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Liquid Chiller Applications

Applications that rely on temperature control vary from various industrial processes to the production of consumer products. Modern day manufacturing depends on precision temperature control to ensure the quality of products and components. Much of what is produced today is designed for complex technical applications that are dependent implements that have to meet the most demanding tolerances.

Industrial liquid chillers are indispensable for cooling machinery, mechanisms, and products across a spectrum of operations. They are pivotal in processes ranging from metalworking, die casting, and plastic injection molding to welding, chemical processing, and industrial refrigeration. Beyond these applications, liquid chillers play a crucial role in large-scale air conditioning, gas cooling, and maintaining precise temperatures for pharmaceuticals and laboratory chemicals.

Liquid chillers play a vital role across various industries, from healthcare and pharmaceuticals to food and beverage, plastics production, HVAC systems, and power generation.

The History of Liquid Chillers

Liquid chillers originated in the 1800s as scientists delved into the effectiveness of liquid refrigerants for air and water cooling. Their experiments revealed that using liquids such as water could effectively cool the air.

Willis Carrier, an innovative American engineer, pioneered the application of heat transfer principles to machinery. In 1902, he unveiled the world’s first modern air conditioning system, a groundbreaking achievement. His invention effectively controlled humidity by circulating humid air through water, extracting both moisture and heat. Carrier’s ingenuity didn’t stop there. In 1906, he patented another revolutionary air conditioning unit, which could both humidify and dehumidify air through a spray-type mechanism. Throughout the early 20th century, Carrier continued to lead advancements in liquid chilling technology. In 1915, he co-founded Carrier Engineering Corporation with several colleagues, a venture that would later become Carrier Corporation, marking a lasting legacy in the realm of environmental control systems.

Air Cooled Chiller – Cold Shot Chillers

In 1931, scientists unveiled a breakthrough: chilling became vastly more effective with the introduction of Freon. By 1938, the Trane Company (now under Ingersoll Rand) commenced manufacturing enclosed chiller systems, pioneering the use of refrigerants akin to contemporary liquid chillers. This innovation catalyzed the development of industrial liquid chillers capable of rapidly cooling enclosed environments.

During the 1920s and 1930s, scientists and engineers pushed the boundaries of heat exchanger and chilling technology. However, their innovations faced a sharp decline in demand during the Great Depression. Not until the early 1950s, amidst America’s post-war economic surge, did these technologies regain popularity. Plastics manufacturers in 1950 started integrating industrial chillers into their production lines. This breakthrough accelerated manufacturing, broadening the scope of plastics applications across various products.

From then on, chillers embedded themselves across myriad industries as indispensable allies. As the 20th century drew to a close, engineers employed chillers to lay the foundations for the global electrical grid. Today, their significance remains undiminished.

Liquid Chiller Design

Chillers vary greatly in their designs and sizes. Smaller chillers are often crafted as compact, portable units suitable for localized use. In contrast, larger chillers are engineered to cool entire facilities efficiently.

Considerations

When crafting a liquid chiller, manufacturers deliberate on numerous technical aspects: cooling capacity, refrigerant choice, power source, evaporator flow rate, and compressor strength. Equally crucial are spatial constraints, operational frequency, fluid temperature, cooling environment specifics, and adherence to industry standards.

To enhance the suitability of your liquid chiller model for your specific needs, chiller manufacturers can incorporate enhancements such as emergency alarms, pressure indicators, and remote-control panels, ensuring optimal functionality tailored to your requirements.

Cooling Capacity

The cooling capacity of an industrial chiller model is quantified in tons or Btu/h (British thermal units per hour). Chillers vary widely in their cooling capabilities. For example, a compact portable chiller may have a capacity equivalent to a fraction of a ton. Conversely, larger systems can comprise multiple units, boasting capacities that reach into the thousands of tons.

