Air Cooled Screw Chiller
- Chiller cooling capacity from 30Ton to 550Ton
- Semi-hermetic screw type compressor
- Air-cooled type condenser
- Temperature control from 7℃to 35℃
- Closed loop shell and tube evaporator
- No need to install a cooling tower
Your Premier Air Cooled Screw Chiller Manufacturer
As a leading air cooled screw chiller supplier, TopChiller provides a complete range of air-cooled screw chiller from TPAS-ASH series, with cooling capacity from 40Ton to 580Ton/130KW to 1950KW and the chiller temperature control range is +30℃ to -30℃.
Besides the standard air-cooled screw chiller control temperature of 7℃ to 30℃, TopChiller also has air-cooled glycol screw chiller control temperature below zero from 0℃ to -30℃.
Each air cooled screw chiller designed from TopChiller has the following features:
Using world famous brand semi-hermetic screw compressor- Bitzer from Germany and Handbell from Taiwan.
Each screw compressor with 4 steps of energy control 25%-50%-75%-100% to make sure the whole screw chiller is stable and guarantee high refrigeration performance. There are also 2 or 3 compressors for optional depends on the required refrigeration capacity.
Highly efficient closed loop shell and tube type heat exchanger as the evaporator, and using air cooled type condenser-Copper tube sleeve aluminum fin with big volume air cooling fan.
Integrated PLC control system with human-computer interface and big LED touch screen panel for easy operation and troubleshooting.
World famous refrigeration spare parts like Danfoss brand thermal expansion valve, Alco dryer filter, Schneider electrical contactor, and overload relay will make sure the whole air cooled screw chiller works under normal conditions.
The above original quality refrigeration spare parts will ensure each air cooled screw chiller at a steady running condition.
TopChiller have exported air cooled screw chillers to the Philippines, Australia, New Zealand, Malaysia, Singapore, Indonesia, Chile, Mexico, Costa Rica, Brazil, Argentina, Colombia, South Africa, Nigeria, Saudi Arabia, Dubai, Spain, Italy, etc.
As a leader of air-cooled screw chiller supplier, TopChiller can provide not only standard configuration chillers but some other customized products.
Please contact TopChiller sales to get the best refrigeration solution of your air-cooled screw chiller.
TopChiller: Your Professional Air Cooled Screw Chiller Supplier
Air cooled screw chiller equip with semi-hermetic screw compressor, also called air cooled screw compressor chiller. It is for large cooling capacity application.
Each air cooled screw chiller manufactured by TopChiller featuring full protection devices including screw compressor overheating protection, low-temperature protection, high/low pressure, anti-freezing, phase-missing, anti-phase with overload, water flow switch and startup latency.
Various refrigerants such as R134a, R407c, R410a, and R404a are all available depending on the screw chiller working condition, application requirements and ambient temperature.
Besides the above features, all air cooled screw chillers designed and manufactured by TopChiller also has an optional function for special requirements including soft-starting, economizer for higher efficiency.
Each air cooled screw chiller with complete stainless steel nonferrous chilled water circuit for high water quality requirement, electronic expansion valve and remote control for monitoring the screw chiller working status.
As we all know screw type air chillers playing very significant roles. Most air cooled screw chillers are widely used for various industries applications such as HAVC, big building&hotel air conditioning, central chilled water supply, chemical processing, die casting,food&beverage processing, pet food, pharmaceutical, plastic processing, automotive, energy&power project, packing, and printing.
Based on the required chillers cooling capacity or refrigeration capacity, we have one screw compressor chiller and dual compressors chiller for your optional:
As a professional air cooled screw chiller manufacturer, TopChiller aims to provide air cooled screw chiller with stable quality, operation efficiency, and energy savings.
It is suitable for air conditioning applications, industry-type process cooling, and large-scale district heat source systems.
Helpful Resources To Know More About Air Cooled Screw Chillers
- What Is Air Cooled Screw Chiller?
- How Does an Air Cooled Screw Chiller Work?
- Key Components of an Air Cooled Screw Chiller
- The Difference Between Air Cooled Screw Chiller and Water Cooled Screw Chiller
- Industrial Applications of Air Cooled Screw Chillers
- Why TopChiller® Can Be a Reliable Supplier for Air Cooled Screw Chillers?
