How efficient are air cooled chillers?

For some of us who have air conditioning chillers at home or industrial chillers in the offices, there are questions waiting to be answered. Only a few of us know how they truly work and there’s one thing that boggles the mind. When it comes to air cooled chillers, energy efficiency has become an ambiguous term.

Air cooled chillers remove heat from water or other fluids. This heat is then dispersed into air through a system called refrigeration.

It all starts when a fluid is forced with high pressure through a tube. This changes the fluid to turn into gas which absorbs heat through the evaporator heat exchanger. This gas then travels to the compressor where it is compressed into a hot gas before being pumped to the condenser. In the condenser, the gas is passed through small copper tubes with thin aluminum fins bonded to them. When ambient air is forced through the condenser via the process chiller’s fans, the gas is condensed back to a liquid state. In this process, the heat that the gas has collected is released through the chiller fans as well. The liquid is sent back to the tubes so that the whole process can start again.

The efficiency of an air cooled chiller depends on the efficiency of the chiller compressor. This can be measured through COP or Coefficient of Performance. A COP is the ratio of heat removed to the electrical input required. In chiller efficiency, the higher the COP is, the more energy efficient it is. If a COP is 5, it means that for every 1 KW of electrical energy input, 5 KW of heat is removed. If a COP is 10, it means that for every 8 KW of electrical energy input, 8KW of heat energy is removed.

Check out the COP of the chiller the next time you’re out chiller shopping. You can now tell the difference in terms of energy efficiency.

How does a air cooled chiller differ from a water cooled chiller?

Industrial chillers are of top priority in most industries and companies worldwide. These chillers help cool the equipments and the environment as well. They help maintain the effectivity of the equipments at hand. Industrial chillers come in different variations and design but still offering the same functionality. They work towards the same purpose but the difference in the way they work help companies choose which one fits the nature of their business.

Industrial chillers can either cool by air or cool by water and they have the same parts. They each have an evaporator, compressor, expansion valve and a condenser. They also have the same functionalities but the difference lies in how they refrigerate fluids which makes a great difference especially for most industries.

An air cooled chiller rejects or gives out heat into the air. They are less efficient when it comes to energy but they are also less expensive to purchase and maintain. This is the reason why air cooled chillers are being widely used in most industries.

A water cooled chiller on the other hand, also gives up heat. However, it gives up heat into another water source instead of into the air. Water cooled chillers are ideal and practical for industries that have cooling plants or a water source ready.

These chillers come in different designs to help industries tend to their needs in the most efficient of ways. Through this, they are given options and can maximize the equipments they have at hand for the improvement of their overall progress.

How Refrigerators work then and now

Process Chillers may come as a foreign term to many of you. This is because it is often only used formally. There are different types of chillers out there and the most common of all is one item that is essential to our everyday living: the refrigerator.

The refrigerator is an air cooled chiller that allows us to chill or freeze things to lengthen their shelf life. But refrigerators back then and now did not follow the same process. 

REFRIGERATORS (then):

At the back of a refrigerator, there’s a long thin tube that goes in loop. This tube is connected to the pump powered by an electric motor. Inside this tube is Freon which is a type of gas but is also known chemically as Chloro-Floro-Carbon or better known as CFC. CFC’s start out in liquid form and are pumped through the coils in the freezer area. Here, the liquid turns to gas and when it does, it absorbs some of the heat that’s in the freezer compartment. This is the reason why air cooled chiller’s freezers are super cold and filled with ice all around especially for used chillers that haven’t been cleaned. The pump sucks the CFC gas and passes it through the thinner pipes located outside the refrigerator and compresses it. The process of compression turns the gas back into liquid form and heat is given off. This is the reason why it’s hot when you stand next to your refrigerator. They cycle continues inside this process chiller.

REFRIGERATORS (now):

Because CFC’s were harmful to the atmosphere if they leak out of refrigerators, manufacturers had to find a way to do away with it. Hence, modern day air cooled chillers use HFC chemically known as tetrafluoroethane. This type of gas turns to liquid if it is cooled to -15.9 degrees Fahrenheit. The process all starts with a motor and compressor that squeezes the HFC and gas heats up. As it cools, HFC turns to liquid. The liquid then flows through a tiny hole called the expansion valve. There is a low-pressure are between the valve and the compressor because the compressor is pulling ammonia gas out of that area. When HFC gets to this area, it vaporizes and turns to gas. The coils go through the freezer and the colder liquid in them pulls heat out of the compartments, leaving freezers super cold. The compressor then sucks up the cold gas and the cycle continues.