Refrigerant Type

The choice of refrigerant hinges on the operational temperatures of the chiller. Among the commonly used options are methane, brine, alcohol, sulfur dioxide, carbon dioxide, ammonia, water, R410A, R134A, and R407C. In earlier years, fluorocarbons and chlorofluorocarbons (CFCs) were prevalent but have waned in popularity due to their ozone-depleting properties.

How Liquid Chillers Work

Chillers employ vapor-compression or absorption methods to perform their cooling tasks. These processes involve a refrigerant that absorbs heat from one location. When the refrigerant condenses, it evaporates elsewhere, releasing the absorbed heat. Cooling towers or vents are often utilized to enhance the cooling process in both methods.

Most chillers operate through a four-stage cycle: compression, condensation, expansion, and evaporation. This process unfolds as follows.

1. Pressurization

Pressurization plays a critical role in the vapor-compression cooling process but is absent from the absorption cooling process.

In a vapor-compressor chiller, the process begins with the compressor pressurizing the refrigerant vapor. Various liquid chillers employ different compressor types for this purpose.

2. Condensation

In this initial phase of absorption chilling, the chiller machine begins by moving the refrigerant into a condenser. The condenser comprises coiled tubes through which air or water circulates. Inside the condenser, the refrigerant vapor undergoes cooling and transforms into a liquid form.

During this stage, a substantial amount of heat is extracted. This heat is subsequently absorbed by the circulating water or air surrounding the tubes.

3. Depressurization

The freshly chilled liquid proceeds to an expansion valve, where it undergoes depressurization. Expansion valves operate by detecting both the current and desired temperatures, adjusting the refrigerant flow accordingly.

4. Evaporation

Once released from pressure, the liquid initiates its evaporation process. As evaporation ensues, the liquid experiences a significant drop in temperature. This transformation occurs as the cooled liquid enters an evaporator or heat exchanger, where it evaporates and absorbs heat in the process.

Types of Liquid Chillers

Absorption chillers harness a heat source to drive their refrigeration cycle. A distinct advantage of absorption chillers lies in their minimal electricity consumption, making them ideally suited for solar power or heat-generating machinery.

Vapor-compression chillers operate by driving the cycle with a compressor. They are proven over time, readily available, and simpler to install compared to absorption chillers.

Different types of vapor compression chillers vary by the gas compressor they employ. Among the most prevalent options are centrifugal compressors, screw compressors, and scroll compressors.

Centrifugal compressor chillers chillers increase fluid pressure by imparting kinetic energy. This energy is generated as the liquid passes through an impeller or rotor, which converts it into higher potential energy by channeling the fluid through a diffuser.

Screw compressor chillers employ dual rotary screws to compress refrigerant liquid. These chillers ensure consistent, uninterrupted cooling at high speeds.

Scroll compressor chillers frequently populate portable cooling units, prized for their compactness and noiseless operation.

Chillers can also vary based on the type of condenser they utilize—whether they rely on air cooling, water cooling, or evaporation cooling.

Air cooled chillers channel ambient air across the condenser, expelling warmed air into the atmosphere. This unique heat release mechanism also enables them to provide heating for facilities during colder conditions.

Water cooled chillers, also known as water chillers, harness flowing water to draw heat away from a refrigerant. While this method of condensation proves highly efficient, it necessitates a reliable water supply, typically requiring a pump and a cooling tower.

Evaporation cooled chillers function similarly, yet they utilize a mist of water previously dispersed into the air. This evaporation enhances the efficiency of heat transfer.

Additional types of liquid chillers encompass process chillers, recirculating chillers, and central chillers.

Process chillers intermittently control temperatures, operating on-demand rather than continuously. They are widely employed in power plants and for rapid freezing in the food and medical industries.

Recirculating chillers operate by continuously cycling vaporized refrigerant back into the initial stage of the process. Typically compact and portable, these chillers excel in efficiency, precision, and uninterrupted performance. Notably, they minimize liquid wastage, making them favored for medical imaging, laboratory experiments, plasma etching, military uses, plastic extrusion, molding, and electronic temperature testing.