What Is Air Cooled Screw Chiller?
Air cooled screw chillers are a water cooling system in which air is used to cool the temperature of the device and improve the production efficiency of the machines.
As there is no need to install a complicated water cooling system and it’s easy to install and highly efficient, air cooled screw chillers are more environmentally friendly compared to other kinds of chillers.
Nowadays, more and more companies are paying attention to energy conversation in their business production and chillers have played a key role in cost savings.
In the marketplace where all kinds of chillers can be found, air cooled screw chillers are widely accepted and popular in factories, shopping malls, hotels, office buildings, and other public places which are in need for cooling systems.
Air Cooled Screw Chiller
How Does an Air Cooled Screw Chiller Work?
Air cooled screw chiller earned its name for being equipped with a screw compressor.
The working principle of an air-cooled chiller with screw compressor is like this: The compressor will release high temperature, high-pressure gas into finned tube condenser, then the condensed refrigerant liquid will flow into a component named liquid container.
The high-pressure liquid coming from the liquid container will be cooled by the heat exchanger in the gas-liquid separator.
After that, the liquid continues to go through the expansion valve and enters the shell and tube evaporator to get cooled and turn into refrigerant vapor featured by low temperature and low pressure.
Air Cooled Screw Chiller Working Principle
When the refrigerant vapor enters the gas-liquid separator again, the refrigerant gas after being separated will be sucked into the compressor.
It might be easier to understand its basic idea if we follow the refrigerant alone to look at where it flows and how the process completes a cycle: The refrigerant vapor is sucked in and compressed by the compressor, and then is released to the condenser where it’s condensed into a refrigerant liquid.
Afterward, it will pass through the expansion valve into the evaporator to get vapored. The refrigerant vapor will go back to the compressor again for the next cycle.
Now let’s take the whole air cooled screw chiller apart and look at its key components closely.
Key Components of an Air Cooled Screw Chiller
Before this article, let’s have a look at below air cooled screw chiller video we finished in our factory. you will get a general idea about this kind of chiller.
1. Screw Compressor
For air cooled screw chiller, we are using Hanbell or Bitzer semi-hermetic screw type compressors.
This type of screw compressor is most crucial among all components in an air-cooled screw chiller as it works as an engine in a vehicle.
Its role is to compress the low pressure, low-temperature gas into a high pressure, high-temperature gas, and then transfer the gas into the finned tube condenser.
Hanbell Semi-hermetic Screw Compressor
A screw compressor is a type of rotary compressor that consists of one or two screws.
The advantage of a screw compressor is that is can compress air by screw action and compress it continuously and stable.
TopChiller® air cooled screw chillers are featured by semi-hermetic double screw compressors. Each compressor is highly efficient and can be managed by the unit controller to modulate the capacity.
Bitzer Semi-Hermetic Screw Compressor
2. Oil Separator
A certain amount of oil will be released when the compressor compresses the refrigerant.
After the oil leaves the compressor, it will circulate throughout cooling components and hinder heat transfer and even reduce the capacity of the evaporator and condenser.
The oil separator is to make the oil disconnected from the refrigerant, which can minimize the amount of oil flowing in the cooling system.
Therefore, it is particularly important to prevent oil from getting more and more in the chiller.
Oil separators in TopChillerr® air cooled screw chillers are smaller in size and fewer moving parts, which make them more effective in the removal of oils in the refrigerant and also lower in terms of failure rates.
A double screw compressor integrated with an oil separator maximizes the efficiency of the air-cooled screw chiller.
For air cooled screw chiller, we are using shell and tube type heat exchanger.
The evaporator is designed to collect the waste heat from the outside and transfer it into the refrigerant.
The cooling process begins with the evaporator, whose tubes contain some kind of liquid refrigerant.
In a shell-and-tube evaporator, the liquid refrigerant at low pressure enters the shell and flows through the tubes, absorbing heat from higher-temperature water that flows through the tubes.
When the water has reached a particular temperature, it will send the heat back to the refrigerant in the evaporator and get evaporated.
In the meantime, the water temperature cools down when the heat is extracted by the refrigerant.
Generally, the evaporator is installed between the compressor and the expansion valve.