Refrigerators in the earlier days are different from how refrigerators work nowadays. The difference may be subtle but the overall effect is huge.

Chiller Efficiency and Maintenance

If your company owns one of those industrial chillers to help maintain various equipments that may be damaged from too much heat, then you’d probably know that chiller maintenance don’t come easy.

A chiller can only be beneficial if its efficiency is at its maximum or remain to be unaffected despite several factors.

A chiller’ efficiency is measured by the amount of energy it needs or it takes to produce a ton of cooling and is usually expressed as kw/ton. All types of chillers including air cooled chillers and water cooled chillers have certain efficiency established before being released out in the market. However, there are a lot of factors that can affect it which can result to poor efficiency and higher operating costs.

An industrial chiller can have an operator to better keep track of the activities. The operators are known by a few titles: Stationary Engineer, HVAC engineer or service technician. Nevertheless, they perform the same job: they watch over the chillers. Chiller operation includes collecting and logging data from different estimates and controls the meters near or on the chiller. There are also service contractors whose expertise is the equipment repair. They are the ones you must call when you need major repairs.

There are three types of chiller maintenance:

Water chemistry – keeps the proper balance and minimizes the effects of corrosion, and debris fouling.Mechanical Maintenance – includes adequate liquid refrigerant, proper lubrication and a series of oil levels and pump curve tests.Operational Procedures – includes calibration of gauges and meters, oil analysis and other different tests that checks the operation process.

Chillers must be maintained and kept well for a longer lifespan. They don’t come cheap so taking care of them is worth the extra years they give as service before they break down.

Chiller Threats

In big industries, chillers use up almost fifty percent of its entire electricity consumption, making them high-maintenance equipment. Because of this, proper maintenance for industrial chillers or any chiller for that matter should be a priority and should be something that is consistently being done.

Poor operating practices cuts down the chiller’s life as well as decreasing its efficiency. These practices include but are not limited to trying to force a chiller to do something that it wasn’t designed to do. You have to understand what your chillers are meant to do. You have to get to know your process chillers or other types of chillers. An important note with these practices is that the consequences are unnoticeable at first. Chillers continue to act normal but time will come when it gives in and breaks down faster than it should.

Chiller maintenance shouldn’t be taken lightly especially for equipment such as this. Good maintenance is essential in keeping chillers in top condition. A brand new air cooled chiller can carry a particular amount of load. Over time, that load decreases gradually. However, if maintenance is ignored then that decrease will happen faster than it should.

Chillers have cooling towers that assist in their efficient operation. They allow chillers to operate efficiently to their maximum potential. It is essential that these cooling towers are kept in top shape because a slight decrease in its performance will have a major impact on the chillers.

A chiller should be properly sized for an efficient operation. For example you have a new air conditioning chiller and the size of the load is sufficient for it to run smoothly. However, changes are made such as new windows or new lighting systems. This decreases the load for chillers and as a result, decreases its efficiency. You have to keep track of this and make sure that the balance is maintained.

Chillers have helped humanity in more ways than one especially in big industries. Therefore keeping them safe and treating them well is just right.

How Chillers Work

In every water cooled chiller, the liquid is separated from the refrigerant by sealed tubes or coils. Water is then passed through a series of sealed tubes in and around a compressed refrigerant of ammonia or Freon. The heat from the warmer water is passed through the metal sealing tubes and into the gas of the refrigerant which is then sucked off through the vessel by a compressor.

Air cooled chillers range in different sizes from the common cold drinking fountain to large industrial chillers that can accommodate thousands of gallons of liquid. Regardless of the size, water chillers all have the same function, which is to remove unwanted heat and cool down the liquid to a desired temperature. After removing the unwanted heat, the cooled chiller will discharge it elsewhere.

