TopChiller Industrial Process Chiller Manufacturer and Supplier China

Industrial Process Chiller-An Ultimate Buying Guide

Various industrial processes help in the manufacturing of different products that are used as our daily life utilities and facilitate our living.

But one important thing about the production of these products is the large amount of heat released as the result of the manufacturing.

Have you ever thought about how this heat is controlled?

This heat is controlled by Industrial Process Chiller which is a device that cools down heat.

It helps in capturing the heat and then reduces the temperature to protect industrial applications from excessive heat damage.

This temperature lowering function of an Industrial Process Chiller makes it extremely useful in various industries for the synthesis of food, beverages, petrochemicals, and plastics, etc.

To help you know more about an Industrial Process Chiller, this guide will cover everything including its working, features, benefits, applications, etc.

Let’s get started.

What is an Industrial Process Chiller?

An Industrial Process Chiller is a refrigeration device that helps in removing the excess heat produced during any industrial process.

Its main function is to lower the temperature of the surrounding by removing heat from the industrial atmosphere.

It has a closed loop in which the chilled water moves continuously and cools down the heat.

It also reduces the cycle time required for industrial applications by increasing the rate of the chilling process.

The excess heat in the industrial area is necessary to be controlled as it can be disturbing to people present within that environment.

This happens because a notable rise in the surrounding temperature may lead to excessive sweating, water loss, headache, etc.

Another big con of this extra heat is damage to the equipment.

High temperature can be damaging to the machine as it can initiate undesirable reactions in the Industrial Process Chiller fluids which ultimately affect the cooling quality.

This eventually results in reducing the efficiency of the machines and affecting their performance.

Industrial Process Chiller prevents these conditions and protects your equipment and people from being harmed by the high heat levels of the industrial environment.

As a result, the quality of equipment and the industrial atmosphere is maintained.

What are the Features of an Industrial Process Chiller?

Some great features of an Industrial Process Chiller are:

• Weatherproof Construction

Its weatherproof construction protects it from unfavorable external environmental conditions.

This construction is facilitated by a galvanized steel sheet which further has a polyurethane coating.

• The Cabinets

The cabinets installed have metal construction with a white epoxy-painted aluminum frame. The frames are exclusively designed to get adjusted to space limitations.

• Control Circuit

The control circuit is responsible for controlling the water flow switch, water regulating valve, flooded head pressure, fan cycling, and short cycling delay.

It also includes the high and low refrigerant pressure, dual pump lead, microprocessor, and remote web-based diagnostics.

• High-Quality Condensers

The high-quality condensers have fans resistant to load damage as they are featured with overload protection. These fans also have high altitude design and enhanced durability.

• Large Reservoirs

An Industrial Process Chiller has a large-sized reservoir that has a vented epoxy-coated steel tank and low-level controls.

The steel tank also has a sight glass to help you see the liquid levels.

• Copper Refrigerant Piping

The refrigerant piping is pure copper and has valves that allow the liquid to flow. The heavy-grade copper helps to provide insulation to the water circuit.

These pipes also have fluid and corrosion resistance properties.

What are the Main Parts of an Industrial Process Chiller?

Several components join to form an Industrial Process Chiller. Some of these components are:

• Compressor:

The working load of the compressor is effectively balanced by automatic alternating operating which functions according to the load changes.

This ultimately helps in improving the service life of your Industrial Process Chiller accompanied by efficient performance and noise reduction properties.

• Evaporator:

A fine layer of thread coats the reinforced copper pipe which makes the evaporator. The main feature of this copper pipe is its excellent heat dissipation property.

A polyethylene (PE) board insulates the evaporator shell. This helps in preventing condensation at this site. Also, this insulation reduces cooling loss.

• Condenser:

Trapezoidal low rib pipes are used in the construction of the condenser, to enhance the heat transfer process. These pipes are made of copper and work for efficient heat transfer.

A smooth surface lines the inner side of the copper pipe which helps in easy cleaning and maintenance of the condenser.

This also prevents excess water pressure production in the pipe and ultimately maintains normal condenser pressure.

