Whatever Type of Process Chiller,
TopChiller Can Fulfill Process Chiller Solution for You.
- Over 20 years process chiller manufacturing experience: TopChiller specialized in process chiller manufacturing over 20 years
- 24 months warranty time: TopChiller make sure all process chillers covered 24 months warranty time
- Famous brand spare parts: Each process chiller from TopChiller uses world first-class refrigeration spare parts
- Technical support& Training service: TopChiller provides full installation&commission service of your process chiller
- 8 Hours troubleshooting: TopChiller promise to respond and solve any process chiller error within 8 hours
- Free process chiller design: TopChiller give process chiller design and solution free of charge to all clients
Why TopChiller Can Be Your Reliable Process Chiller Manufacturer and Supplier
Process Chiller: Your Premier Choice
Of Industrial Chillers
Process chiller is a refrigeration system or water cooling system using a refrigerant (R407c, R134a, and R410a) that provides cooling water for certain production processing or industrial applications.
TopChiller is your best process chiller manufacturer and supplier in China for over 20 years.
Process chillers developed from TopChiller are designed for the most rugged environments and conditions and even for various industrial applications demands.
As a leading process chiller manufacturer, TopChiller uses a branded hermetic scroll type compressor from Copeland, Danfoss, and Panasonic. These top brand compressors feature high efficiency, high COP, low vibration with a long service time.
The above original quality compressor and high-efficiency heat exchangers will help each process chiller remain in good condition and guarantee the best cooling performance.
All process chillers manufactured by TopChiller are widely used for cooling MRI medical machines, plastic machines, laser machines, welding machines, food&beverage processing, extrapolating industry, and semiconductor industries.
With 20 years of experience in process chiller design and manufacturing, TopChiller provides a complete range of processing chiller with a large range of cooling capacity from 1.5KW to 210KW and temperature control range from -25℃ to 35℃, with temperature stability ±0.5℃ to 2℃.
High-quality process chiller made by TopChiller company having some features and advantages below:
1. Energy Saving Design: TopChiller process chiller design features the storage method of cooling.
Each process chiller has a chiller barrel that consists of a big volume stainless steel storage tank with an immersed stainless steel evaporator.
The capacity of the storage tank and length of the evaporator of the process chiller is sized to meet the heat removal requirements of the application.
This takes advantage of the fly-wheel effect of cooling where the energy is stored in the coolant to produce consistent, reliable outlet temperature.
2. Complete Temperature Control: Temperature adjustable within a range of -25° to +35°C and will temperature stability within ±1.0°C.
If the heat load from the application swings in large amounts, the process chiller will deliver the coolant at a consistent temperature.
3. Condenser Options: TopChiller process chillers are offered with the integral air-cooled type condenser, integral water-cooled condensers, or remote air-cooled condensers to meet all your specific requirements.
4. Coolant Loop Options: TopChiller process chillers serve closed-loop, open-loop (POC), and single-pass applications depending on your applications and demands.
5. HFO Refrigerant: Each process chiller charged R407c, R134a, or R410a refrigerant, eliminates the use of ozone-depleting and high GWP (Global Warming Potential) refrigerant as per the Montreal Protocol.
6. Fully safety protection devices, our process chillers are equipped with all necessary protection devices including high/low-pressure protection, water flow protection, compressor overload protection, and overheating protection.
These protection devices will protect your process chiller from running normally.
Our process chillers are widely used in various industries and production processes.
The major applications include:
1. Laser industry
By controlling the temperature of the laser machine, the process chiller can keep the laser cavity-free from thermal deformation, stable output power, and beam quality, and improve the service life and cutting accuracy of the laser. The main laser processing equipment that the chiller can be applied to are laser engraving and cutting machines, laser welding machines, laser marking machines, etc.
2. Numerical control machinery
Through the water circulation temperature control of the spindle of the numerical control machine tool, the process chiller can keep the spindle at a lower temperature, extend the service life of the spindle, and improve the accuracy of the carving and cutting quality. The main numerical control mechanical equipment used is the spindle carving machine, resistance welding machine, argon arc welding machine, etc.
3. UV printing and UV lighting
By controlling the temperature of the UV-LED lamp, the process chiller can keep the stability and durability of the UV light source. The main UV printing and UV lighting equipment used in the chiller include UV flat printing machine, UV screen printing machine, UV-LED UV curing lamp, UV-LED UV curing equipment, etc.
4. MRI and CT Medical machines
Through the water circulation, the process chiller can cool and control the heating part of the medical equipment to improve the stability of its detection. The main medical equipment used includes a CT scanning machine, MRI machine, medical beauty instrument, photon machine, laser hair removal machine, and so on.
5. Other machines or industrial process
In modern industries, more and more heat is generated during their production. We must use the process chiller to provide constant cooling water to maintain your machine and process at the proper temperature.
Only by using the process chiller can protect your facilities and increase your production output. This is why we need to apply the process chiller.
TopChiller has exported hundreds of high-quality process chillers to the world yearly.
The major countries and regions are the Philippines, Australia, New Zealand, Malaysia, Singapore, Indonesia, Chile, Mexico, Costa Rica, Brazil, Argentina, Colombia, South Africa, Nigeria, Saudi Arabia, Dubai, Spain, Italy, etc.
If you are searching for a good process chiller supplier as your business partner?
If you want to buy a new process chiller to cool your machine or production process?
please contact TopChiller to get a free design and price list of your process chiller.
Process Chiller is a widely used efficient cooling device for different operating machines where heat removal is necessary for industrial operational safety and durability. It provides chilled water for collecting process heat in the evaporator and transfers heat to cool the refrigerant. Ultimately heat is discarded out through the condenser.
Process Chiller of TopChiller contains essential components such as a brazed plate evaporator, water/air-cooled condenser, expansion valves, and scroll compressor for refrigeration. Safety devices, temperature controlling unit, integral pump, and power supply are also attached.
Process Cooling System is widely used for different applications such as the food and beverage industry, extrapolating industry, milk processing, plastic industry, industrial machines, brewery production, UV printing, CT scanning, medical industry, lasers, and semiconductors manufacturing.
TopChiller is a world-reputed manufacturer and supplier that offers standardized designs and custom-oriented Process Chiller for the global market. We are a growing enterprise among top-rated stakeholders and retailers with extensive working experience and endless dedication to meeting customers’ needs virtually.
Are you looking for an efficient Process Cooling Solution for your processing machines and industrial instruments?
Process Chiller manufactured by TopChiller is the best choice that assures to stays cool processing fluids consistently. Confirm your order today by calling our sales team, and you can select any design from our diverse portfolio or order freely for customized services.
Features and Advantages:
Process Chiller manufactured by TopChiller is renowned for its reliable design, features, and various benefits as given below:
- The unit is prevented from tight superheating by installing reliable electronic expansion valves. A stepper motor is also attached to maintain the precise position of valves for the pressure-relieving refrigerant.
- The brazed plate evaporator is the central hub of the chilling process, where the refrigeration cycle gets started. It is situated between expansion valves and the compressors. Hot processing fluid transfers its heat to refrigerant at evaporator site for regaining its cooling.
- Chilled water is provided by a water reservoir that acts as a coolant and assures continuous heat dissipation from processing machines to produce cooling.
- Rotating scrolls mediate an energy-efficient scroll compressor to compress the low-pressure refrigerant. It converts refrigerant into a high-pressure gas for feasible heat discharge at the condenser.
- Air-cooled or water-cooled condensers are connected between compressor and evaporator. Heat collected from process fluid is undertaken by the condenser and discarded by ambient air or chilled water circulation.
Process chiller data sheet
TopChiller: Your Leading Process Chiller Manufacturer and Supplier
Why we are always calling this kind of chiller is the process chiller?
Just because process chillers are always used in a variety of industrial applications to provide a steady cold-water source for cooling your products, production process, and machines.
Process chillers manufactured by TopChiller serve various industrial applications as below:
All process chillers are ideal for cooling machines in all industrial applications like welding machines, food and beverage, dairy processing, plastic injection and molding, semiconductor, welding machines, laser machines, medical CT, and MRI machines.
Our engineering team will design, manufacture and install the entire process chiller systems, specific to your industrial application.
Additional applications of the process chillers include dough mixers, jacketed vessels, roll cooling, cooling tunnels, wine, distillation, kind of heat exchangers, and more.
TopChiller has R&D technical engineering with rich experience in process chillers.
We are willing to provide all technical support and full-time service to valued customers.
Please contact our engineering team to get a professional process chiller solution for your industrial process.
Process Chiller: Your Complete Buying Guide from TopChiller
Chapter 1. What is a process chiller?
What is a Process Chiller? Frankly, the process chiller is regular but specially designed for certain industries or applications.
A process chiller is a refrigeration system using refrigerants that can provide a steady cooling source for a process or industrial application.
TopChiller with 20 years’ experience only offers process chiller and other industrial process chiller systems.
In the process chiller, one refrigeration circuit consists of a compressor, condenser, thermal expansion valve, an evaporator, and charged some refrigerant.
In a word, the above process chiller components can remove heat from a process load to provide consistent setpoint temperatures 24 hours a day, 7 days a week, or 365 days one year.
Process chillers made by TopChiller are specially designed for the most rugged industrial applications and conditions unlike commercial chillers or HVAC chillers.
Chapter 2. How does the process chiller work?
Now we all know process chillers are widely used in various industrial applications, but how does the process chiller work?
A process chiller may use an air or water condenser in its cooling process(they are an air-cooled type or water-cooled type depending on air or water)
As the subcooled liquid refrigerant powered by a compressor, passes from the condenser(air-cooled or water-cooled) to the evaporator(tank coil, plate heat exchanger, or shell and tube type), a thermostatic expansion valve causes the pressure and temperature to drop.
The refrigerant then picks up the heat from the fluid flowing through the evaporator, changing from a liquid to a vapor.
Then back to the compressor, this flows in a continuous cycle continually cooling the process.
This is the complete working principle of a process chiller.
Chapter 3: What’re the components of a process chiller?
If we want to know the components of a process chiller, we need to understand how many kinds of process chillers there are?
Normally TopChiller divides process chiller into 2 types: air-cooled process chiller and water-cooled process chiller.
Air-cooled process chiller and water-cooled process chiller, are made up of many different refrigeration parts depending upon your process chiller design and specific requirements.
But no matter air-cooled type or water-cooled type, each process chiller incorporates a compressor, condenser, evaporator, thermal expansion valve, water pumps, pipes, high-pressure refrigerant relief valves, and possible cooling towers(for water-cooled type), tanks, filters, and exhaust fans(for air-cooled type).
For evaporator types, we have tank coil, stainless plate heat exchanger, and shell&tube heat exchanger for options.
Chapter 4: Applications of process chillers
Process chillers can provide a constant cooling source for kinds of applications and industrial processes.
Let’s have a look at the major applications of process chillers:
Process Chiller for Plastics Industry:
You may see there is a very popular use of process chiller for plastic machine and plastic product production.
The plastics industry uses process chillers to reduce cycle times in injection molding and blow molding by regulating temperatures.
The most advantage of using a process chiller can also improve the quality of finished plastic products.
Process Chiller for Baking Industry:
Process chillers can be also found in the baking industry.
The baking industry may use process chillers in its process of food mixing.
The chilled water from a process chiller may be used to allow longer mixing times which can improve the final quality for any grade of flour, can also improve productivity.
Process Chiller for Food Industry:
The food industry is another most used application of process chiller.
The food industry always uses process chillers to cool any process such as chocolate manufacturing, vegetable processing, meat massagers/injectors, and confectionery manufacturing.
Process chiller will help shorten the processing time and improve product quality in the food industry.
Process Chiller for the Pharmaceutical Industry:
Process chillers can be also used in the cooling pharmaceutical industry.
The heat from emollient vats needs to go somewhere outside. This is where a process chiller from TopChiller can help pharmaceutical companies save money by reducing the total manufacturing time.
By using a process chiller can also savings in labor costs in the pharmaceutical industry.
Process Chiller for Printing Industry:
Process chillers can be used to regulate temperatures in presses and rollers which leads to a reduction of stretching and bleeding.
Using a process chiller, in turn, decreases the time needed to print which improves efficiency and leads to higher quality products at a cost-saving.
Besides the above industries, process chillers can also be used in some other industries include boat & airplane manufacturing, metal finishers, skating rinks, chemical industry, composite manufacturers, laser cutting machines, dry cleaners, medical equipment, and military applications.
Please contact TopChiller engineering to customize your process chiller for your business.
Chapter 5: Why TopChiller can be your reliable process chiller supplier?
TopChiller has 20 years of experience in process chiller manufacturing.
Every year TopChiller export 1500-2000 units of process chillers from 2.5KW to 600KW all over the world.
Besides the above applications, our process chillers are widely used in medical equipment like CT and MRI machines, laser machines, welding machines, vacuum machines, beverage and milk processes, food and drinks industry.
TopChiller has a rich experience in your process chiller sizing, correct process chillers design, and manufacturing for various industrial applications.
We give 24 months warranty time for each process chiller unit manufactured by TopChiller.
During this warranty time, if you have any process chiller problem or error, TopChiller will give you the solution within 8 hours.
We also have an after-sales service team ready for your call, we can do process chiller onsite startup and commission.
What TopChiller can do is help the process chiller end-users not worry about the process chiller quality.
If you are looking for a high-quality process chiller manufacturer, please make sure to contact with TopChiller. We are so confident that you will be satisfied with our process chiller performance.
After viewing the above words, I think you will get a better understanding of the process chiller.
Frankly, a process chiller is not the major machine or key point of the whole production line, But your production can’t run normally without a proper process chiller.
After all, the process chiller is one kind of refrigeration system that will provide a steady cooling source for your applications for years.
I am sure there are many process chiller suppliers that give various kinds of different process chiller brands in different quality and price levels, but make sure to find a reliable process chiller.
Because you will use this process chillers for many years, not for one week or one month.
Process chillers manufactured by TopChiller are all quality assured, are your first choice if you are searching for such a process chiller.
Process Chiller: The Ultimate FAQ Guide
This guide will help you choose high-quality and reliable process chillers for industrial needs.
Whether you want to learn about the classification criteria, working principles, applications, cost, or specifications, you will find everything in this guide.
So, if you want to be an expert in process chillers, read this guide.
- What is Process Chiller?
- What are the Common Applications of Process Chillers?
- Why do you need a Process Chiller for Your Application?
- Which are the Available Types of Process Chillers?
- What are the Key Components of Process Chillers?
- What are the Salient Features of a Prime Quality Process Chiller?
- How does a Process Chiller Operate?
- Where Should You Install a Process Chiller?
- How Do You Maintain a Process Chiller?
- What are the Core Differences Between a Process Chiller and HVAC System?
- Which are the Common Types of Compressors Associated with the Process Chillers?
- Are There Other Auxiliary Components of Process Chillers?
- How do You Differentiate Between a Process Chiller and Air Conditioning Chiller?
- How do You Customize Process Chillers?
- How do Manufacturers Guarantee the Quality of Process Chillers?