At TopChiller®, air cooled screw chillers are equipped with shell and tube heat exchanger, and also provides options for SS tank with copper coil and plate heat exchangers.
All are selected for R22, R407c, R134a, R404A refrigerants and many other applications.
Shell and tube evaporator
Condensers in air-cooled screw chillers are able to harness the air around to cool down the hot refrigerant which flows through the tubes.
In a typical air-cooled chiller, the condenser will condense the hot, high-pressure refrigerant vapor flowing through the tubes to a liquid.
Air Cooled Condenser
Then the condenser is used to lower the temperature of the refrigerant below the saturated condensing temperature, which enhances the refrigeration effect and improves system capacity eventually.
The condenser coils are usually made of copper tubes and aluminum fins and are assembled in the form of W to offer a larger heat exchange surface.
Air Cooled Condenser
5. Expansion Valve
Expansion valves expand the refrigerant before it enters the evaporator.
Air cooled screw chillers usually use either electronic expansion valves (EXV) or thermostatic expansion valves (TXV).
Thermal Expansion Valve
TXV is very common and it has one side attached to the pressure of the refrigerant and the other side is connected to the sensing bulb, which is installed near the outlet of the evaporator
The expansion valve reduces the pressure of the liquid refrigerant, which makes the liquid temperature getting lower.
Thermal Expansion Valve
The heat molecules inside the refrigerant are able to spread out when the refrigerant leaves the orifice of the expansion valve.
The liquid refrigerant gets cold under a massively reduced pressure and it will get access to the evaporator after leaving the expansion valve.
Thermal Expansion Valve
The Difference Between Air Cooled Screw Chiller and Water Cooled Screw Chiller
Both air-cooled chiller and water cooled chiller are composed of a compressor, an evaporator, a condenser, and an expansion value.
They work under similar principles to finish the heat transfer but they use different components to cool the condensers.
Water cooled chillers use water consumption whereas air cooled chillers need air. As mentioned above, when a chiller comes with a screw compressor, it will be named a screw chiller.
Therefore, there are screw compressors for both kinds of chillers. However, the air-cooled screw chiller is noteworthy as it has the following advantages compared to water-cooled screw chiller.
1. Smaller Occupation Area
When we take an air-cooled screw chiller alone, it is bigger in size than a water-cooled screw chiller.
However, a water-cooled screw chiller requires a cooling tower, pumps and other necessary components, which will make the whole set of a water-cooled chiller take up more space .
And as a result, air-cooled screw chiller requires a smaller area of occupation.
2. Easier Operating System
As there is no need for a water cooling system, air cooled screw chillers actually have simplified the cooling system.
What’s more, the company managers do not need to hire workers to install the cooling tower, pumps, and pipes.
In a society where labor costs are getting higher, it’s a key issue to keep the daily maintenance and repair costs running low.
Without the components in water chillers, air cooled screw chillers will bring the companies to cost savings on the labor.
3. Less Impact on Building Appearance
For most of the water cooled chillers, a cooling tower is a must for water cooling system.
The cooling tower is often installed inside the building, which not only creates a negative impact on the building appearance but also is disharmonious with other objects on site.
Architects oftentimes are opposed to the use of cooling towers, as they think cooling towers are doing harm to the atmosphere inside the construction.
Air cooled screw chiller, instead, generally will not exceed 3 meters in height and much shorter than a cooling tower.
This is why air cooled screw chillers are more popular in constructions where appearance is a key factor for the business.
Air Cooled Screw Chiller VS Water Cooled Screw Chiller
4. Lower Cost on On-Going Maintenance
Water cooled screw chillers are less expensive than air cooled screw chillers in terms of the product cost and the operating expenses.
However, when it comes to expenses on cooling towers, water pumps, pipes, and water processing, etc.,
the investment on water-cooled screw chillers will bring fewer benefits than air cooled screw chillers in the long run.
Let’s have a deep look at the difference between air cooled screw chiller and water cooled screw chiller:
1. The chiller structures comparison
The air-cooled screw chiller unit adopts air cooling mode (fan cooling); the water cooling chiller unit adopts cooling water cooling mode, and the water pump plus cooling tower and circulating pipeline cools the unit.
