TopChiller Industrial Chiller System Manufacturer and Supplier in China

Industrial Chiller System-An Ultimate Buying Guide by TopChiller

Many industrial processes produce excess heat damaging to the machinery, so it is essential to be removed from the machine.

An Industrial Chiller System takes the excess heat from the machines, and this way, it stabilizes the temperature.

The Industrial Chiller System is composed of a compressor, evaporator, expansion valve, and many other components that collectively work together in getting rid of excess heat.

There are various features and benefits of using an Industrial Chiller System over others, which we are going to mention here.

Also, this guide will provide complete information covering the construction, working, applications, maintenance, efficiency, and various other things about the Industrial Chiller System.

What is an Industrial Chiller System?

Industrial Chiller System is the water cooling machine used to cool your manufacturing processes or various industrial applications.

An Industrial Chiller System functions as the refrigeration device that removes heat from a system and transfers it to another to lower the temperature of machines, industrial rooms, and process fluids.

Whether you use the Air Cooled Industrial Chiller System or the Water Cooled Chiller System, it completely depends upon the application and which one suits your needs.

However, the Water Cooled Industrial Chiller System is preferable in the case when water or any liquid is circulating throughout the process.

The manufacturing process, metal plating, oilfield manufacturing, and food processing all require the use of an Industrial Chiller System to maintain a consistent temperature.

So, if you are looking for effective cooling solutions for your industry, try the Industrial Chiller System.

But always pay good attention to the safety requirements and maintenance of your Industrial Chiller System to make it efficient and durable.

Industrial Chiller System Manufactured by TopChiller

What are the Parts of the Industrial Chiller System?

The seven major elements of An Industrial Chiller System are:

1. The Evaporator 
2. Water Tank
3. The Compressor 
4. Control Unit
5. The Condenser 
6. Power Panel
7. The Expansion Valve

The Industrial Chiller System evaporator can run at a low temperature and pressure than the condenser.

Industrial Chiller System Parts Diagram

What are the Main Features of an Industrial Chiller System?

It utilizes highly demanded compressors from the United States and Japan, which are known for their energy efficiency, reliable quality, low noise, and long service life.

These high-quality compressors have continuous cooling power for industrial operation.

The Industrial Chiller System condenser and evaporator are both specially built with high efficiency and good heat sharing output to ensure that our devices work smoothly.

It is completely charged with environmentally sustainable refrigerants, such as R407C, R134a, and R410A that are selected depending on the specific needs and industrial working conditions.

It has a simple size, is simple to operate and mount, and is also simple to clean and maintain, saving you time and money.

Moreover, it is quiet and produces very little noise while operating.

It provides you with an efficient and cost-effective process temperature management solution because of the quality construction and work.

What are the Evaporators Used in an Industrial Chiller System?

Shell; Tube Evaporators:

Generally, the refrigerant flows through the tube side of the device while the process fluid flows through the shell side.

Copper, cupronickel, or stainless steel tubes may be used. Cast iron, zinc, cupronickel, or stainless steel may be used to produce the shell.

This evaporator has smaller pressure drops than Brazed Plate technology and is available in normal construction up to 500 tones.

Brazed Plate Evaporators:

Many manufacturers use these evaporators in the manufacturing of the Industrial Chiller System.

The supreme performance, lower costs, and 316L stainless steel or copper construction are all major benefits of this technology. From fractional tonnages to 140 tones, this style is available.

Evaporators Used in an Industrial Chiller System

What are the Compressor Types Used in an Industrial Chiller System?

Reciprocating Compressor:

A rotating compressor operates with pistons that are powered by a motor. It provides a tiny volume of the refrigerant at high pressure.

Reciprocating compressors can be dual voltage and range in horsepower from three to sixty. The majority of reciprocating compressors are semi-hermetic, which ensures that they can be serviced.

Centrifugal Compressor:

Centrifugal pumps have a low number of moving parts, making them a popular option in the industry.

They’re both more energy-consuming and provide more refrigerant flow than a reciprocating compressor of comparable capacity.

Centrifugal compressors are ideally suited to applications of high capacity yet low pressure, such as ventilation fans, cooling units, and air movers.

The centrifugal compressor uses the centrifugal force for achieving chilling. Capacity ranges from sixty to several hundred tones on average. These magnetic bearing compressors are hermetically sealed and operate at 230 or 460 volts.