- Steps to Optimize the Performance of Process Chillers?
- How Often Should you Conduct Process Chiller Maintenance?
- What Indicators Negatively Influence the Process Chiller Efficiency?
- What is a Process Chiller Tonnage Requirement?
- What is the Cost of a Process Chiller?
- What is the Lifespan of a Process Chiller?
- How do you Eliminate the Chances of Fouling and Scaling in the Process Chillers?
What is Process Chiller?
A process chiller is a refrigeration unit that cools down processes or even an industrial application.
The chillers have got unique kinds of chemical compound refrigerant that provides cooling to the processes.
Usually, the chiller unit has circuit compartments where the heated water flows through.
It undergoes a continuous series of refrigeration/absorption cycles.
The resultant cooled water then expels heat from the entire associated process.
With that, the process chillers would maintain a consistent set point of thermal temperatures throughout the week.
Unlike other commercial chiller units, process chillers are the most adaptable for harsh working conditions and environments.
What are the Common Applications of Process Chillers?
The following are the typical applications of process chillers.
Plastic chiller; in the plastic industry, the chiller significantly decreases cycle rates while performing injection molding and blow molding while controlling temperatures.
Laser chiller; in industrial applications, the vast demand for heat expulsion, especially with laser cutting machines, get sorted with cooling.
MRI Chiller; the chiller always provide a chilled temperature for all your brand MRI types of equipment, including healthcare machines, C.T. scans devices, linear accelerators, PET, etc.,
The welder chiller explicitly provides a cooling effect to the high heat emitting welding machines, thereby guaranteeing a longer service lifespan.
Semiconductor chiller; this process chiller regulates semiconductors’ temperatures.
Thereby providing accurate temperatures, thus lowering defects while increasing the yields during operations.
Milk chilling; In the food industry, the process chillers cool down the milk processing function while guaranteeing a suitable shelf life for the milk products.
Fermentation chiller; in the brewing industry, the process chillers are applicable to enhance fermentation by maintaining an appropriate temperature for the process.
Ice Rink Chiller; usually applicable in ice skating rink to maintain a suitable temperature sufficient for continually keeping the ice present in the rink intact all the time.
Anodizing Chiller; the machine always cools the rectifier and tanks during the anodizing process, which constipates lots of unnecessary heat.
Ultimately, it enhances the performance of metal finishing.
Re-circulating chiller; the chillers provide necessary cooled liquids at favorable temperatures (-25⁰Cto 30⁰C )for use in the laboratory and also for cooling laboratory equipment
Explosion-proof chiller; issue reliable and efficient cooling conditions in hazardous environments and for critical purposes.
The chiller does not provide any type of ignition whatsoever.
The brewery chiller maintains consistent thermal properties for the various brewing machines and processes while enhancing the brewing process.
Food and Beverage processing chiller; the food industry utilizes the process chillers to cool down most of the processes, specifically food and beverage related.
HVAC chiller; this heat regulating device combines heating, air circulation, and conditioning to reach cooling levels.
The concrete chiller; provides a chilled temperature for sufficient cooling of the concrete mixers and concrete batching plants, thus eliminating overheating chances.
Hydroponic water chiller; found in the hydroponic gardens, and growers’ houses, provides an appropriately chilled water temperature-based nutrient solution for irrigating the plant’s roots.
Pool chiller; the machine effectively cools the swimming pool’s water during hot seasons while subsequently heating it during winter to a suitable temperature.
CNC cooling; the CNC chillers are useful in cooling CNC machines and spindles, eliminating occurrences of faults associated with excessive heat.
Grinding machine chiller; during grinding, lots of heat gets released, and as such, the chiller cools the grinder, thereby improving the quality of the products while preventing breakdowns.
Edm Wire cutting cooling; wire cutting expels much heat harmful to the machine; fortunately, the EDM chiller supplies the EDM and wire cutting machines with chilled water.
Ozone generator chiller and water cooling system; much heat gets released during ozone production, prompting efficient cooling. The chiller would thus increase the efficiency of the machine.
The vacuum coating machine chiller and cooling system; provides sufficient cooling for the vacuum coating equipment, thus improving the quality of the crystal by increasing their luster and binding force.
Ice cream and yogurt chiller cooling system; ice cream and yogurt form properly regulated low temperature.
Consequently, the chiller maintains that exact appropriate temperature.
Ink printing chiller and cooling system; this specific chiller provides adequate cooling during the printing processes, especially in the presses and rollers. Ultimately this limits bleeding and stretching.
Pharmaceutical chemical chiller solves excessively emitted emollient vats heat, thereby saving expenditure by reducing lead time and labor costs.
Soap chocolate chiller provides an optimum cooling temperature of about -20⁰C favorable for soap shaping. Besides, the machine offers enough cooling for chocolate demolding.
Why do you need a Process Chiller for Your Application?
process chiller system
No machine can achieve a perfect efficiency rate; at least there has to be some compensation.
Most often, the machines and specifically the industrial machines, release vast amounts of heat when running.
That level of heat is detrimental to the machine’s performance in several ways.
Firstly, the excessive heat would overheat the machine system.
Thereby leading to system shutdown, malfunction, production lapse, or correctly pre-mature equipment failures.
Most remarkably, it may lead to a reduced equipment service life span.
Nevertheless, the good news is that a chiller system comes in handy to help in such circumstances.
Primarily, a process chiller provides sufficient cooling to the machine plus numerous other advantages.
I. The process chiller provides your machines with enough and constant cooling temperature together with pressure.
II. It removes varying temperatures and pressure, thereby simplifying the process optimization and development.
III. It ultimately guarantees the highest product quality.
IV. The chiller re-circulates cooling water, unlike a rather wasteful single pass through the system. Consequently, recirculation hugely conserves water while reducing expenditure, which is can be too expensive.
Which are the Available Types of Process Chillers?
We can widely classify the process chillers into two broad classes, ie. Central chillers and compact chillers.
Central chillers are highly efficient at cooling several processes within a factory floor simultaneously.
The central chillers are robust.
They accommodate cooling loads from as low as 15 tons to over 300 tons.
Besides, they offer cooling temperatures approximately ranging from – 20⁰F to 65⁰F.
Lastly, due to their versatility, the central chillers are applicable in a wide range of applications from chemical processing, metal finishing to grinding.
Elsewhere, the process chillers are user-friendly and straightforward to operate.
Most of them are automatic and thus do not require sophisticated manipulation.
The material for constructing the machines also makes the chiller durable and able to withstand harsh conditions.
Compact chillers; the compact chillers are ready to use small level application type chiller.
Usually, they are efficient for use in applications that require small cooling loads.
Such small-scale cooling processes are in typical pharmaceutical, plastic, and chemical processing.
Subsequently, they are available in limited cooling loads, ranging from 1 ton to about 40 tons.
And interestingly, the compact process chillers are your perfect choice if you operate on space constraints.
These chillers will only consume little physical space; no wonder most of them are typically portable.
Most importantly, irrespective of their sizes, they still maximally operate efficiently to cool your applications.
Next, we can further classify the process chillers into other minor though critical groups.
Such may include the following;
Water-cooled process chiller; this is a refrigeration unit that cools process fluids and may also dehumidify the air.
They are applicable in both commercial and industrial setups to provide cooling processes.
A unique attribute of the water-cooled chiller is the use of water-cooled compressors to offer to cool.
To better enhance their efficiency, these chiller types have a fixed cooling tower, which further provides additional cooling.
Water-cooled chillers usually operate highly efficiently and are capable of handling huge demands of tons of cooling.
However, the chillers are better suited for an indoor operation setting since they do not heavily rely on ambient air ventilation.