• Protection Device:

A protection device is also installed in the Industrial Process Chiller which further contains a high and low-pressure switch, temperature control switch, and a compressor.

It also includes the overheat protector, overload protector, abnormal indicator, and frequent start protector for protection purposes.

• Computer Control System:

A Programmable Logic Controller helps in the remote monitoring of this chiller. The good thing about this system is that it is easy to install, simple to operate, and highly protected.

• Box Material:

The Computer Numerically Controlled (CNC) punching machine processes the box plate of this chiller.

This plate is covered with electrostatic powder baking paint which has a pleasant appearance and excellent sound insulation properties.

How does an Industrial Process Chiller work?

The main element that majorly contributes to the working of an Industrial Process Chiller is its fluid component.

The main function of this fluid is to bring off cooling.

The working of this chiller revolves around two main principles, one is heat adsorption and the other is vapor compression.

The heat of adsorption refers to the amount of heat or energy released during the adsorption of vapor on any surface.

The most widely used refrigerant in the heat adsorption process is lithium bromide. The main property of lithium bromide which makes it effective in the refrigeration process is desiccation.

Desiccation refers to the act of inducing or retaining dryness conditions.

On the other side, vapor compression is the process that allows the refrigerant to undergo a phase change for cooling and conditioning purposes.

This phase change involves turning the vapor into its liquid state.

What are the Applications of an Industrial Process Chiller?

Industrial Process Chiller is widely used in various industries for providing efficient chilling in various processes. Some of the most significant applications are:

• Cover Area Cooling:

Whenever any product or equipment is being manufactured, a lot of heat is produced. This heat starts gathering up in the environment and eventually leaves unhealthy effects.

So it is necessary to reduce this heat from the industrial environment to make it safe and healthy for the people present around.

An Industrial Process Chiller can be extremely helpful in this situation as it effectively reduces the temperature.

This improves the environmental condition and makes it safe and healthy for the people present around.

This keeps industries cool during manufacturing processes or warm weather conditions. A good thing about this chiller is that it has an easy and cost-effective installation process.

• Process Cooling:

The manufacturing processes carried out in industries involve high heat of friction produced by the working of different parts of the manufacturing equipment.

This causes wear and tear of the components which ultimately decreases the performance of the equipment. To prevent this damage, it is necessary to run the equipment smoothly.

An Industrial Process Chiller aids in the protection of your equipment by cooling the circulating liquid which indirectly reduces the temperature of the area to be cooled.

This helps in maintaining suitable temperatures of the equipment and its surroundings.

These chillers come in various forms that are specially used for specific processes.

It is because the range of processes being carried out in industry varies from plastic production to petrochemical cooling.

So, each process uses its own compatible Industrial Process Chiller.

• Plastic Manufacturing:

The manufacturing of plastic is a temperature-sensitive process and requires keen temperature maintenance.

If the temperature is low and enough heat is not being provided to the process, plastic will get hard and shaping will be difficult.

On the other side, if the temperature is too high and excessive is being provided to the process, the plastic will start melting and shaping will be disturbed.

During plastic manufacturing, a fixed temperature is provided for correctly molding the plastic. After molding, the next step is to cool down the plastic to make the shape permanent.

For this purpose, an Industrial Process Chiller is quite helpful as it can provide extremely low temperatures for efficiently chilling the plastic.

This saves the cooling time of the plastic ultimately speeding up its shaping process.

• Metal Plating and Anodizing:

Metal plating is an effective technique to coat metal and protect it from external environmental factors. This coating ultimately helps in improving its life and maintaining its quality.

The two main choices in metal plating are either to go for electroplating or choose electro-less plating. Both these types of plating have a high-temperature demand.

Similar to metal plating is another technique known as anodizing, which reduces corrosion chances of non-iron surfaces.

This process also requires a high temperature for strong electrical bonding for efficient finishing of the surface.

As both metal plating and anodizing have high-temperature demands, the heat production of these processes is also very high.

To protect the industrial environment from this high temperature, Industrial Process Chiller is very helpful.