Screw Compressor:

The screw compression is very much efficient and quick. A screw compressor has two screws (male and female) that are mounted together in a stationary casing.

The gas is compressed when the rotors spin due to direct volume reduction between the two rotors.

These compressors are also semi-hermetically sealed, have dual voltage, and range in horsepower from 40 to 1000.

There are also single screw compressors, which compress air using a single spinning screw that moves between two-star wheels.

Industrial Chiller System Centrifugal Compressor Details

What is the Difference Between a Water Cooled Industrial Chiller System and an Air Cooled Industrial Chiller System?

Cooling towers, condenser water pumps, cooling fluid tanks, and make-up pumps are all necessary components of a Water-Cooled Industrial Chiller System.

The Water Cooled Industrial Chiller System has higher costs typically and also a higher life as compared to the Air Cooled Industrial Chiller System. This makes it more reliable if observed considering the overall costs and investment.

Also, using water instead of air often results in a lower footprint, taking less space in comparison.

Air Cooled Industrial Chiller System, on the other hand, works without cooling towers or water and employs fans to generate a flowing stream of air.

However, since it needs a lot of fresh air to expel excess heat from buildings, so for it requires additional room to be stored.

Water Cooled Industrial Chiller System

How Does the Industrial Chiller System Work?

In an optimal loop, the condenser of the Industrial Chiller System performs two functions.

The high-pressure vapor must first be saturated before any condensation can take place (de-superheated).

The refrigerant’s temperature must be lowered to the equilibrium temperature by transferring enough heat from it. Condensation will begin at this stage.

The content of the refrigerant (percentage of refrigerant in vapor state) will begin to decline as heat is transmitted from the refrigerant vapor to the air (or water, if a water condenser is used) until the refrigerant is fully compressed.

This happens at the condenser’s outlet in a perfect system. In the real world, some sub-cooling at the condenser outlet is to be anticipated.

When the refrigerant loses pressure in the tubing and parts, sub-cooled liquid offers protection from liquid flashing.

The refrigerant in the Industrial Chiller System is now liquid and at very high pressure and temperature. Before it can be used as a heat transfer medium, it must go through one more change: temperature reduction.

By lowering the strain, this can be achieved. The pressure-temperature relationship of the refrigerant is an unbreakable law.

When a saturated liquid’s pressure is decreased, the law controlling its life demands that it maintains the maximum temperature at the new pressure.

So, in an attempt to decrease the temperature, the strain must be lowered, which necessitates some form of constraint. It would be preferable if the constraint could self-regulate in response to changing device load demands.

The thermostatic expansion valve accomplishes this by acting as an elastic restraint that reduces liquid refrigerant pressure while modulating to maintain constant superheat at the evaporator outlet.

The thermostatic expansion valve is a superheat regulator, so it won’t keep the vapor pressure constant.

This only offers the required constraint to lower the pressure to a certain degree, which is determined by the compressor height, thermostatic expansion valve, size load, load requirement, and device requirements.

If a steady evaporator temperature is needed, all that is required is to sustain the pressure that corresponds to the required saturation temperature. An evaporator pressure regulating valve is attached to the system to achieve this.

The thermostatic expansion valve in the optimal cycle has undergone a pressure drop. Where there is a combination of liquid and vapor, subcooling or superheat cannot occur.

As a result, every point in the Industrial Chiller System where the refrigerant occurs in two states is at average temperature with its pressure.

As a way of eliminating the heat needed to reach this lower temperature, some of the liquid refrigerants must boil. This is another heat transfer method that results in a lower liquid temperature.

The improvement in refrigerant efficiency of the Industrial Chiller System is due to the liquid that is sacrificed during the boiling phase.

The higher the temperature difference between the liquid and the evaporator, the more liquid would need to be boiled to meet the new saturation temperature. As a result, the refrigerant efficiency improves even further.

The refrigerant passes into the evaporator tubing as a blend of saturated liquid and vapor for the final leg of its trip.

Warm air is blown over the evaporator, where it is transported to the boiling refrigerant and converted to gas.

There is a latent heat gain to the refrigerant that results in no temperature rise when the refrigerant undergoes a state shift.

The final molecule of the saturated liquid boils off at the evaporator outlet, which is attached to the compressor inlet, in the perfect cycle. As a result, the vapor at the compressor’s pipe of the Industrial Chiller System is saturated.

The loop repeats until the refrigerated space temperature is reached, at which point the machinery turns off.

Industrial Chiller System Working Diagram

What Applications Require an Industrial Chiller System?

In a variety of sectors, Industrial Chiller System may be used to cool operations. Here are some applications of using the Industrial Chiller System.

Food Processing

Industrial Chiller System is commonly used in food manufacturing and processing activities that necessitate a high level of temperature control accuracy.

Winery Industrial Chiller System, for example, is used to maintain a consistent temperature during the fermentation and preservation of wine.

Bakery Industrial Chiller System assists in the cooling of mixers, potable water, and yeast jacketed containers, all of which are essential bakery components.

Metal Finishing

Temperature management is critical in metal finishing processes such as electroplating and electroless plating to eliminate excess heat since the metals are normally bonded at extremely high temperatures.

Metal-finishing Industrial Chiller System is used in some industries to cool the anodizing liquid in a heat exchanger, and glycol/water is used as a cooling medium to lower the temperature within the tank.

Injection Molding

The manufacturing process is a mass-production process that uses a mold, thermoplastic pellets, and an injection molding machine to create plastic components.

For avoiding problems like cracks, warping, and internal pressures in the finished product, the process and melt must be kept under strict temperature limits.

An injection molding device will provide a constant stream of super-cooled fluid to the mold, guaranteeing maximum product consistency.

Space Cooling

An Industrial Chiller System can help avoid extremes of temperature in spaces in industrial plants that produce a lot of heat from the heavy-duty equipment they use.

It also reduces the cost of buying different cooling HVAC systems.

Industrial Chiller System Applications

What are the Benefits of Using an Industrial Chiller System?

During operations, Industrial Chiller System keeps the machines at a stable working temperature and cools the components. Here are only a couple of the benefits of using an Industrial Chiller System to cool your equipment:

Tight Temperature Control

The smartly designed arrangements that utilize variable recurrence drives (VFDs) and distribution tanks to keep temperatures underneath +/ – 1°F are always impressive to use for tight temperature control.

Scalable

The Industrial Chiller System is expandable for potential expansion, with the capacity to accommodate 1-100+ pieces of equipment.

Continuous Operation

It offers several redundancy solutions to ensure that the equipment stays cool throughout its operations.

Moreover, it ensures that the process runs continuously, from several refrigeration circuits with normal lead-lag control to auto-changeover pumps.

It provides power management solutions such as automated scrolls, cylinder unloading, and hot gas bypass because the Industrial Chiller System must satisfy the changing demand of your application.

Oil Chilling Capabilities

The manufacturing climate is tough on machine tools, so keeping oil cold is important. Overheating a machine tool may result in premature failure and extended downtime.

Oil Industrial Chiller System is developed primarily for industrial machine tools to improve performance, safety, and machinery life

How to Maintain your Industrial Chiller System?

• Clean the condenser and evaporator routinely to keep your Industrial Chiller System running easily.
• Keep the cooling tower spotless consistently, and there ought to be no garbage or different obstructions in the cooling tower.
• Air Cooled Industrial Chiller System should keep the outside of the radiator spotless and clean it routinely to keep up great execution.

The key role of the valve is to regulate the flow and course of the refrigerant.

It is often important to use the valve regularly in everyday use if the Industrial Chiller System must be switched off or turned on.

Moreover, it necessitates extra care during installation to ensure proper operation without interfering with the safe operation.

Industrial Chiller System Cleaning

How to Perfectly Install your Industrial Chiller System?