Central chillers, also referred to as central chilled water units, are essential components within central air conditioning systems. These units utilize internal chilled water coils to regulate air temperature effectively.

Medical Chillers are specialized cooling systems designed specifically for medical purposes.

Thermoelectric chillers excel in medical contexts due to their exceptional reliability, precision, and accuracy. These qualities are pivotal in safeguarding vaccines, medications, and experimental integrity against spoilage and deterioration.

TECs exhibit remarkable versatility due to their high scalability, enabling the production of miniature refrigerators that other cooling methods cannot achieve. This capability makes them integral in the creation of compact, portable refrigeration systems essential for storing medicines and insulin.

Laser Chillers play a crucial role in regulating laser temperatures. Thermoelectric chillers offer precise control over water flow, ensuring minimal vibration and exceptional accuracy. They maintain long-term temperature stability for cooling laser systems. TECs (Thermoelectric Coolers) are ideal for laser applications due to their reliable fluid flow, rapid response time, broad temperature range, and straightforward design with few moving components. Moreover, their compact size allows for installation in confined spaces without sacrificing laser performance.

Advantages of Liquid Chillers

Liquid chillers bring numerous benefits to their users. Firstly, they offer reliability by delivering consistent, uniform cooling that safeguards sensitive products from potential damage. Secondly, they optimize space usage effectively; whether manufacturers require a compact design or a portable unit, liquid chillers can accommodate diverse needs. Thirdly, they excel in rapid cooling compared to alternatives like ice or nitrogen systems. Lastly, liquid chillers provide cost-effective cooling solutions, making them accessible for various applications.

Liquid Chiller Accessories

When outfitting your liquid chiller, essential accessories to consider are protective coatings, condenser filters, remote controls, emergency alarms, spare parts, phase monitors, lights, gauges, locks, vibration dampeners, and additional refrigerant. For tailored guidance, discussing your specific application with your supplier is highly recommended.

Liquid Chiller Standards

Your liquid chillers must meet varying standards, dictated by factors like your location, industry, and application. Regulations are particularly stringent when chilling products destined for consumption, such as medicine, food, and beverages. In such cases, compliance with FDA and/or USDA standards is essential. Furthermore, due to the involvement of potentially hazardous refrigerants, EPA and/or OSHA approvals may be necessary depending on your setup. It’s advisable to ensure your chillers also adhere to AHRI specifications for comprehensive compliance.

Things to Consider Regarding Liquid Chillers

To secure a top-notch liquid chiller, partnering with a trusted manufacturer is key. To aid you in this quest, we’ve curated a roster of reputable manufacturers, accessible on this page. Each one boasts extensive experience and rigorous vetting. However, while all excel in their own right, not all may perfectly suit your needs.

To identify the ideal manufacturer among these options, we suggest starting by documenting all your specifications, requirements, questions, and concerns. Make sure to include your budget, timeline, preferred delivery and installation support, as well as post-installation requirements. Next, thoroughly review the products and services offered by the companies listed here. Continuously refer to your checklist for comparison. Choose three to four liquid chiller companies that best meet your application needs and request a quote from each. It’s advisable to engage in phone conversations to gauge their customer service approach firsthand. Once you’ve conversed with your top picks, analyze their responses and make your selection accordingly. It’s a straightforward process that ensures you find the right fit.

Process heat control

The main function of chillers is to circulate a fluid at a constant and controlled temperature in a closed loop for processes and operations that require stable temperatures. The system of a chiller includes a pump to circulate fluid, a refrigeration system, and a temperature control unit. Chiller temperature control is an on or off contact that controls the motor or solenoid of the compressor with pressure sensitive elements that change temperature constraints.

Fluid chillers remove heat from a hot source to a cold source using a refrigeration circuit and fluid circuit, which work together to move heat away from a process to maintain a constant and stable temperature. This form of chiller is the most common. It is a closed loop system that circulates fluid to a process and back to the chiller where it releases the heat from the process.