The refrigerant enters the heat exchanger in the form of a liquid and it comes in contact with the sealed tubes that contain the water and while this happens, it flashes into a gas. The flashing of the refrigerant happens when the heat is exchanged from the warmer water through the metal tubes and into the recirculating chiller. The heat, which is now in gas form, gets carried away by the suction of the compressor.

Through the operation of a fan, the machine’s condenser releases heat that was captured by the gas into the air. The gas then turns back into a liquid or condenses as it cools and then exits the condenser. The liquid refrigerant is then forced back into the heat exchanger vessel to perform the same work of removing heat from the warm water. This is the same process that is used on a refrigerator.

Always remember that proper maintenance on the chiller is needed to lengthen the appliance’s lifespan.

Choosing the Right Company to Repair Your Chiller

It’s normal for appliances to get serviced from time to time. There are just some things that need to be taken into consideration before settling on a company that can do the service for you. Refrigeration units and other similar appliances like water cooled chillers are not easy to fix and should be handled meticulously, which means that trying to do the repairs on your own is not the best option.

Chillers such as air cooled chillers, recirculating chillers and others types are very complicated and you need a certified specialist to get the job done quickly and efficiently. The last thing you want to do is have your own business down longer that it needs to be. If you try to repair the unit on your own because you’re trying to save money, don’t bother. You may end up having to spend more in the end. Finding a company that can get the job done right at an affordable price is easy. The first thing you need to look for is a company that has several experiences in chiller maintenance and one that is familiar with your unit.

Thinking of a company that charges low prices for servicing may not always be your best option, since they may not be familiar with your type of unit and can take twice as long to fix the problem. If the company is familiar with the brand of your industrial chiller, they can easily diagnose the problem and have your unit up and running in no time.

Hiring a certified company to repair your unit can have its benefits. Some offer a warranty and other “perks” which is important for you. Being careful about what kind of company you hire to fix your valuable assets is something more essential than money. By doing this, you can save more in the long run.

Steps to Prolong A Chiller’s Duration

If you own an air or water cooled chiller, always make sure you keep it maintained regularly, otherwise its performance can gradually degrade. This can result in temperature variations that can affect productivity and quality. Chillers are supposed to provide heat removal and cool down the temperature of temperature-sensitive equipment. Air cooled water chillers are not only for industrial use. Some people have them at home for their aquariums.

Most chillers don't require much attention to keep it working effectively, although like any other machinery or appliance, it needs regular check-up and cleaning. Contacting the dealer can help you with regular chiller maintenance.

There are three basic steps to ensuring that your chiller gives you optimum performance. The first one is to inspect and clean the air filter. Air cooled chillers rely on a steady flow of air over the condenser coils and a filter is used to cleanse the incoming air and prevent dust. A dirty filter restricts the flow of the chiller, which is needed for it to perform properly.

The second step is to check heat transfer fluid levels. Cooling fluid levels can be determined with simple visual inspections. The fluid is the lifeblood of the cooling system and without it, heat removal cannot occur. Checking the heat transfer fluid's properties is the final thing to do. Dirt and other particles can make its way into the industrial chiller, causing damage to the pump and clog other parts, which is why this step is just as important as the first. Not cleaning the parts thoroughly can impair chiller operation. Simply follow these three steps to ensure optimum performance from your chiller.

How Some Water Chillers Are Used

Chillers, sometimes called water cooled chillers, is a machine that is used to cool large facilities such as industrial, commercial and institutional places. A water cooled chiller uses heat from liquid by means of a vapor compression cycle. It is generally made up of a compressor, a condenser, an evaporator and metering devices.

Air cooled chillers and other industrial chillers circulate roughly four hundred tons of water at a time. Chiller such as this are expensive and large, so they are kept on the sides of buildings or on rooftops. Often, they are used in lieu of evaporative cooling towers, since they allow refrigerant chemicals to come into direct contact with cooled water.

Compressors in air cooled water chillers have different compression methods with its own benefits and disadvantages. There are four compression techniques: centrifugal compression, screw-driven compression, reciprocating compression and scroll compression.

Scroll compression is small in size and cost effective while centrifugal compression is energy efficient. The compressor is a key aspect of every water chilling device and selecting the right type of compressor is important if you want your machine to have optimum performance. Instead of pumping in water city, water chillers can let you save lots of money in a year because they can pump water in a closed circuit. This is why they are also called recirculating chillers. Doing this reduces overall water usage and provides an ecologically friendly way to cool water.