• Kindly review your Industrial Chiller System for any damage or crash, and select the best location for installation and potential maintenance.
• The floor where the Industrial Chiller System is mounted must be level within 6.4mm and can tolerate the weight it.
• The Industrial Chiller System can be installed in a computer room that is between 4.4 and 43.3 degrees Celsius. For regular repairs, there should be adequate space around and above the unit.
• At the terminal of the Industrial, Chiller System leave a channeling space for cleaning the condenser tube group or utilize an entryway opening or other reasonable opening.
• While the device is operating at full power, choose the water pipe with the required pipe diameter, the cooling system, and the cold water system, and link them correctly.
• The water flow rate through the evaporator and condenser should be between 1.0 and 3.6 m/s for typical applications.
• Regardless of the load, the water flow should be steady.
• Both chilled water and cooling water piping should be planned and constructed using standard techniques. To maintain the positive pressure and flow in it, the chilled water pump should be mounted on the inlet drain.
• A damping tube should be mounted in the piping to maintain flexibility and keep the evaporator water from being drained while the pump is switched off.
• To avoid tension being added to the materials, the pipe should have good support outside of the Industrial Chiller System. The hangers are in use to make pipe orientation easier.
• A vibration isolator can be mounted on the tubing to minimize the Industrial Chiller System working noise and vibration.
• The water management specialist should assess the water content of the evaporator and condenser to use the commercial device economically and effectively.
• Low water quality can cause scale to inhibit heat transfer, cause corrosion and sedimentation, breed organic matter, and undermine the unit’s efficiency. This way, the costs of operation and repair will rise.
• Good efficiency can be preserved by using adequate water handling and washing the package regularly.
• If the current water quality cannot be changed using suitable techniques, it might be important to cause the package to have a high fouling factor.
• Kindly add a filter to the water pipe’s inlet and clean it daily.
• All nozzles must be rust-proofed after the test leak is finished.
• Users should take any of the following steps to make routine maintenance work easier:
• Control valves and the tube containing cocks should be mounted as close to the device as possible on the inlet and exit pipes of cooling water and chilled water.
• For simple cleaning, hanging rails and beams should be mounted above the machinery.

Industrial Chiller System Installation

What Are Some Main Safety Tips for the Industrial Chiller System?

Check Refrigerant Leaks

The amount of refrigerant circulating through an Industrial Chiller System compressor determines how quickly it cools. Valve stems can become loose over time, causing refrigerant leaks.

The Industrial Chiller System’s cooling capability may also be impacted by refrigerant leakage from the compressor or the injection of moisture into the system.

Maintenance of Suitable Chilled Water Flow Rate

To ensure good Industrial Chiller System cooling results, the rate of chilled water flow must be sustained. For effective heat exchange, devices need 2.5 to 3 gallons per minute per ton.

At 2.5 GPM per ton, a temperature exchange of 10°F is common, and at 3 GPM per ton, an exchange of 8°F is typical.

Check for the Non-condensable

Holding moist air out of the device is another important part of Industrial Chiller System management since these components will decrease device performance and increase energy consumption.

Inspect the Motors and Starting Mechanism

Sensor calibration, microprocessor control inspection, and electrical contacts, wiring, and cabling protection tests are also recommended on a routine basis.

Industrial Chiller Systems must therefore be checked daily to ensure that they are completely operating.

Install Variable Speed Drives

The motors of the Industrial Chiller System consume a lot of energy while they’re working, which affects the cost of service.

Variable frequency drives (VFDs) can conserve energy while changing the motor speed suits motor performance to load, eliminating energy loss.

Even on emergency power generators, these VSDs may cause Industrial Chiller System to work normally.

Industrial Chiller System Refrigerant Leaks Checking

How to Enhance the Efficiency of your Industrial Chiller System?

1. Variable Frequency Drives Increase Chilling System Efficiency

Installing a VFD is one way to reduce running costs and improve performance. This would allow you to change the lock in the head pressure of the Industrial Chiller System and to keep compressors from constantly starting and stopping.

It will also allow the enabling of the refrigeration system’s air unit evaporator fans to work more quietly and effectively.

2. Replacing the Filters and Drainage of the Refrigerant Oil Enhances the Efficiency

Draining refrigerant oil can only be performed by qualified experts who know how to do it safely and efficiently.

The Industrial Chiller System oil can never be withdrawn from the refrigeration system or the high-pressure receiver without first consulting a professional.

Draining from an oil pot or oil silk is the safest method since it reduces the possibility of exposing the device to the environment.

3. Refrigeration System Energy Audit

An energy audit of the Industrial Chiller System is another way to increase performance. The audit will make clear guidelines for how to reduce energy consumption for your facilities and facility.

The energy audit examines the power use of your Industrial Chiller System and compares it to that of a more efficient system.

4. Chilling System Maintenance Tasks

The easiest way to reduce running costs and avoid system errors is to do routine maintenance. Any repair works should be performed daily, while others should be completed only once a year.

