment compatibility.
Also, the nature of your industry plays a significant role in the selection process of chillers to meet specific application requirements.
For example, the food and beverage industry may prioritise hygiene and temperature consistency, while the plastic industry may need a chiller that efficiently handles high cooling loads.
Case Studies
To highlight the importance of careful chiller selection, let’s explore two case studies:
Case Study 1: Atlas Copco TCX in the Plastic Industry
In a plastic manufacturing plant, high ambient temperatures can still adversely affect even a water-cooled industrial chilling system, leading to overheating and subsequent production slowdowns.
The plant decided to leverage the Atlas Copco TCX chiller, renowned for its high cooling capacity, as a solution. The chiller was able to handle the high load on the refrigeration system efficiently, even in high ambient temperatures. How? By optimising pump pressure to obtain values at the desired flow, ensuring a constant temperature. As a result, the production pace was maintained, and overall energy consumption was significantly reduced, leading to substantial cost savings.
Case Study 2: Atlas Copco TCA in the Food and Beverage Industry
A renowned food and beverage manufacturing company faced challenges maintaining a constant low temperature in its storage facilities, impacting food safety and hygiene standards. They opted for the Atlas Copco TCA chiller, well-known for its intelligent control system, incorporating all chiller sensors into one system to maintain temperature constancy.
The TCA’s remote monitoring capabilities enabled the company to track system performance in real-time, allowing for predictive maintenance and reducing the risk of unexpected breakdowns. The robust system could maintain the desired low temperatures even under high ambient temperatures. Consequently, the company was able to uphold its hygiene standards while enhancing operational efficiency.
These examples emphasise the significance of aligning chiller selection with industry-specific requirements for optimal performance.
Key Takeaways on Choosing The Right Chiller
The Significance of Choosing The Right Chiller
Investing in a chiller requires careful consideration. Opting for the appropriate chiller can boost efficiency of industrial chiller operations efficiency while managing expenses effectively.
The selection process is critical in determining energy consumption, directly impacting your bottom line. By selecting a chiller that aligns with your specific needs in terms of capacity and features, you can ensure a smooth process flow and maximise the efficient operation and lifespan of the equipment.
Planning for the Future
It’s essential to anticipate future changes to determine the best chiller for your application. Industries evolve rapidly, and your operations may expand or transform, necessitating a different chiller size and performance characteristics to cool the process equipment.
Therefore, when selecting an industrial cooling system, consider its flexibility and adaptability to meet future requirements. Remember, an industrial chiller is not just a one-time purchase; it’s a long-term investment. Making a wise choice now can help you avoid costly upgrades or replacements in the future.
For personalised advice on the perfect chiller solution or help in configuring an industrial cooling system for your business, schedule a consultation with one of our experts today.
Additional Resources
Interested in exploring this topic further? We have curated a list of valuable resources that provide more key details on industrial chillers: