How to select the right industrial chiller
Industrial chillers are critical in manufacturing plants where equipment must be maintained at a cooler temperature. Components generate heat, and if overheating, can become damaged. Similarly, equipment and machines perform better when they’re cool.
The wrong industrial chiller can lead to a cascade of costly problems to your operations and bottom line.
From air-cooled and water-cooled chillers to process chillers and portable units, there are dozens of chillers on the market to choose from. Selecting the right industrial chiller is not just about avoiding problems either – it’s also about improving your bottom line. The ideal chiller can significantly reduce energy consumption, enhance operational efficiency, and extend the lifespan of your equipment. It can even contribute to a greener footprint by minimising water usage and waste.
Atlas Copco chillers, for example, use advanced variable speed drive (VSD) technology to adapt energy use based on load, reducing costs and environmental impact.
In this guide, you’ll learn the different kinds of industrial chillers and which one is best for your business.
Understanding Your Cooling Requirements
Selecting the correct chiller for your application begins with understanding your cooling needs. This involves calculating the heat load, which refers to the amount of heat that must be removed to maintain stable process conditions. Factors such as the type of equipment used, production speed, materials involved, and ambient temperature all play a part.
Ambient conditions are especially important. A rise in surrounding temperature can increase the load on the refrigeration system, affecting chiller performance. If overlooked, this may even damage the chiller unit during operation. For demanding environments, industrial chillers must be specified to meet specific application requirements, not just general cooling needs.
It is also essential to assess the cooling fluid. Many industrial water chillers use a glycol and water mix, but the cooling water circulation assembly and additives must be compatible with the system to ensure longevity and efficiency.
If your heat load varies or precise control is required, opting for a chiller with variable speed drive technology can help. This enables the chiller to operate in line with demand, thereby reducing energy consumption and enhancing temperature stability.
As chillers are an essential part of many industrial processes, selecting the appropriate chiller size and configuration is a critical decision. Expert consultation can make this easier, ensuring the industrial chiller for your application delivers lasting performance, efficiency, and reliability.
The Importance of Choosing the Right Chiller
An overperforming chiller is an unnecessary expense, while an underperforming chiller will struggle and potentially fail, leading to costly downtime. It’s about finding that Goldilocks chiller – one that’s just right for your needs.
Air cooled chillers remove the water dependence associated with water cooled chillers. Not needing access to local water supplies, or a separate external tower, helps to ensure lower operating costs. Wastewater is no longer an issue when using air cooled chillers, which eliminates major environmental concerns.
Water cooled chillers are another option. These offer persuasive efficiencies while requiring a regular water supply to function. A water pump and a tank are usually needed for these systems. However, they tend to have a longer lifespan compared to their air cooled cousins.
Atlas Copco chillers with oil-free technology ensure Class 0 certified cooling for industries like food and beverage, pharmaceuticals, and semiconductors. This level of oil-free performance guarantees product safety and system reliability.
In either case, when correctly sized and specified, chiller technology more than pays for itself in just a few years compared to not using one at all.
Specifying a Chiller Installation
Plant managers need to consider factors such as the process fluid mixture, the cooled temperatures required, pressure levels, desired flow rates, and more.
Other aspects that influence chiller selection are also the setup, and installation including where the installation is operating. Space constraints, ambient temperature, and whether elevation also affects the operational efficiency of the industrial chiller units.
- Process Fluid Performance
Cooling fluids must be compatible with the industrial chiller. The process of cooling fluid is typically a blend of propylene glycol or ethylene, combined with up to 50 percent water. This manages setpoint temperatures at the end of the range. Operators often add a corrosion inhibitor to prevent seal degradation, too.
Atlas Copco chillers integrate stainless steel centrifugal pumps, ensuring resilience against corrosion and breakdowns.
- Cooling Fluid Temperature
Setpoint temperatures alter cooling capacity with industrial chillers. As the setpoint is lowered, capacity drops. This changes which chiller is selected based on its intended purpose. To help with this, you can examine the published performance data of individual chillers.
A chiller should also tolerate the lowest ambient temperatures through the season to operate as expected.