Industrial Chiller System Filter Replacement

What Are Some Common Problems and Solutions of the Industrial Chiller System?

It is not important to take action if the high and low voltage warnings are brief or only exist for a few seconds while the power is switched on, but the Industrial Chiller System will pause and restart if the high-pressure warning happens early.

Here are a few options for dealing with this issue.

• High-pressure detectors are mounted on Industrial Chiller System, which is mostly connected to the cooling water system. The cooling tower is cooled by pumping cooling water from the water-cooled unit.

When you neglect to close the cooling water valve after using it, the cooling water cannot be returned to it, resulting in a high-pressure loss. Often, try and see if the cooling tower is down.

As a consequence, cooling water is delivered cleanly and consistently.

• If the cooling water flow is too small, or if the temperature is too high and the heat is not good, this issue will arise. The cooling water has a poor flow rate.

Check to see if the device’s corresponding mounting pipe is the same size as it or if the water valve is set to the maximum setting. Heat dissipation is poor when the temperature is too hot.

Follow the prior inspection for the Water Cooled Industrial Chiller System. If it is Air-Cooled, we must search to see if the installation atmosphere temperature is greater than 40 degrees Celsius.

If it reaches the limit, it must be exhausted promptly to ensure that the device is properly ventilated.

• Unless the device is used for an extended period, debris such as scale will quickly collect in the pipe wall or the copper condenser pipe.

This would eventually impact the refrigeration cycle mechanism, so it should be serviced daily.

• Check to see if the refrigerant level is too high. Before leaving the plant, the automotive device would be completely charged with refrigerant.

As a result, the customer would not need to charge the refrigerant during use if there is no refrigerant leakage. Too much refrigerant can cause the machine to stop running.

• Check to see if the expansion valve is too short. To troubleshoot, the user should slowly change the expansion valve’s opening.

Industrial Chiller System Expansion Valve

FAQS of Industrial Chiller System

How Much Does the Temperature of the Air Decrease by the Cooler of the Industrial Chiller System?

The cooler of the Industrial Chiller System reduces the temperature of the air by 4 to 6 degrees. This temperature is dependent on the humidity as well as the environment’s temperature.

What is the Construction of the Tower of the Industrial Chiller System?

Most of the time, the Industrial Chiller System has a cooling tower made up of fiberglass reinforced plastic, wood, concrete, or steel.

What is the Size of the Water Cooled Industrial Chiller System and the Air Cooled Industrial Chiller System?

On average, in the Water Cooled Industrial Chiller System, the sizes range from 35 to 15,000kW. On the other hand, the size of the Air-Cooled Industrial Chiller System ranges from 25 to 2000kW.

What is the Purpose of Installing the Buffer Tanks in your Industrial Chiller System?

The purpose of installing the buffer tanks in the Industrial Chiller System is to provide an increase in the total system volume.

What Factors to Consider Before Selecting a Cooling Tower of the Industrial Chiller System?

The few factors that you need to consider before selecting a cooling tower for the Industrial Chiller System include the amount of water to be chilled, the temperature of the entering water and leaving the water, and the heat of the rejection measured in kW.

What is the Power Source for the Industrial Chiller System?

The power source of the Industrial Chiller System is the electric power that is specified to the system, given in frequency, voltage, and phase.

What do you mean by the Cooling Capacity for the Industrial Chiller System?

The cooling capacity of the Industrial Chiller System refers to the capacity or ability of the unit to remove excess heat from the fluid being circulated throughout the Industrial Chiller System.

What Does the Process Pressure of the Industrial Chiller System refer to?

The process pressure of the Industrial Chiller System refers to the pressure that is essentially required for the pump to properly function while chilling the machines.

What is the Pump Rating of the Industrial Chiller System?

The Pump Rating of the Industrial Chiller System is the highest bearable pressure flow at a certain speed.

What are the Types of Industrial Chiller System?

The three common types of the Industrial Chiller System include the water-cooled, air-cooled, and evaporative condensed chillers.

What is the Reservoir Capacity of the Industrial Chiller System?

The reservoir capacity of the Industrial Chiller System is the capacity of the chilled fluid reservoir measured in gallons.

What is the Most Used Cooling Medium for the Industrial Chiller System?

The most used cooling medium for the Industrial Chiller System is refrigeration, with water as the most commonly used coolant.

100% Quality Tested Industrial Chiller System