5 Reasons Why Your Business Needs water chiller cooling system？

An industrial water chiller is essential for any facility using large machinery that generates significant heat. These chillers help maintain a low temperature within your facility and cool down internal machine equipment. By understanding how these chillers work, you can make informed decisions about your cooling needs. Let's dive into the details of industrial water chillers.

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What is a Chiller?

Chillers are widely used in both commercial and industrial settings. Essentially, a chiller is a refrigeration system designed to cool liquids or mechanical equipment. The primary function of a chiller is to remove unwanted heat while maintaining stable temperature, pressure, and current in the machinery or production process. This is done by circulating a heat-absorbing process through the refrigeration cycle within the chiller.

Industrial chillers are used to control the cooling—either directly or indirectly—of products, mechanisms, and machinery in various industries. Despite the different types of industrial chillers, they all use air or water as a cooling method during the refrigeration cycle.  

For instance, an air-cooled chiller cools the system with fans, while a water-cooled chiller uses circulated water from a cooling tower. These systems can cool water to below ambient temperature or even below freezing. Water chiller capacities are typically measured in cooling tons, KCAL/hr, or BTU/hr. For instance, Creworks' 6-ton water chiller can achieve cooling capacities of up to 61,200 BTUs per hour.

Why Do You Need a Chiller System?

Industrial operations generate heat through friction and high-powered equipment like furnaces or engines, or through temperature-sensitive materials such as plastics. To prolong the lifespan of heavy-duty equipment and speed up production via shorter cycle times, chiller units are installed to circulate cooled liquid through the equipment.

Selecting the right chiller for your application can help you save costs, reduce downtime, and increase production capacity and operational efficiency. The two main types of industrial chillers used today are air-cooled and water-cooled chillers, which we will discuss further.

Types of Industrial Chillers: Air-Cooled vs. Water-Cooled

There are two types of condensers used in chillers: water-cooled and air-cooled. In a refrigerant cycle, the hot refrigerant gas from the compressor needs to be cooled in the condenser. It then enters the expansion valve into the evaporator to generate chilled water and achieve the desired cooling cycle.

Air-Cooled Chillers

Air-cooled chillers have condensers that use ambient air to cool the hot refrigerant gas. These chillers are usually installed in areas with good airflow, as they rely on fans instead of cooling towers to dissipate heat. An air-cooled chiller absorbs heat from processed water and transfers this heat into the air.

Water-Cooled Chillers

Water-cooled chillers have condensers that use water from a cooling tower to cool the refrigerant gas. Once the refrigerant is cooled and released via an expansion valve, it cools the circulating water in the chiller to reach the target temperature. The processed water acts as a medium for heat transfer.

Air or Water Chillers: Which One Suits Your Needs?

Both air-cooled and water-cooled chillers are designed to facilitate the discharge of heat from the production process. They produce the same cooling capacity under the same compressor power. Therefore, your decision should be based on your working environment and the purpose of use.

Creworks, a top manufacturer with over 40 years of experience in the chiller business, is globally recognized in the market.  To learn more about our reliable and customizable chillers for various sectors, explore our Chiller & Cooling Water Series.

How Do Industrial Water Chillers Work?

Nearly every industrial process generates heat. If this unwanted heat accumulates, it can reduce the productivity of your machinery and factory. Excessive heat could even lead to shutdowns or early equipment failure. Incorporating a cooling process into your industrial system design can help avoid these issues.

Components of a Chiller

The essential components of a chiller include a compressor, condenser, expansion valve, and evaporator. These components work together to circulate a refrigerant that removes heat from a process, operation, or space.

Compressor

The compressor is the major component of a refrigeration unit. It circulates the refrigerant (freon gas) and converts it from low-pressure to high-pressure before it travels to the condenser to discharge its heat.

Condenser

The condenser cools the gas by transferring heat from the refrigerant to the outdoor cooling medium (air or water). It also condenses the refrigerant, converting it from a gas to a liquid.

Expansion Valve

The liquid refrigerant passes through the expansion valve before entering the evaporator for heat exchange. The expansion valve lowers the high pressure and temperature of the refrigerant liquid, converting it into a low-pressure, low-temperature wet vapor, which is then sent to the evaporator.