Air-cooled process chillers; this chiller type has air-cooled type compressors that heavily rely upon ambient air to cool the refrigerant.
Hence providing the much-needed chilled temperature.
Therefore, with the propellor fans’ utilization, the air-cooled chillers would provide consistent temperatures for cooling your processes.
Since they rely on ambient air circulation, these chillers are best suited for outdoor installation.
Centrifugal chillers; the centrifugal chillers are a unique category of machines that utilize centrifugal-type compressors.
They are hugely versatile and powerful machines capable of harnessing huge cooling loads up to thousands of tons.
Therefore, they apply both media to large-scale cooling processes.
Oil-chiller: machine this chiller provides adequate cooling to the hydraulic oil, lubricating oil, and machine tools’ cooling oil.
The chiller cools the system down by re-circulating oil, thereby averting any possible chances of temperature increase.
Glycol chiller; the glycol chiller effectively dissipates heat from your production process.
The chiller uses a glycol-type coolant explicitly.
The major pro with the glycol coolant is its low freezing point, making the chiller suitable for extremely low climatic regions or weather.
Also, the glycol mixture has an improved rate of anti-corrosion properties hence appropriate for application in harsh working conditions.
Screw chiller; screw chiller is a particular type of chiller with a screw-type compressor to pump the refrigerant throughout its system.
They are most prevalent because they are easy to install, economical, and produce little to no sounds.
Better still, they are suitable for high-rise buildings.
Besides, they are appropriate for large cooling loads with a continuous run time of 24 hours a day throughout the week.
Scroll chiller; another process chiller type that utilizes hermetic scroll compressors.
They are adaptable for use in both industrial and non-industrial applications.
Also, they are, however, reliable for small cooling loads.
They are also small in size while offering sporadic cooling run times of shy than 24 hours a day.
Portable chiller; this is a chiller type with a unique configuration of incorporating all the essential chiller components within a single footprint.
Such chiller parts include the refrigeration circuit, compressor, cooling tank, condensers, pump, and reservoir.
Together, with all that then the chiller becomes portable in terms of mobility.
What are the Key Components of Process Chillers?
Parts of process chiller
Depending on the specific design and type of application, a process chiller may consist of numerous components.
That is critical to enable the individual machine sufficiently adaptable to its particular working conditions.
Nevertheless, the following are the major parts of a process chiller you will undoubtedly find in almost all machines.
- Evaporator – The refrigerant passes through the evaporator to cool down the process application as its temperature rapidly rises.
The resultant refrigerant, having gained heat from the process, evaporates, changing into a gaseous state while inside the evaporator.
- Compressor – the compressor is responsible for increasing the refrigerant pressure without reversing its state.
What happens precisely after the refrigerant exits the evaporator while at low pressure.
- Condenser – The condenser’s purpose is to extract the refrigerant’s heat of compression gained from the compressor.
Again, the condenser could either be air-cooled or water-cooled.
Air-cooled condensers utilize surrounding air to cool the refrigerant, whereas the water-cooled types use a cooling tower with water for cooling refrigerant via evaporation.
- Expansion valves – a metering gadget for controlling the rate of flow of the
- Controls; most chillers have intelligent microprocessor controls together with safety and operating controls.
- Cooling towers – it stores water for use in cooling the refrigerant by evaporation means.
- Piping and tubes
- Refrigerant relief valves
Parts of process chillers
P.S The pumps, cooling towers, tanks, fans, and filters are only available in water-cooled type chillers, whereas the fans are for use with the air-cooled chillers.
Components of process chillers
Parts of the process chiller system
What are the Salient Features of a Prime Quality Process Chiller?
Below are some of the typical characteristics of a highly efficient process chiller.
Highly efficient compressor; the chillers should have a wholly installed energy-efficient compressor.
Such type will significantly save your energy bills and increase reliability.
These compressors may include the hermetic type, suction gas-cooled types, or compressor built with a crankcase heater.
Multi-compressor option; chillers with several compressors have some essential pros: reliability and capacity modulation.
The multiple compressors enable the machine to have an inbuilt redundancy.
Besides, it makes it easier for the device to easily switch operations depending on the immediate prevailing number of required chillers.
All that makes the chillers achieve a super level of efficiency.
Intelligent microprocessor controller; the process chillers have a unique smart microprocessor controller with an on and off switch that you can use to run the system from a distance smoothly.
Besides, the controller incorporates a remote control alarm monitoring switch.
Generally, the microprocessor controller makes it easier to control the machine remotely.
Ease of installation; the machine would come when pre-tested at the factory, fully wired, refrigerant charged, ready chilled water tanks and pipes.
Therefore, you should only need to add chilled water plus make electrical connections before preparing for use.
Load balancing structure; a significant challenge with the process applications is a fluctuating heat load.
The implementation of a load balancing system thus solves the problem.
It ensures a steady supply of temperature by maintaining water at both low and high loads.
Specifically, the load balancing valve caters to intense loads.
Highly efficient heat transfer; the chiller system has unique optimizations to enhance heat transfer while preventing corrosion.
Those elements include aluminum fins, anti-corrosive coated fins, among others.
Low noise propagating design; the condenser fan design takes care of peaceful and efficient working, making the chiller noise-free and silent.
How does a Process Chiller Operate?
The operation of the process chiller is dependent upon the physical characteristics of its corresponding coolant/ refrigerant.
As a result, the chillers may have two basic working principles; heat absorption or vapor compression.
Heat absorption; The chillers that utilize the heat absorption principle are energy-efficient machines.
They work by pumping the coolant via a heated process in a cooling unit cycle.
The commonly used refrigerant in the chillers includes lithium bromide.
Vapor compression; a vapor compression refrigeration unit comprises a compressor unit.
The compressor achieves the cooling effect by changing the state of a heated coolant vapor to its corresponding liquid form.
Most often, vapor compression chillers come pre-installed with air/ water-cooled condensers.
Now below is the process by which the chiller operates;
Step one; evaporator; the process begins right here where the refrigerant settles in as it immediately starts getting heated while cooling the process medium.
Continuous heating in the evaporator changes the state of the refrigerant to a low-pressure gaseous state.
Next, the refrigerant moves into the compressor.
Step two – compressor; the chiller compressor physically presses the now gaseous refrigerant to increase its pressure while conserving its physical state.
The result is a high-temperature pressurized gas that would need to release the heat.
Step three condenser; depending on the chiller type, the compressor may either be water-cooled or air-cooled.
In the condenser, the refrigerant releases the heat of compression it acquired from the compressor.
The resultant refrigerator is then a low temperature and low-pressure liquid.
Step four; expansion valve; lastly, the liquid refrigerant moves to the expansion valve then into the evaporator, and the cycle begins again.
P.S chiller systems are basically of two types, ie.
An open-loop system is suitable for large cooling requirements and a closed-loop system for smaller applications.
An open-loop system is extensively open, exposing the water to environmental elements, specifically at the storage tanks or cooling towers.
The danger of that system is the possible contamination of the water.
Elsewhere, a closed-loop system is entirely sealed so that the liquid and water flow through pipes and tubes with no chance of contamination from the surrounding.
Where Should You Install a Process Chiller?
Your process chiller’s precise location is relative; it entirely depends on numerous factors for consideration, including the machine’s size.
Yet, it also depends on your application.
At times, you may opt for setting up your chiller just close to or beside your application in cases whereby your application covers a small area.
If not so, then the chiller could be in a different secure room from your application when you need minimum disturbance due to emitted noise.
Elsewhere, you may opt to keep your chiller outside, mainly if you operate an air-cooled condenser.