Air cooled chillers operate in a similar fashion as fluid chillers but release heat into the atmosphere. They circulate cool water through lines to a condenser. The water moves heat to a cooling source, such as a central chiller, domestic water supply, or cooling tower.

In each case, the function of a chiller is to control the temperature of a process such that the product being produced is of the highest quality. Chillers are an essential tool for manufacturing operations and come in various forms. Single zone and dual zone chillers have a temperature range from -10°F to 100°F (-23°C to 38°C) and are available with variable speeds to reduce operational costs.

In all aspects of any operation, from auto parts to pharmaceuticals, minute control of the temperature of a process is a necessity. Chillers use pressure sensitive elements to change temperature and pressure parameters using a contact on and off switch. Although this may seem to be a simple process, it becomes more complicated and complex when multiple fluid loops and a wide range of temperatures need to be controlled and monitored.

Process Vessel Temperature Control

Temperature control is an essential aspect of modern manufacturing since it determines the quality and performance of products. Referred to as TCUs, these highly sophisticated and technologically advanced devices are used to regulate, monitor, and control the temperature of injection molding, blow molding, extrusion, and plastic processing within a very narrow range, since slight alterations or changes to process temperatures can drastically affect the condition of the final product. The mechanism of a TCU raises and lowers the internal temperature of processing using internal heaters and cools them directly with a heat exchanger. Temperature control units are precision engineered to maintain and sustain a specific temperature level throughout an application.

Pharmaceutical Temperature Control Units

The pharmaceutical industry requires chillers that provide precision control of the temperature since such close control is necessary for formulating new drugs and their production. This aspect of the process is provided by various forms of pharmaceutical chillers, which are used for the manufacture of antibiotics and complex cardiology medications.

The various types of pharmaceutical chillers include central chiller systems and mobile, compact process chillers with systems being able to handle 10 to 200 tons while compact chillers having capacities of 1 to 40 tons. As with all forms of chillers, pharmaceutical chillers have an evaporator, pump, refrigerant relief valve, cooling tower and pipes, condensers, filters, fans, and tanks, using air or water condensers.

How Pharmaceutical Chillers Work

The operation of a pharmaceutical chiller involves the four basic stages that are found in all chillers, which are compression, condensation, expansion, and evaporation. The refrigerant is a central aspect of the chiller process. It takes several forms and can be water, ammonia, hydrochlorofluorocarbons, and combinations of these and other chemicals. The function of the refrigerant is to absorb heat and ensure the mixing consistency of pharmaceutical products.

Stage 1 – Evaporation – The first stage of the chiller process is evaporation, where the heat from the water or process fluid is absorbed. As the refrigerant enters the evaporator, it changes from a liquid refrigerant into a low temperature vapor that absorbs the heat from its surroundings and cools the water or process fluid.

Stage 2 – Compression – The low pressure vaporized refrigerant enters the compressor where force is applied to it elevating its pressure and temperature for the next stage of the process. Various types of compression methods are used in chillers and include scroll, screw, and semi-hermetic, which are powered by an electric motor. During the compression process, the low-pressure vapor is converted into a high-pressure gas.

Stage 3 – Condensation – During condensation, heat from the high pressure and high temperature gas is released into the atmosphere or a cooling medium and the refrigerant transforms back to a liquid. Condensers can be air cooled, water cooled, or a combination of both, depending on the environmental conditions. They are a form of heat exchanger that is used for the process of transforming the gas to a liquid.

Temperature Control Systems For Pharmaceutical Processing

Pharmaceutical product quality is dependent on precision temperature control from research analysis to full scale production. The necessity for temperature control is found in the flow process control for external reactants in the production of complex biopharmaceutical products, which is a necessity in the chemical synthesis of pharmaceutical ingredients and ensures the best possible reaction conditions as well as increases yield, selectivity, and safety.

Wiped Film Still Temperature Control

Distillation, a process of purifying a liquid by heating and cooling it, is performed used several different types of methods and processes. The wiped film method or thin film method is one of the most popular methods since it is a highly effective way to concentrate heat sensitive materials. The process of wiped film distillation is used on high boiling point solutions in large scale manufacturing.