It maintains normal temperature by using either a heat exchanger or a liquid-containing coil to reduce the temperature levels.

• Food Processing:

For chilling food with the help of an Industrial Process Chiller, the chilled liquid is moved through the cooling coils to keep the temperature low.

In baking, this is good for maintaining a suitable temperature of the dough and batter. This chiller is also helpful in chilling beverages.

Wineries and breweries have a constant low-temperature storage requirement to prevent any adverse reactions that can affect their taste and properties.

How to Choose the Perfect Industrial Process Chiller for your Applications?

For choosing the best Industrial Process Chiller, consider these points:

• Heat Load/Cooling Capacity

Determining the heat load of your Industrial Process Chiller is necessary to confirm whether it is suitable for your application or not.

For this, always remember the higher is the heat load capacity the better will be the performance.

• Refrigerant 

Choosing the suitable refrigerant is important for the efficient performance of your Industrial Process Chiller.

Make sure that the refrigerant is environmentally friendly and compatible with your chilling applications.

Also, check out the flow rate of the refrigerant as it also contributes to the overall performance of your Industrial Process Chiller.

• Installation

Another important thing to consider is the compatibility of your Industrial Process Chiller with your desired environment.

Choosing between an indoor or outdoor Industrial Process Chiller entirely depends upon the application you are using it for.

What you need to keep in mind is that the Industrial Process Chiller for indoor usage has a different size and accessories than the one for outdoor usage.

• Cooling Performance 

Always choose the Industrial Process Chiller that has the highest efficiency and gives the best performance. These two things will let you enjoy a better user experience.

What are the Benefits of an Industrial Process Chiller for your Applications?

Industrial Process Chiller has a wide range of benefits in Industrial use. Some of these benefits include:

• The coil in-tank evaporator design helps in preventing blockage.
• Deadheading protection of the pumps with the help of an internal water bypass facility.
• Scroll compressors add efficiency to the performance and have improved durability.
• The air filters installed in the condenser reduce the maintenance requirements by preventing blockage and damage.
• A built-in hydraulic unit that saves space and provides better optimization. It has easy installation which saves you from stressing over a secondary circuit installation.
• Variable liquid adaptations of the control system to adjust the circulation speed of the refrigerant.
• Also, it helps in the effective modulation of the compressor’s refrigeration capacity as per the flow rate and temperature of the liquid.
• The safety refrigeration circuits have reduced refrigerant charge that favors safe installation in all environments.

How to Improve the Efficiency of your Industrial Process Chiller?

Increased efficiency means that your Industrial Process Chiller would be able to function at a better speed and perform better action.

Here are a few ways in which you can enhance its efficiency:

• Treat Condenser Water

The water from the water supply contains many contaminants, dirt, and biological growth therefore it must be treated before it enters the condenser.

Treating means the removal of any contaminants, sand, or corrosive components.

These unwanted substances may accumulate in the tubes and cause further damage and erosion leading to compromised function of the Industrial Process Chiller.

The most effective way to get rid of the dirt and debris in the tubes is through the tower bleed or blowdown process. There is a sensor that is sensitive to water conductivity.

An automatic valve allows some water and all the contaminants to dump.

You can also carry out a visual inspection to check for any obstruction or accumulation in the coils that indicates the untreated water.

There should be an annual inspection to check the water quality.

• Reduce Entering Water Temperature

Another way to increase the efficiency is to lower the temperature of the water that is entering the condenser.

The chilled water setpoint can be reduced and helps in overcoming the deficiencies like eroded coils.

It may solve your problem temporarily but it will permanently damage your Industrial Process Chiller.

The damage is caused because your Industrial Process Chiller has to work harder for the cooling as it was producing before.

• Control Water Velocity

It is necessary to regulate the flow rate because a very low flow rate leads to laminar flow which reduces the efficiency of your Industry Process Chiller.

Typically, the minimum flow rate is about 3 ft per second. Also, make sure that the flow rate is not high because it can give rise to turbulent flow and cause vibrations.