How Do You Maintain a Process Chiller?
Maintaining a chiller involves a wide scope of techniques and measures.
Whereas a chiller failure can be unpredictable, you can implement some necessary procedures to avert most failures by conducting a holistic maintenance plan.
Below are a few quick tips for maintaining your process chiller:
- Quarterly inspect the chiller holistically.
- Check for any refrigerant leaks routinely and fix the faulty ones.
- Check if all motor voltages and amps are correct.
- Check whether all the electric starters, motors, relays, and contactors are operating appropriately.
- Inspect all hot gas and unloader operations.
- Regularly test the water, oil, and refrigerant to ensure that they maintain an allowed continuous threshold.
Most importantly, you have to make, follow, and record a detailed maintenance checklist for all your chillers.
That should involve a daily, monthly, semi-annual, and annual maintenance checklist.
What are the Core Differences Between a Process Chiller and HVAC System?
Chillers and HVAC systems are conspicuously distinct and varied with their mode of operation and design.
Below are the vital differences between the two
· Water and Refrigeration Circuit
Process chillers have two distinct sets of circuits, i.e., the refrigeration circuit and water circuits, which operate independently.
That is quite significant, especially when the machine fails, leaving the device running half its capacity.
On the flip side, the HVAC system has a combined set of water and refrigeration circuits, which work dependently.
Applications; Process chillers provide direct cooling for several industrial and non-industrial processes.
Alternatively, typical HVAC systems control the underlying environmental temperature conditions without fundamentally providing direct cooling for processes.
Cyclical usage applications; in winter or cold weather, the HVAC system’s air conditioning element becomes redundant since air cooling would not be necessary.
However, the process chillers are dynamic and can transform into heating devices, thus critical under prevailing weather conditions.
Component incorporation; typically, most process chillers come with complete pumps, storage tanks, cooling towers, and controls.
On the contrary, the HVAC system comes as standalone equipment without any add-on components.
It, therefore, means that you will need to buy the other parts separately.
Which are the Common Types of Compressors Associated with the Process Chillers?
The following are the primary categories of process chillers components
- Rotary Screw compressors
- Scroll compressors
- Reciprocating compressors
- Centrifugal compressors
- Frictionless centrifugal compressors
Are There Other Auxiliary Components of Process Chillers?
For an additional level of flexibility for your chiller, you should consider adding the following extras;
Dual point power system; incorporates a second set of power lines for supplying two refrigerant circuits.
Electrical options; such as switches, circuit breakers, overloads, phase voltage monitors, etc
Multi-language set keyboard and interface; for use with several languages such as Spanish, German, French, etc.
Vibration isolators such as neoprene pads, spring isolators, seismic isolators, etc
Noise reduction add-ons; isolator pads, compressor acoustic blankets, etc.
Control options; non-reversible heat pumps, EMS interface.
How do You Differentiate Between a Process Chiller and Air Conditioning Chiller?
Process chillers and air conditioning chillers are distinct when you consider the following key elements:
Application; process chiller typically extracts heat/ thermal energy from processes leaving them at the required chilled temperature.
However, an air conditioning chiller reduces the air temperature in a room circulating by withdrawing the warm air.
Whereas process chiller has a wide range of applications in industrial and non-industrial settings, air conditioning chiller restricts air conditioning.
Operating temperatures; process chillers can operate at varying temperatures with different fluids and varying flow rates.
Pumps and cooling circuits; the process chillers can work with multiple pumps and circuits optimally.
Besides, these components come when fully integrated and manufactured by the chiller manufacturer.
On the contrary, air conditioning chillers use a pressurized system while installing contractors who source and install pumps and reservoirs.
Energy efficiency; the configuration of the process chiller’s energy efficiency rating is according to Non-Standard part-load value (NPLV) standards.
However, that of the air conditioning chiller follows the Integrated Part Load Value (IPLV) standards.
How do You Customize Process Chillers?
You can either fully or partially customize your process chillers as you deem fit for your application.
Some of the easiest and standard parts to customize include the following:
Explosion-proof process chiller
Heat exchanger and tanks; The available customization options for the tank and heat exchanger include; Fluid level sight glass, Variable Frequency Drive (VFD), tank fittings, low-level tank indicator with alarm, etc.
Controls; customized control options include custom programming for control of the application, a central regulator for multiple chillers, remote/ onboard touchscreen options, text alerts/ email information via email, or text alerts whenever there is email.
Partial or complete redundancy; full capacity redundancy, auto-changeover redundant pumps, dual/ multi-circuit units, complete electrical isolation, etc.
How do Manufacturers Guarantee the Quality of Process Chillers?
To guarantee the quality and the authenticity of the machines, the manufacturers have to employ several yet critical techniques.
These procedures include proper/useful manufacturing and holistic tests.
Proper/ effective manufacturing; the quality of the machines begins right from the manufacturing point.
Acceptable standards of manufacturing directly relate to better quality standards of the device.
But then, you can only approve a good manufacturing practice by verifying the kinds of quality certifications achieved by the manufacturer.
A reliable manufacturer should, therefore, be authorized and certified by quality standard bodies.
Tests; a critical type of test is the Factory Acceptance Tests (FAT).
The manufacturers conduct this test to assess the functionality of the machine right after manufacture and before shipping.
Therefore, it helps the manufacturers review the already manufactured devices then make system adjustments if need be.
Steps to Optimize the Performance of Process Chillers?
I. Inspect your chiller at least quarterly and maintain a log.
II. Routinely inspect your chiller for any possible refrigerant leak.
III. Verify whether the compressor’s operating pressure is of appropriate working range.
IV. Monitor all gas and unloader activities.
V. Check and correct all motor voltages and amps.
VI. Inspect all electrical starters, relays, and contractors.
VII. Always utilize superheat and subcooling temperature readings to achieve the highest efficiency.
VIII. Obtain line readings from the discharge lines.
How Often Should you Conduct Process Chiller Maintenance?
It is pretty apparent by now that a chiller needs comprehensive maintenance to enable it to achieve its optimal performance and efficiency.
Whether you’re using a water chiller or air chiller, they all require maintenance.
Most importantly, you need always to keep records of all the maintenance you do.
Consequently, you can thus conduct five series of maintenance throughout the year.
The schedules include Daily routine maintenance, monthly routine maintenance, regular semi-annual maintenance, and annual routine maintenance.
Note; every schedule of maintenance has got sets of maintenance descriptions that you should implement.
Besides, to strictly adhere to your program, you can keep and follow your machine’s maintenance checklists.
What Indicators Negatively Influence the Process Chiller Efficiency?
Interestingly, most chiller users are not fully aware of how inefficiently they could be operating their machines.
Such standard ineffective procedures may result in: chiller consuming a high amount of energy, thus attracting special energy rates, poorly performing, and having a shortened life span.
Even though numerous factors decrease the chiller’s efficiency, below are the most common ones:
Unwanted operating procedures, apart from reducing the chiller efficiency.
Poor operational protocols may also significantly decrease the service life span of the machine.
Kindly note that you should refer to the chiller’s technical manual whenever you are doubtful about any operation.
Neglected/postponed/canceled or ignored maintenance; maintenance personnel has to ensure that they follow the letter’s maintenance protocol.
Failure to precisely follow the outlined plan would hamper the chiller’s efficiency.
Overlooking cooling towers; just like other integral components of the chiller, the cooling tower is equally essential.
Its operation directly impacts the general machine’s efficiency.
Therefore, efficiently maintaining and operating the cooling towers enable the chillers to work efficiently.
Oversizing; to avert accidentally oversizing the chiller, you may consider installing variable frequency drives on the operating chillers.