From the perspective of water-cooled installation, it can be divided into two types: built-in water cooling and external water cooling. For the built-in water cooling, it is mainly composed of a radiator, a water pipe, a water pump, and a sufficient water source, which is destined that most of the water-cooling heat dissipation system has a large volume and requires a sufficient space inside the chassis.
Therefore, the air-cooled screw chiller unit only needs an air-cooled condenser or a fan. Water-cooled screw chillers need to be equipped with cooling towers, pumps and circulation lines. Water cooled type from the structure is more complicated than air cooled type.
The air-cooled screw chiller is suitable for areas where the water source is located in a tight area. It is more advantageous to use an air-cooled chiller unit for a refrigeration system with a longer annual operating hours.
The annual comprehensive cost of the air-cooled refrigeration unit is lower than that of the water cooling system. However, if the water cooling system is managed and the water supply is controlled below 3%, the annual cost of the water-cooled screw is lower than that of the air-cooled screw chiller.
2.Advantages and disadvantages of water cooled and air cooled screw chiller
Disadvantages of water-cooling chiller: For open-type cooling circulating water system, since the cooling water absorbs heat, it is in contact with air, CO2 escapes into the air, and dissolved oxygen and turbidity increase in the water, causing four major problems in the cooling circulating water system: corrosion, knot Scale, algae breeding and sludge.
If the water quality is not treated, the refrigeration equipment will be seriously damaged, and the heat exchange efficiency will be greatly reduced, resulting in a waste of energy.
Therefore, it is very important to carry out corrosion inhibition, scale inhibition, sterilization and algae treatment on the system water.
Disadvantages of air-cooled screw chiller: The air-cooling chiller unit’s cooling capacity is slightly higher than that of the water-cooled unit, but the annual comprehensive cost of the air-cooled unit is slightly lower than that of the water-cooled chiller unit.
The results of the technical and economic analysis show that it is reasonable to configure air-cooled condensers for medium and small chiller units. The longer the annual running time of the chiller unit, the more favorable it is to adopt air-cooled screw chiller.
For a summary, The initial investment of air-cooled screw chiller is relatively high, and the power consumption per unit of refrigeration capacity is also slightly higher than that of water-cooled units.
However, the annual comprehensive cost of air-cooled screw chiller is basically the same as that of water-cooled units. The longer the annual running time of the chiller, the more favorable it is to the air-cooled unit.
The initial investment recovery period of the air-cooled screw chiller compared with the water-cooled screw chiller is shorter. The amount of water replenishment of the water cooled screw chiller is an important factor affecting its cost.
Strengthening maintenance management and reducing water consumption are important aspects of reducing the cost of water-cooled screw chiller.
Industrial Applications of Air Cooled Screw Chiller
Air cooled screw chillers are very popular refrigeration equipment which can provide steady and reliable water cooling sources for both industrial and commercial usage.
For air cooled screw chillers used in a variety of industries for process cooling and here are some typical examples of how they can be helpful for the production.
The printing industry involves a variety of products ranging from newspapers, postcards, to packaging goods.
There are many products that can be found in our daily life when it comes to paper products. Digital printing, an already thriving sector of the market and there is growing momentum for this industry.
Digital printing refers to the process of printing from a digital based image directly to another type of media.
A picture, document or another kind of digital format is received from a personal computer and then sent to a printing device where it’s processed and placed on any desired material.
TopChiller® air cooled screw chillers have been serving the printing industry for years.
In the printing industry, chillers are used to dissipate the heat created by the heated printing rollers in the process of friction.
Air cooled screw chillers are also able to cool the paper when it comes out of the ink drying ovens.
Air cooled screw chillers can help companies save costs as they can be used to control temperatures in presses and rollers to reduce the chances of stretching and bleeding.
In doing so, the production time is reduced and the manufacturer will be able to produce more printed products every day and achieve more profits.
Air Cooled Screw Chiller for Printing Press
2. Cement Cooling
Cement is usually mixed with water to form the material known as concrete whose temperature is in a great extent determined by the water used in the chemical combination of cement aggregates and water.
Most of the application is for batching plant and other cement plants.
In the meantime, water gets more quickly evaporated at higher temperatures and if the temperature of the concrete is too high, more water will be evaporated.
Therefore, the concrete cooling is required to cool the water before the hydration.