It also produces noise and erosion that is not good. Also, the maximum flow rate that is safe for your Chiller is about 12 ft. per second.

• Maintain Refrigerant Charge 

A maintained and sufficient refrigerant level is necessary for an Industrial Process Chiller to be efficient.

The amount of cooling depends upon the degree of movement of the refrigerant through the Compressor per unit time.

Check for any leaks, moisture, or air in the system of the Chiller because these factors can also lead to decreased efficiency.

It is important to keep the refrigerant charged so that the compressor doesn’t have to work harder than its strength.

• Remove Non-Condensable

Moisture and air can easily leak into the coils of the low-pressure chiller.

Such non-condensable can decrease the efficiency of the Chiller by 4% when the load is 60% and by 7% when the load is 100%.

Air acts as an insulator in the tubes and it prevents the exchange of heat and increases the condensing temperature.

High temperature makes it difficult for the Industrial Process Chiller to perform its function thus reducing the efficiency.

Another way to deal with the non-condensable is to install purge units on a low-pressure Industrial Process Chiller. It helps in minimizing air leakage and refrigerant loss.

Positive pressure chillers that use HFC-134a, HFC-410a, and HCFC-22 are capable of replacing low-pressure chillers.

However, an advanced Industrial Process Chiller does not require a purge unit because non-condensable can’t enter it.

• Modulate Speed

The motor of an Industrial Process Chiller needs a very high power voltage and bears a lot of electrical loads.

Varying the speed of the motor is not an effective way to enhance the capacity of a Chiller.

• Remove Air From The Refrigerant System

Air stuck in the loop raises the pressure at the compressor discharge. The compressor’s workload is increased as a result.

• Double-Check Hot-Gas Bypass And Unloader Performance

This is most widely used to manage power on reciprocating compressors. Check if they’re working correctly.

How to Install your Industrial Process Chiller?

Some important things that you must consider when installing your Industrial Process Chiller are:

• Fit a regulation valve in the flow pipe.
• For maintaining the proper flow make sure to install a manual bypass together with a flow regulating valve.
• Do install filters at the entrances of the pipes.
• Take care of the minimum diameter of the pipe as it will affect the flow rate.
• Choose an anti-corrosion pipe material
• Fit the auto-air vents at a good height.
• Do not over-tight the connections during pipe fitting to prevent damage in the future.
• Check the pipes with water first and ensure that there is no leakage before filling the refrigerant.

How to Operate an Industrial Process Chiller?

There are a few things that you must know for operating an Industrial Process Chiller. These things are:

• Do some research about the operation of an Industrial Process Chiller and read the user guide in detail.
• Check out its different types of controls and alarms.
• Provide the power supply to finally turn on your Industrial Process Chiller.
• Adjust the performance settings as per your requirements.
• Open the valves, start the pump and the cooling towers to begin the flow.

What Safety Precautions you should follow When Using your Industrial Process Chiller?

It is essential to operate your Industrial Process Chiller carefully to avoid any damage or loss. Here are some precautions that you can follow for safe operation:

• Make sure to lift it carefully and from recommended lifting points only.
• Do not touch the electrical components when the power supply is on.
• Avoid exposing the electrical parts to water or moisture to prevent shock and damage.
• Handle repairing and replacement issues professionally.
• Maintain a suitable distance with sharp edges to avoid any injury.
• Do not throw any solid object into the pipe to prevent clogging and blockage.
• Install pipe and tank filters to prevent the entry of dirt and other obstacles.

What are some Maintenance Tips for your Industrial Process Chiller?

It is important to maintain your Industrial Process Chiller so that it lasts longer and performs at its maximum efficiency.

• Keep a Daily Log

Maintain a log of the performance of your Industrial Process Chiller. When you will monitor it daily, you can readily catch any problems.

And if the problem is identified in the initial stages, it can be readily eradicated and in this way, you can save it from further damage.

Keep a record of all the operating temperatures, fluid levels, flow rates, and pressures.

The Industrial Process Chiller is now equipped with a microprocessor but a daily log that you make on your own would be more beneficial.