Snubbing substitute fuel chillers; directly replacing a chiller with an exact version of the replaceable one can be devastating.
The dynamics in technology directly translate into some other new and useful fuel sources for the machines.
These recent trends of energy sources include natural gas, steam, or gas for operating your chiller.
What is a Process Chiller Tonnage Requirement?
The chillers’ tonnage is precisely the amount of cooling load that the machine can efficiently process.
Find below the tonnage requirements:
- Never use an undersized unit because you would not achieve your intended cooling level.
- Do not oversize the chiller because it will similarly operate inefficiently.
- Having a slightly higher tonnage chiller than the load is relatively better than an undersize or excessively oversize.
What is the Cost of a Process Chiller?
The prices of process chillers are far varying, like the available options.
However, the prices depend on the tonnage, chiller type, and application.
What is the Lifespan of a Process Chiller?
The lifespan of the chiller hugely depends on how better you keep it.
But still, the chiller type and its construction material greatly influence the machine’s durability.
Nonetheless, screw process chillers are the most durable for about 20 years, while scroll compressor chillers last for about 8 -15 years.
Similarly, air-cooled chillers under optimum conditions may last for 20 years.
Finally, a fiberglass cooling tower may serve you for up to 35 years.
How do you Eliminate the Chances of Fouling and Scaling in the Process Chillers?
With the chiller’s consistent operation, the evaporator and condenser tubes continuously accumulate minerals and sludge in their compartments.
It is such consistent deposits of those materials together with dirt that causes scaling and fouling.
Scale accumulation is detrimental to the overall chiller unit performance and efficiency.
Firstly, they insulate the tubes while also promoting corrosion.
To avoid all that, you can perform these two main preventive measures:
Firstly, regularly check the water treatment and ensure that it is according to the required standards.
Secondly, clean and inspect the evaporator and condenser tubes.
Ensure that you annually review the evaporator and condenser tubes.
Also, pay attention to the pressure drop.
A sharp rise in pressure drop from inlet to outlet with about 3 – 4 PSI indicates a potential surge in fouling and scaling, thus requiring cleaning.
At TopChiller, we offer a range of process chiller systems depending on your specific requirements.
Contact us now for all your process chiller needs.
Process Chiller – The Ultimate FAQ Guide by TopChiller
When it comes to cooling down a machine, a facility, and a product during or after the industrial procedure.
A Process Chiller is what exactly you need.
At the point when HVAC water chillers are not adequate in giving cooling power, businesses may rather select to utilize a Process Chiller.
Process Chiller would be effective in fulfilling this purpose.
How might you make item innovation in the assembling business?
What is a Process Chiller and how might it influence your business decisions?
If you have been investigating a refrigerant system for your industry, we have delineated some central issues about Process Chiller.
Let’s start it
- What is a Process Chiller?
- What are the Features of a Process Chiller?
- How does a Process Chiller work?
- Why do you need a Process Chiller for your Applications?
- What are the Types of Process Chiller?
- What are the Applications of Process Chiller?
- What are the Components of Process Chiller?
- How to Size Process Chiller for your Application?
- How to Choose a Right Process Chiller for your Applications?
- How to Increase the Working Efficiency of your Process Chiller?
- How to Maintain a Process Chiller?
- What are some Main Challenges of Process Chiller?
- Why TopChiller is your trustworthy Manufacturer of Process Chiller?
- FAQ of Process Chiller
1-What is a Process Chiller?
A Process Chiller is a refrigeration system utilizing halocarbon refrigerants. It gives cooling to Industrial or mechanical applications.
A refrigeration circuit in a Process Chiller contains compressor(s), condenser(s), heat extension valve, and evaporator(s), at the very least.
Together, this equipment in a Process Chiller reduces heat from a Process Chiller load to give predictable setpoint temperatures 24 hours every day, seven days per week.
Process Chiller is intended for the roughest conditions and environment lot, unlike business or HVAC chillers. It utilizes mechanical refrigeration to reduce heat from a Process.
It is utilized in a few applications from machine instruments for food preparing and bundling to medical imaging equipment.
Process Chiller is made to work at various temperatures with various liquids and diverse flow rates. It can work with numerous pumps and different cooling circuits.
The systems are commonly incorporate a pump and reservoir planned by the manufacturer, which is coordinated into the Process Chiller design.
A Process Chiller is a machine that reduces heat from a liquid through vapor pressure, adsorption refrigeration, or assimilation refrigeration process.
This liquid would then be able to be flowed through a heat exchanger to cool equipment, or another process flow, (for example, air or process water).
As an essential result, refrigeration in Process Chiller makes wasted heat that should be depleted to the atmosphere, or for more prominent productivity, recovered for warming purposes.
Process Chiller may cool as much as 40 tons of refrigerant at a time and control the temperature in assembling or mechanical areas.
Process Chiller is utilized in a few industries and applications where heat should be reduced from the liquid used for cooling items or machinery.
Process Chiller Manufactured by TopChiller
2-What are the Features of a Process Chiller?
As micro processers have developed throughout the most recent couple of many years, Process Chiller manufacturers currently have exceptional opportunities to give upgraded control features cost-effectively.
In this section, we have discussed highlights, viewed as critical in the present Process Chiller market.
- In-Place Screen and PLC Software Updates
In a Process Chiller, the capacity to refresh the control interface (screen) and/or the programmable controller without expecting to remove this equipment from the Process Chiller.
A typical technique is to download updates, preferably at no expense to the client, from the manufacturer’s site and move the records to the Process Chiller’s equipment through a USB jump drive.
- Multi Compressor Automatic Lag/Lead-
This basic element guarantees equivalent wear and tear on the Process Chiller’s compressor(s).
When the lead compressor running hours have stretched out past the compressor hours by roughly 500 hours, the service duty of the compressor will switch.
- Remote Start / Stop
In some cases, Process Chiller is mounted in remote locations. In these cases, it might be beneficial to have the ability to switch the Process Chiller on/ off.
Having a contribution to the control system to perform start/stop is a basic component.
- Internet Remote Control Access via Browser to Process Chiller
Utilizing a standard Internet program, for example, Internet Explorer or Firefox, a client can access and control the Process Chiller over a local area network.
Note: In many cases, this will require a custom IP address.
- Remote Alarming via Email or Text
If a Process Chiller’s working condition becomes shaky, it is viewed as ideal for the control system to communicate through a troubled email or text.
Note: In a request to communicate the Process Chiller, it should be associated with the host building’s organization with admittance to the Internet.
Some firewall design or VPN connection might be required.
- Replaceable Plugin Control Relays
- The Process Chiller control system uses pilot obligation transfers to control the different systems inside it, for example, compressors, pumps, fans, and economizers.
- VPN Secure Remote Connectivity In Process Chiller
Virtual Private Networking (VPN) is utilized to interface distantly over a safe network connection.
A VPN can be utilized to distantly interface with a Process Chiller through an Internet connection.
VPN normally does not need a firewall setup.
- Highly Visible User Interface in Process Chiller
Process Chiller work in many indoor and outside applications.
Significantly, the UI is noticeable, particularly in splendid daylight circumstances, to effortlessly control the highlights of the Process Chiller Control System.
- Expandable Memory
As new Process Chiller control upgrades become accessible, requests on the internal memory will intrinsically rise also.
As interest in memory develops, it is vital to have the capacity to extend the control system memory of the Process Chiller.
- On-Screen Event Logging
A significant element in Process Chiller is to have history, saved on the Process Chiller’s UI.
The data can significantly reduce diagnostics time, particularly when any discontinuous issues take place.