Evaporator

The evaporator is where the actual heat exchange happens. The processed water from the expansion valve enters the evaporator to start the cooling process.

Which Industries Need a Water Chiller?

Water chillers are used in various industries, including:

• Plastic manufacturing and processing
• Metal forming
• Food and beverage processing
• Machinery
• Chemical and pharmaceutical
• Medical (MRI, CT scanner, x-ray, linear accelerator, laboratory)
• Shoe industry
• Laser cutting
• Transportation manufacturing
• Semiconductor
• Composite manufacturing

Things to Consider Before Selecting a Water Chiller System

Using a water chiller in a factory has numerous benefits. However, these benefits can only be realized if you have the right chiller installed. Consider the following questions before purchasing a water chiller system:

• What's the heat load of your intended application?
• What coolant type, target temperature, and flow rate does the chiller system provide?
• In what environment will the water chiller be installed, and what are the site conditions?
• Does this water chiller model meet or exceed the required capacity? (check the chiller performance curves)

Save Time with Creworks' Industrial Commercial Water Chiller

In addition to expert advice, a top-tier manufacturer creates water chiller models that effectively maintain component temperatures during operations, thereby optimizing production efficiency. Here are several advantages of selecting Creworks' 5 ton industrial chiller:

• High Cooling Capacity: CREWORKS' CWTH-5 water chiller offers powerful cooling, handling up to BTUs per hour, ensuring effective temperature control for industrial processes.
• Efficient Water Usage: With a spacious 16-gallon (60 L) water tank and a circulation rate of 29 gpm (110 liters per minute), it maximizes cooling efficiency while conserving water.
• User-Friendly Design: Features like an observation window for water level monitoring, corrosion-resistant brass water inlet and outlet ports, and real-time temperature sensors with a digital display ensure easy operation and maintenance.
• Reliable Performance: Equipped with a 7.5 hp compressor using R407C refrigerant, it maintains a stable water-cooling system within 3℃ of a constant temperature, supported by indicator lights and alarms for quick troubleshooting.

Every invention comes with a con, and the technology and engineering work to overcome that challenge to create a perfect solution for industries. And that is the reason why every complex machinery uses chillers. When the machines work so well, the obstacle that hinders their functioning is heating. This is where Chillers come to the rescue.

What is the Significance of Chillers? Why use a Chiller?

Any industrial process generates heat as its byproduct. With heat being generated, no process or machine can be 100% efficient. If this heat is not removed, it worsens the situation causing reduced production, the shutdown of equipment, and even premature equipment failure. So it is vital to incorporate some sort of process that removes the heat in the system. That is where a chiller comes into the picture. A chiller provides multiple benefits by providing cooling. It provides the optimum temperature and pressure to the industrial process.

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EVR Electricals has a wide range of chillers that varies in size and design to suit different applications. We have small and portable chillers for small applications and large central chillers designed to provide cooling for the entire process.

Working of Chiller

Chillers are a key element in all HVAC systems across commercial and industrial applications. Its job is to remove the heat from the system and maintain the optimum temperature of the electrical appliance. In general, Chillers transfer the heat from an internal environment to an external one with a help of a heat transfer device and a refrigerant.

Chiller systems pump coolant or refrigerant through a specific process resulting in heat extraction from relevant areas in the system. Other main components of a chiller are a compressor, a condenser, an evaporator, and an expansion valve. The evaporator in a chiller functions as a heat exchanger and transfers the heat captured to the refrigerant. During the heat transfer, the refrigerant evaporates thereby reducing the process temperature. The compressor, on the other hand, removes the refrigerant from the evaporator and ensures constant pressure for heat absorption at an appropriate rate. Finally, the condenser converts the refrigerant back to a liquid state.

In a chiller unit, there are two heat exchangers involved – The evaporator and the cooling coil. In addition to the evaporation process, the evaporator also acts as a heat exchanger. It contains the primary refrigerant on one side while the other side has the secondary refrigerant or water.