• Keep Tubes Clean

Make sure that all of your coils and tubes are free of dirt, sand, mud, and any other biological contaminants.

These dirt molecules can accumulate in the tubes and cause damage to your Industrial Process Chiller if not removed.

A large Industrial Process Chiller can have more than five miles of tubes of the evaporator. Therefore, the transfer of heat is necessary for maintaining good efficiency.

Eroded or corroded tubes greatly reduce the efficiency of your Industrial Process Chiller. It can also have contaminants like accumulated minerals, salts, algae, and other impurities.

Clean the condenser tubes with a brush rather than using any harsh chemicals or detergent. There must be at least one deep cleaning once a year.

• Check the Wires

Make sure you carefully read the sensor calibrations on microprocessor controls. This helps in enhancing the efficiency of your Industrial Process Chiller.

Also, make sure that all of the connections of your Industrial Process Chiller are intact. Look for any worn-out wiring insulation or loose connections.

Go for a test run to see the motor windings for resistance and it helps in preventing insulation faults.

Make sure that the shaft is sealed so that there is no leakage of the refrigerant and thus maintains efficiency.

Carry out a cleaning routine for the motor cooling air vents of your Industrial Process Chiller so that the cooling process can be maximized.

• Analyze Compressor Oil

For the optimum function of your Industrial Process Chiller, check the lubrication oil and send it for a spectrometry chemical analysis.

This analysis is to detect any moisture, metals, or other contaminants.

If the oil is contaminated, it should be readily changed and replaced with fresh oil, and also the underlying of the contamination shall be corrected.

If you find high moisture levels in your purge unit, there can be a huge change inefficiency of your Industrial Process Chiller.

Also, make sure that you replace the oil filter whenever necessary so that you can maintain the efficiency of your Industrial Process Chiller.

How to Solve the Most Common Industrial Process Chiller Problems?

There are multiple problems that you might have to face when using an Industrial Process Chiller.

These solutions to the most common usage problems will help you solve the issues more effectively:

• Not Turning On

In this case, make sure that there is no fuse in the circuit, the wiring is properly intact and the power supply is on.

• Not Cooling Properly

Set the temperature according to the liquid involved in the chilling process. Use a compatible refrigerant that meets your chilling demands.

• The Pump Is Not Running

If the pump is not running look for the following things: the valve is fully open and the refrigerant volume is adequate.

• Slow Performance 

Make sure that your Industrial Process Chiller can handle the provided load. Check the voltage supply and look for stable electrical connections.

FAQ of Industrial Process Chiller

Which Liquids are Commonly Used in an Industrial Process Chiller?

The most commonly used liquids in an Industrial Process Chiller are water, ethylene, or propylene.

Other than this, other liquids such as methanol, ethanol, or glycol are also used sometimes.

What is the Suitable Temperature Range for an Industrial Process Chiller?

The suitable temperature for an Industrial Process Chiller ranges from 35 to 45 °F.

What is the Purpose of Using Water in an Industrial Process Chiller?

Water is used in an Industrial Process Chiller is to dehumidify the air. It helps in removing heat and lowering down the temperature of the surrounding.

What do you mean by Industrial Process Chiller Refrigerant?

In an Industrial Process Chiller refrigerant is the liquid that lowers the water temperature with the help of an evaporator.

The important consideration of a refrigerant is that it must have a low boiling temperature.

What does the Refrigeration Unit in an Industrial Process Chiller?

The refrigeration unit includes all the parts of an Industrial Process Chiller that are involved in the evaporation and condensation process.

What does the Flow Rate of an Industrial Process Chiller Refer to?

The flow rate of an Industrial Process Chiller refers to the speed of the flow of the refrigerant through the tubes.

What do you mean by Industrial Process Chiller Efficiency?

The Industrial Process Chiller efficiency is the amount of cooling obtained for each unit of electricity consumed.

What does the Chilling Load of an Industrial Process Chiller Mean?

The cooling demand on an Industrial Process Chiller is referred to as its chilling load.