- On-Screen User Help Information
It is a common occurrence for the Process Chiller control and other documentation to vanish during or not long after the chiller establishment.
Process Chiller Temp Controller
3-How does a Process Chiller work?
A Process Chiller may utilize an air or water condenser in its cooling process. As the refrigerator liquid passes from the condenser to the evaporator, a thermostatic developed valve makes the pressing factor and temperature fall.
The refrigerant in Process Chiller at that point gets the heat from the liquid coursing through the evaporator, transforming from a liquid to a vapor.
It flows in a constant process consistently cooling the process. A Process Chiller deals with the rule of vapor pressure or vapor ingestion.
Process Chiller gives a consistent progression of coolant to the cold side of a Process Chiller water system at an ideal temperature of about 50°F (10°C).
The coolant in Process Chiller is then taken out through the process, extricating heat out of one side (e.g., machinery, process equipment, etc.) as it flows back to the return side of the process water system.
A Process Chiller utilizes a vapor pressure mechanical refrigeration system that links with the process water system with the help of a gadget called an evaporator.
The refrigerant circles through an evaporator, compressor, condenser, and developed gadget of a Process Chiller.
A thermodynamic process happens in each of the above segments of a Process Chiller. The evaporator works as a heat exchanger with the end goal that heat caught by the procedure coolant flow moves to the refrigerant.
As the heat transfer happens, the refrigerant dissipates, transforming from a low-pressure liquid into vapor, while the temperature of the process coolant lessens.
The refrigerant at that point flows to a compressor, which plays out different functions.
To begin with, it removes refrigerant from the evaporator and guarantees that the pressing factor in the evaporator stays adequately low to assimilate heat at the right rate.
Second, it brings the pressing factor up inactive refrigerant vapor to guarantee that its temperature stays sufficiently high to deliver heat when it arrives at the condenser.
The refrigerant in Process Chiller then returns to a liquid state at the condenser.
The inactive heat surrendered as the refrigerant changes from vapor to liquid is diverted from the climate by a cooling medium (air or water).
4-Why do you need a Process Chiller for your Applications?
No mechanical process, machine, or engine is 100% effective, with heat being the most widely recognized result of those inefficiencies.
If the heat is not taken out, it will gather over the long haul causing reduced production times, equipment closures, and even untimely equipment dissatisfaction.
It is important to consolidate cooling into mechanical Process Chiller system configuration to keep away from these issues.
Utilizing a Process Chiller to give cooling has many advantages.
A Process Chiller gives steady temperature and pressure in your industrial process. Disposing of temperature and pressing factors improves the process development and optimization, guaranteeing the best item.
Rather than an inefficient, single go through systematically, a Process Chiller recycles the cooling water.
The distribution limits the expense of water utilization which can be costly and ecologically unpleasant.
The clinical (medical field), assembling, and food processing enterprises all utilize Process Chiller to keep lower temperatures in their required place.
Process Chiller is utilized for laser cutting and welding, metal cutting and shaping, programmed welding, plastic shaping, metal splashing, pressure-driven system, clump cooling, photographic processing, and printing.
Dairies, bottling works, food processing plants, MRI, and CAT filter machines additionally require the utilization of Process Chiller to work appropriately.
Process Chiller is also utilized to achieve a wide range of cooling applications that change from industry to industry other than chilling off or cooling down the machine.
In plastic shaping, Process Chiller decreases process durations in infusion shaping by reviving the cooling process.
In food processing, a large quantity of cold water is utilized when baking, to permit the batter to blend for more, bringing about better products. They additionally cool chocolate items, meat, and vegetables.
In medicine production, emollient tanks get very hot, and the Process Chiller help brings down their temperature rapidly.
Print machines require a Process Chiller system for rolling and squeezing to lessen the draining and extending of photos.
They are even utilized in wineries to prevent clouding, cooking, and staining of the wine during aging.
Other businesses that enjoy the benefits of the use of a Process Chiller incorporate boat and plane assembling, skating arenas, synthetic industry, composite producers, and the United States government utilizes numerous for military applications.
5-What are the Types of Process Chiller?
We categorized Process Chiller into two classes:
Central and compact. Central Process Chiller has a working scope of – 30°F to 65°F and deals with from under ten to more than 200 tons.
Compact Process Chiller is a more modest adaptation of the central chiller and is extremely flexible going from one to 40 tons.
These Process Chiller completely coordinate with turnkey arrangements. If actual space is restricted, this is an ideal decision.
Process Chiller can utilize two unique sorts of condensers, air-cooled and water-cooled.
Air-cooled condensers in Process Chiller resemble the “radiators” that cool auto motor.
They utilize a mechanized compressor to compel air across a system of refrigerant lines.
Except if they are exceptionally intended for high-surrounding conditions, air-cooled condensers require encompassing temperatures of 95°F (35°C) or beneath to work adequately.
Water-cooled condensers in Process Chiller play out a similar capacity as air-cooled condensers, however, require two stages to finish the heat transfer.
To begin with, heat moves from refrigerant vapor into the condenser water.
At that point, the hot condenser water is taken out to a cooling tower where the process heat is at last released to the climate.
- Water-Cooled Process Chiller:
Water-Cooled Process Chiller includes a water-cooled condenser associated with a cooling tower.
They have generally been utilized for medium and huge installations that have a proper water supply.
Water-Cooled Process Chiller can create a steadier performance for business and mechanical cooling in light of the general authority to the variances of the surrounding temperature.
- Air-Cooled Process Chiller:
Air-Cooled Process Chiller depends on a condenser cooled by the climatic air.
Along these lines, Air-Cooled Process Chiller may discover regular application in more modest or medium formations where space commandingly may exist.
An Air-Cooled Process Chiller can represent the most useful decision in situations where water shows scant assets.
Water Cooled Process Chiller
6-What are the Applications of Process Chiller?
Process Chiller has applications in several industries.
Truth be told, the uses of Process Chiller fluctuate as the choices are accessible for specially crafted chiller.
Despite the various uses, all offer the required eliminating heat from a process.
Plating in Process Chiller through electrolysis and aluminum anodizing both require incredibly high temperatures.
To ensure the protection of equipment and laborers, makers use the process to remove the unnecessary and extra load of heat in Process Chiller.
If the plating shower is not at the right temperature, the eventual outcome endures, particularly with zinc and chrome plating.
Process Chiller improves the shower temperature for the plating Process to make the ideal item.
- Plastics Industry
The plastics industries require a Process Chiller for Thermoforming, expulsion, and enhancement.
The Thermoforming Process heats a huge sheet of plastic to a particular temperature to form it to the ideal shape.
Expulsion makes long bits of plastic by pushing the softened plastic through an extruder. Embellishment utilizes an assortment of molds that hold the dissolved plastic in the ideal shape.
Temperature control is essential for every one of these processes. That is the place where Process Chiller’s cooling becomes an integral factor.
In certain cases, for example, expulsion, the Process Chiller will require extra hardware, a channel for the cooling liquid, or an emergency heat exchanger.
- Food Processing
Food production and capacity both require to be alert related to temperature control.
Process Chiller can keep up low temperatures required for viably chilling fixings or establishing the cool conditions to store items.
Applications of Process Chiller
7-What are the Components of Process Chiller?
The main components of the Process Chiller are a condenser, an Expansion valve, a water box, compressor, evaporator, power panel, and control units.
- The condenser is arranged preceding the extension valve and behind the compressor.
Condenser functions as a heat eliminator from the Process Chiller that was produced by the evaporator.
The nature of the condenser may shift in like manner and it additionally relies upon the refrigeration organization from where you got it from.
It is vital for keeping a couple of things, and particularly the segments of the refrigerator in view while checking for the Process Chiller organizations.