The cooling coil is another heat exchanger which transfers heat from air or other process fluid to chilled water. The cooling water entering the coil is referred to as the chilled water supply while that leaving is called the chilled water return.  For most chiller units, the heat exchange process produces a temperature difference between the chilled water supply and return which is approximately 8 to 16°F (4 to 9°C). This temperature difference is known as the cooling range. By determining this temperature range and the cooling load, the required chilled water flow rate can be estimated.

Vapour Absorption Vs. Vapor Compression Chillers

Chillers are broadly classified into two types – Vapor absorption and Vapor compression chillers. The way in which the heat is removed from the system differs in both of these types. Vapour compression chillers use a mechanical compressor driven by electricity to pump the refrigerant around the system whereas the vapour absorption ones use heat for this purpose.

Of the two, Vapor Compression chillers are the most commonly used type of water chiller.

Air Cooled Chillers Vs. Water-cooled chillers

Based on the condenser type used in a chiller unit, they are categorized into Air-cooled and Water-cooled Chillers.

How does an Air-Cooled Chiller work?

An Air-cooled chiller forces air into the refrigerant lines with the help of a blower. They follow the same principle as the Car radiators. Air-cooled chillers require an ambient temperature of 95°F or 35°C or below to work effectively.

Air-cooled chillers have the advantage of lower installation costs. The maintenance of an air-cooled chiller is also simple as compared to a water-cooled chiller. Air-cooled chillers occupy less space, but will mostly reside outside a facility. Thus, the external environmental elements will compromise their functional lifespan.

How does a Water-cooled chiller Work?

Water chillers, on the other hand, use a water-cooled condenser connected to a cooling tower. Firstly, It transfers the refrigerant heat from the evaporator to condenser water and then discharges the heat from the condenser water to the cooling tower.

Water chillers are used in industries where a cooling water supply is readily available.

A chiller recirculates the cooling water instead of wasting it through a single-pass system. This recirculation minimizes the cost of water consumption which is both economic and environment friendly.

For larger installations, Water chillers are preferred as they can provide a more constant performance for commercial and industrial air conditioning compared to air-cooled chillers because of the relatively lesser fluctuations of the ambient temperature. They are mostly installed inside the buildings and are protected from environmental factors. Water chillers offer a longer lifespan compared to air chillers.

Industrial water chillers are used in a variety of applications including moulding, tool and die-cutting, food processing and beverage industry, chemicals, lasers, etc.

Water Chillers buying and maintenance

There are certain factors to keep in mind while installing a water chiller for an HVAC application. In addition to the load calculation, the controls, configuration, and piping also must be considered while specifying the design requirements to your manufacturer. Other factors include,

Cooling load and Capacity  

The rate at which heat is extracted from the system to keep a required temperature for the process is called the cooling load. It is usually represented in tons of refrigeration (TOR) or BTU per hour. Once the cooling load is calculated, the cooling capacity can be established. It refers to the rate of cooling, one chiller unit can provide. Generally, it is a little higher than the cooling load.

Water supply and Flow rate

The amount of water supply required to a chiller unit and the flow rate at which it has to be supplied also must be considered. Since the cooling coil exchanges heat between the chilled water and air, cooling coil specifications must also be included while calculating the cooling capacity.

To get the most out of your Water Chillers, there are certain things you should do. These will not only significantly improve your chiller efficiency but also reduce your operation costs.

• Routine inspection on the condenser coils for clogging and corrosion
• Refilling the refrigerant at frequent intervals as the cooling capacity greatly depends on the refrigerant.
• Ensure proper water flow to the cooling tower. Any contaminants like sand or debris can impact the condenser efficiency.
• Proper Safety controls that prevent harmful variations in the compressor pressure.
• Preventive measures to be taken to avoid inflow of air and moisture into the chiller systems

Conclusion

It is necessary to incorporate a Water Chiller in your industry machinery irrespective of your business. Chillers save your equipment from heat and ensure the long-lasting working of the machines.

EVR Electricals, the best manufacturer and supplier of water chillers in Chennai and India, has a team of experts to build quality products that reduce the maintenance costs of the customers drastically. Get in touch with us today! Also, feel free to comment your thoughts on water chillers.

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