TopChiller® Air cooled screw chillers are the perfect choice to regulate the temperatures of the concrete and ensure that problems will not arise from hot concrete.
Cement Plant Chiller
3. Plasma Cutting
Plasma cutting is used on different kinds of materials such as aluminum and stainless steel.
In the plasma cutting, the plasma cutting torch is a big heat source as it’s usually the power leads, which contained a metal cable inside and the cable can conduct a great amount of electrical current.
A lot of heat will be generated and the heat has to be removed to prevent the hoses from melting.
The air cooled screw chillers supplied by TopChiller® are a suitable water cooling partner for plasma cutting machine.
Air cooled screw chiller can control the temperatures of the production devices and keep the cutter at the required temperature all the time to secure the quality of the products coming out of the machines.
infographic plasma water cooling chiller
4. Plastic machinery
Air cooled screw chillers are also widely used in plastic processing and plastic machinery including: plastic injection molding, plastic extruders and extrusion line, blowing molding machine.
The function using air cooled screw chiller is to provide the cooling water flow rate for cool the plastic mold temperature down to make sure the product quality and production efficiency.
Why TopChiller® Can Be a Reliable Supplier for Air Cooled Screw Chillers?
1. Premium Quality and Excellent Performance of Products
TopChiller® Air Cooled Screw Chillers are aimed to optimize the energy efficiency of the target devices.
And the use of such chillers will reduce operating costs and improve business profitability, effectiveness, and energy conversation.
By employing a semi-hermetic dual screw compressor, TopChiller® air cooled screw chillers are energy efficient and able to regulate energy performance levels from 0% to 100% for maximum electricity savings.
Working at high noise levels will affect the health of the workers and more and more employees opt for a quiet environment to work in.
It’s also crucial that companies should focus on noise reduction, especially in sound-sensitive workplaces.
With single main rotors and mufflers built inside, TopChiller® air cooled screw chillers are able to reduce sound levels and vibration to the minimum when they are either running at part load or full load conditions.
Air Cooled Screw Chiller
2. A Comprehensive Range of Services
Since the chillers are daily used in various industrial processes, it’s extremely important to ensure the chiller is operating normally.
If the chiller gets out of order, it might result in a critical decrease in cooling capacity and even economic damages.
For every chiller purchased from TopChiller®, its quality must be carefully checked before shipment to ensure the client will receive a satisfying chiller.
In the meantime, TopChiller® also provides a comprehensive range of services for pre-sales questions and after-sales issues, covering everything from product inquiries to maintenance support.
All clients can still expect professional and personal care and reliable services from our support team at any time.
TopChiller® has served customers from over 58 countries and regions. All of our air cooled screw chillers come with an 18-month warranty and we are always to offer lifetime technical support to our valued clients.
3. Certifications and Awards
All air cooled screw chillers manufactured by TopChiller® are CE marked and comply with standards products sold in Europe.
In China, TopChiller® also earned a series of awards conferred by the government for energy saving and technology innovation.
4. Customizable Products
As there are many industries and each industry may require chillers of specific sizes and cooling capacities.
It’s very important to check if there is one chiller that just can meet your requirements and achieve maximum profitability for the production process.
At TopChiller®, we provide a wide range of air-cooled chillers and screw chillers also come with various specifications for the customers to choose.
If you have a custom request that can’t be found on our website, please contact us right away and we would be more than happy to help.
TopChiller® is committed to sustainable development and the concept has been integrated into our corporate culture.
The air cooled screw chillers supplied by TopChiller® are energy efficient and suitable for printing, cement cooling, plasma cutting, and many other industrial applications.
The cooling capacity of our premium air cooled screw chillers ranges from 30 Ton to 550 Ton and their operating sound levels are very low in all conditions.
TopChiller® air cooled screw chillers are widely used by all kinds of industrial companies all over the world.
If your current chiller shows signs of aging and you are considering replacement, we are confident that you will find using our screw chillers will help you a lot on production efficiency and cost reduction.
With 20 years experience in air cooled screw chiller manufacturing, TopChiller is willing to provide all technical support to clients worldwide.
If you are searching for a high-quality air cooled screw chiller manufacturer, Please do contact TopChiller team to get an ultimate air cooled screw chiller solution.