Wiped film distillation is popular due to its ability to produce an extremely thin film inside the evaporator. The key to the success of the process is precision control of the temperature during distillation, which requires even regulated lowered temperatures to avoid damage to the distilled compounds.

Industrial Food Processing Temperature Control Equipment

As every chef and gourmet cook will tell you, the key to the successful preparation of food is temperature control. This is especially true for industrial food processing, which cooks, fries, boils, and prepares tons of food products for resale and commercial use. Cooking processes for industrial food preparation involves the use of huge friers with vats of oil that has to be kept at a constant temperature as food passes through the oil. Any deviation can lead to undercooked or over cooked food products.

Methods for temperature control for food preparation involve making the most efficient use of energy and ensuring the safe cooking of food products. Although the main focus of temperature control for food preparation is on cooking equipment, a certain aspect of the process has to be in regard to the environment where the food is prepared since surrounding factors can influence the performance of a temperature control device. When clients, engineers, and designers begin the process of developing a temperature control system for a food preparation company, they very meticulously and carefully examine every aspect of the process from the location of windows in a facility to the placement of cooling fans and entrances. Such careful planning ensures that installed equipment will provide optimum performance have the necessary controls to produce high quality and tasty food products.

Temperature Control in the Extrusion Industry

In the extrusion industry, materials to be processed have to be heated to a temperature that makes them pliable and firm such that they can forced through an extrusion die. Any variation in the temperature, such as too hot or not hot enough, can delay the processing and lead to poor product performance. It is essential, during extrusion, that the temperature of the material be at the perfect level to easily be processed and shaped.

An important part of product manufacturing is the injection molding of polymers that are pressed between the halves of a die to produce cell phone cases, small gears, computer components, and many of the products we rely on. Every aspect of the molding process has to be monitored, controlled, and overseen to ensure the temperature of the polymer is at its optimum level. Again, as with extrusion, the polymer material must be kept at a precise temperature throughout the molding process to ensure even and uniform hardening of the produced product.

Mold Temperature Controller

One of the key factors regarding the injection molding process is precision control of the temperature of the mold using temperature control units to ensure the quality of the parts and products that are produced. Precision control of temperatures helps manage and regulate mold temperatures to assure the quality of the molded product, increase efficiency, and reduce per unit production costs. It has been statistically proven that precise control of the temperature during the molding process determines the quality of produced components.

Redundant Chillers

A chiller is a process unit and refrigeration system that removes heat from an industrial fluid by cooling water or the fluid. They are a vital part of maintaining temperatures to ensure process and production efficiency. Redundancy in a chiller system is designed to eliminate downtimes, reduce energy costs, and guarantee optimal performance of critical systems. Redundant chillers have parallel circuit components that provide full redundancy.

Redundancy in a chiller refers to backup components or systems that ensure the continuing performance of a chiller in the event of the failure or malfunction of a component. Such a system prevents unplanned down times that can lead to production losses or increased cost of production.

The implementation of a redundancy system has several benefits and provides protection of systems and operations. The immediate benefit of a redundancy system is reliability, a factor that makes the system less vulnerable to the effects of single component failure. In many ways, the investment in a redundancy system is similar to an insurance policy that lowers the negative consequences of shutdowns and work stoppages.

All manufacturing operations are susceptible to down times due to system failures. An essential aspect of good management is to develop plans that lessen the likelihood of such occurrences. An investment in a redundant chiller system that is designed to activate at the indication of component failure is one step that can be taken to guarantee continuous operation.

The various redundant systems that can be installed on a chiller system include full chiller units, backup pumps, backup cooling towers, and electrical systems. Extra chiller units are the ultimate in redundant systems, since they simply take over the functions of the failed unit. Redundant pumps ensure circulation continues when a primary pump fails while redundant cool towers provide extra cooling capacity. Backup power supplies are a common aspect of all forms of production and are an essential part of ongoing chiller performance.

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