Chillers are also used in evening out the temperature in aquariums and also in manufacturing circumstances where water has to be at a fairly precise temperature so that finicky equipment or products can be used and produced properly. Water chillers have also become important in some people's everyday life and proper maintenance can help you save money in the end.

Chillers are Significant for Aquariums

When it comes to keeping your aquarium residents happy and healthy, having the right temperature is important. A sudden change in temperature can actually make your aquatic pets stressed, thus increasing the chance of them dying. This happens especially to the inhabitants of reef aquariums. This type of aquarium needs lots of special equipment, such as lighting, water pumps and an air cooled water chiller or water cooled chiller.

The cooled chiller is needed to produce the right water temperature, and without it the water can be so warm to a point where it can no longer hold enough oxygen to sustain the inhabitants. If you need a chiller for your aquarium at home, install it as early as possible. If the budget for a new chiller isn't enough, a used chiller that is in good condition would do just fine. Just keep in mind that they need adequate space and ventilation, and also remember to avoid putting the chiller in an enclosed aquarium stand since it can cause overheating of both the chiller and the aquarium.

When choosing a chiller, make an estimate of the maximum temperature your setup may produce as well as considering the temperature requirements of your aquarium inhabitants. There are different types of chillers available all over the market, such as in-line chillers, thermoelectric chillers and drop-in chillers to name a few. Thermoelectric chillers are the ones intended for the use of small aquariums. In-line chillers are those for large systems that are used primarily with saltwater reef setups, while drop-in chillers have a probe that is placed directly into filters. Whatever type or brand you choose to use, the most important thing is regular chiller maintenance to prolong its existence.

Purchasing a Used Industrial Chiller

If you're a person interested in purchasing a used chiller for an expansion or probably a renovation, you've made the right decision. Industrial chillers are available in high quality models because of factors like remodeling and liquidations. Chiller models with short runtimes are increasingly available on the market.

When it comes to buying used chillers from a surplus buyer, the price and range of quality are usually reliable. A few categories like the manufacturing date, price range and usage capacity are very common labels that a potential buyer should consider before purchasing the chiller.

Various providers offer air cooled chillers, water cooled chillers and a wide range of other semi conductor equipments. When buying second hand chillers, make sure you pick a company that can provide you with a high quality chiller. There are actually lots of advantages when you buy a used chiller. The major advantage is that it saves time and money. Previous use of the unit ensures us that the equipment is working well. There are lots of shops that offer to buy-and-sell your used chiller equipment.

Used chillers are available with different specifications. When buying one, make sure that there's a label stating the chiller type together with a description of the item, date of manufacturing and selling. It should also consist the approximate shipping weight, original list price and power supply. A brand new, high quality used water chiller would cost around $5,000 in its list price but would be available for you in the sell price of $1,500.

Purchasing new and expensive chillers isn't necessary. Used chillers that are well taken care of are not only light on the wallet, but they also serve its purpose.

Choosing the Type of Chiller for Your Business

When purchasing air cooled water chillers or any industrial chiller for that matter, there are things that we should all learn before buying them. First things first, we should of course know how they operate. Not all chillers operate the same. Knowing how they work will help us in deciding which chiller is the best for us and our businesses.

Chillers usually have six parts. The condenser, pipes, refrigerant, pumps, refrigeration equipment and a coolant expansion reservoir. Depending on the size of the unit, cooling water can be up to 20 degrees Celsius and can circulate up to four hundred tons of water. Whether you need a small one or a large one for your industrial equipment, there will always be a unit to meet your needs.

If you are still starting your business and the budget is a bit tight, purchasing used chillers that are in good condition can help you save. There are various companies that can help you with chiller maintenance so the unit's lifespan will be prolonged.

There are many different types of chillers to choose from, that oftentimes it can get a bit confusing. There are air cooled chillers, water cooled chillers and other types that are used as oil coolers. Some questions that a novice should ask is what the maximum and minimum heat loads will be. They should also ask whether the system will be able to reject the heat to the outdoors and what the available power supply is.

The answers to the questions are important in order for the chiller to have optimum performance. Contacting the local distributor of your choice can also help in leading you to the right direction.