Atlas Copco offers chillers for demanding environments that sustain efficient operation even at extreme ambient temperatures up to 46°C.
- Process Flow and Pressure Requirements
Insufficient flow rates lead to inadequate heat transfer, causing temperatures to rise. This not only compromises the quality of your products but also puts unnecessary strain on your equipment, prematuring wear and tear.
On the other hand, undersized pumps or pressure relief issues can restrict flow, forcing the pump to work harder and potentially shortening its lifespan. This can lead to costly repairs and unplanned downtime, disrupting your production schedule.
To avoid these pitfalls, it’s crucial to carefully calculate your process flow and pressure requirements. Consider all components of your cooling loop, including pumps, impellers, and seals.
- Chiller Operating Environment and Spatial Constraints
Heat dissipation by air-cooled chillers is needed to avoid overheating. The chiller operating environment is a significant factor here, and a rising ambient air temperature reduces potential heat transfer.
For chillers with a condenser relying on liquid cooling systems, the pump, compressor, and other parts may overheat should the chiller equipment get too hot. Higher ambient temperatures directly contribute to this and reduce the lifespan of affected components. Around 40-degrees centigrade is the typical maximum ambient temperature limit for many chillers, but each model varies.
Adequate air circulation space surrounding the chiller matters too. Proper airflow is needed for optimal performance, with insufficient airflow eventually damaging the chiller.
- Installation and Environmental
Where you install your industrial chiller matters. An oversized chiller uses valuable real estate in factories. In tight spaces, a compact chiller is your best bet. But remember, even compact chillers need enough room for airflow and maintenance access.
If your chiller is facing harsh conditions, such as dust, debris, or extreme temperatures, you will need some extra protection. Think air filters to keep the chiller’s insides clean and sump heaters to prevent freezing in colder climates.
Indoor and outdoor installations each have their own considerations. Indoor chillers might need additional ventilation to dissipate heat, while outdoor chillers need to be weatherproofed. Your chiller size might also change depending on whether it’s battling the elements outdoors or enjoying the comforts of an indoor environment.
Choosing the right chiller for your space and environment isn’t just about fitting it in – it’s about ensuring it operates at its best, no matter the conditions.
Maintenance, Safety, and Control
Industrial chillers are a vital component of many production environments, and maintaining them efficiently helps prevent downtime and prolong equipment life. With front access to key components, such as the cooling water circulation assembly and corrosion-resistant parts, the latest designs simplify routine maintenance.
Built-in safety features help protect the chiller during operation. These include temperature, pressure and flow sensors, as well as sealed refrigerant circuits to prevent leaks. If connected to the plant’s water supply, monitoring the water flow rate and quality is important to safeguard long-term performance.
Control technology has also improved. Touchscreen panels give operators quick access to system data and alarm notifications. Remote systems, such as Atlas Copco’s SmartLink, offer predictive maintenance tools that reduce unplanned downtime and improve overall chiller performance.
Choosing the best chiller for your application involves more than cooling power alone. It includes ease of maintenance, system protection, and how well the unit supports efficiency in industrial operations over time.
Conclusion
The question of how to select the right industrial chiller is worth considerable review. It’s all too easy to make a misstep when determining the size of the chiller you require. Remove the confusion over what is an optimal industrial cooling system for you, by talking with our team at Anglian Compressors. We can address your specific requirements through a detailed consultation.
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FAQ
What factors should I consider when selecting the ideal chiller for my facility?
Selecting the ideal chiller is a critical decision that depends on factors such as cooling demand, ambient temperature, and installation space. It is essential to determine whether standard chillers meet your specific application requirements or if a different chiller is necessary to optimise performance and efficiency.
How do advancements in chiller technology improve system reliability?
Recent advancements in chiller technology have enhanced reliability by improving control systems, simplifying maintenance, and providing better protection during operation. Features like easy access from the front and the cooling water assembly also reduce servicing time and support long-term performance.
Why does the correct chiller size matter?
Determining the correct chiller size for your process is crucial. An oversized unit wastes energy, while an undersized system can compromise chiller performance and potentially disrupt operations. Understanding water flow rate, process load, and application needs will help ensure your chiller operates optimally.