- The fundamental work of an expansion valve in Process Chiller is to expand the refrigerant dropping its pressure and intensifying the volume.
Process Chiller has different kinds of extension valves, for example, electronic, heat, fixed the hole, and pilot-operated thermal expansion valve. Water boxes inside a Process Chiller to straight flow and isolate the exit and passage.
- The compressor in Process Chiller is the principal exchanger as it creates a compelling variety to mix the refrigerant around.
There are four kinds of compressors, for example, screws, centrifugal, reciprocating, and scrolls.
- The evaporator is arranged between the compressor and the expansion valve.
It functions as a combiner of undesirable heat from the structure and mixes it into the refrigerant, so it tends to be reached to the cooling tower.
- Power Panel is utilized to simply gather to the Power Chiller.
It tends to be offended to the plant room divider alongside control links running between them.
The fundamental work of the power panel is to deal with the electrical force flow to the refrigerator.
- Control units in Process Chiller are collected on the refrigerator.
Its fundamental work is to notice the different parts of the performance of the Process Chiller and deal with these things by changing.
These control units produce cautions for the group and after that shut the Process Chiller.
Process Chiller Compressor
8-How to Size Process Chiller for your Application?
When measuring the size of the Process Chiller for your application, it is important to guarantee the unit is sufficiently measured to deal with the most extreme process loads in the most difficult scenario site conditions.
This could prompt an inappropriately estimated system that will introduce issues in true working conditions in Process Chiller.
There are a few significant elements that should be viewed when estimating a size Process Chiller.
These incorporate maximum ambient temperature, outlet water temperature, glycol concentration, and elevation above sea level.
Take care while checking specialized datasheets and pamphlets.
In Process Chiller, cooling capabilities are frequently expressed as an ostensible condition.
In North America, ostensible conditions are considered as 45°F leaving water temperature, 55°F bay water temperature, and 95°F Ambient temperature.
A few organizations, especially those focusing on the European market, may show the cooling limits at an altogether different arrangement of conditions.
In Europe, ostensible conditions are characterized as 15°C (59°F) leaving water temperature, 20°C (68°F) channel water temperature and 25°C (77°F) encompassing temperature.
All in all, what is the difference? Think about that as a 10.8 kW Process Chiller evaluated at 59/68/77 conditions, would perform at just 7.9 kW when appraised at 45/55/95 conditions. That is roughly a 25% contrast!
9-How to Choose a Right Process Chiller for your Application?
Purchasing your Process Chiller for your business or personal use can be a robust expense, however, it is an investment that is justified, despite all the trouble over the long haul.
As you start buying Process Chiller, consider these two inquiries, to help you settle on the most ideal decision.
What Are You Cooling? What’s Your Budget?
Your first thought ought to be what you need to cool with your new Process Chiller.
Various applications will require a diverse cooling system. You would prefer not to buy some unacceptable sort of Process Chiller by mistake.
You likewise ought to consider the developing pace of your business. If you figure you may require all the more chilling limit not far off, it very well may be shrewd to twofold the limit of your Process Chiller from the beginning.
Your spending will simply affect your Process Chiller choice.
Before you survey costs, take a look at your income to examine the amount you can contribute.
Recall that a Process Chiller can significantly reduce production time, which will save you work and production costs.
10-How to Increase the Working Efficiency of Your Process Chiller?
The working efficiency of a Process Chiller depends on the system staying uninterrupted.
A refrigerant in Process Chiller leakage reduces the cooling capacity of the system.
Consistency observing for leakage in Process Chiller can prevent issues by cautioning upkeep when a flaw happens.
Also, the system of Process Chiller may expect an adjustment to run as proficiently as could reasonably be expected, regardless of whether the surrounding temperature changes radically.
Observing flow rates and activity is right now fundamental and better approaches to watch these qualities will get significant later on.
Process Chiller system will work more productively through appropriate progressing expert support and maintenance.
The majority of our customers get this and have embraced a month-to-month Process Chiller upkeep and backing plan as a component of their everyday area best practices as early notice signs that permit you to make a move before any issue gets worse.
Here are two of the most well-known accepted procedures that boost Process Chiller productivity:
Screen Refrigerant Charge:
Just as a lawful necessity to guarantee zero refrigerant leakage, a Process Chiller’s cooling effectiveness requires proper refrigerant levels inside the system.
Setting up the right refrigerant charge can hugely improve measure Process Chiller effectiveness by decreasing cooling costs by as much as 15%.
Compressors are almost consistently the absolute most intensive energy consumer in the system.
Introducing head pressure control with a low consolidating temperature in a cooler climate will give a commonplace saving somewhere in the range of 2% and 4% of compressor power for each 1°C decrease in gathering temperature.
Maintaining Condenser Cleanliness:
The assessment and improvement of the Process Chiller plant should be seen generally.
Changes must be actioned depending on exact information and current profiles.
Therefore, it is important to monitor actively proficiency to distinguish any adjustments in execution and anticipate upgrades that can be made as fast as could be expected under the circumstances.
11-How to Maintain a Process Chiller?
Steps to Maintain a Process Chiller Daily:
Turn off your Process Chiller first.
Proper visual inspection to make sure every equipment of Process Chiller is working properly.
Check all set points for proper use.
Steps to Maintain Process Chiller:
- Check evaporator and condenser in Process Chiller.
- Checking Temperature as per the producer’s requirement.
- Lead leak testing on all fittings in Process Chiller.
- Verifying Control functions.
Moreover, Process Chiller systems will work more effectively through appropriate continuous support and maintenance.
Most industries recognize this esteem and have made plans as a component of their everyday office best practices. Some normally accepted procedures for Process Chiller system’s maintenance include:
Assess and Clean Condenser Coils:
Heat movement affects Process Chiller systems and stays essential to delivering productive Process Chiller activity.
Routine support and maintenance ought to examine condenser coils for stopping up and free air section.
Maintain and Keep Refrigerant Charged up:
A Process Chiller’s cooling remainder relies upon appropriate refrigerant levels in the system.
Keeping up and maintaining appropriate refrigerant charges can significantly affect energy productivity by decreasing cooling costs by almost 5-10%.
Maintain Keep up condenser water.
Condenser water loops utilized with cooling towers should maintain the actual water flow as planned.
Any trash like sand, erosive solids, and pollution materials can influence the condenser water loops.
Fouling or scaling can repress the water flow and incredible impact on the Process Chiller’s working effectiveness.
Some Other Essential Steps for Maintaining and Optimized Performance of Process Chiller:
- Examine your Process Chiller quarterly.
- Regularly check for refrigerant leakage.
- Check voltages.
Process Chiller Maintenances
12-What are some Main Challenges of Process Chiller?
Process Chiller cooling is not fully secure.
A few difficulties exist with the existing Process Chiller system.
In any case, advancements in the Process Chiller, businesses desire to bear a portion of the current issues to make measure cooling more productive and compelling later on.
- Climate and Cooling Towers.
- Particulate Matter in the Cooling Liquid.
- Water Use of Water-Cooled Process Chiller.
- Bacteria in Water Towers.
13-Why TopChiller is your trustworthy Manufacturer of Process Chiller?
The overall activities of the TopChiller Group offer a more prominent profundity of specialized help.
And more noteworthy experience than any other person on the planet with sans oil diffusive innovation and its effective conveyance of lifetime energy cost savings.
Because we focus on results in producing Process Chiller. For us, it is all about what adds value to you and your business.
Our team has experience working for major corporations as well as for many different Process Chiller’s Industries.
We understand the pressures weighing on business owners and senior decision-makers, whether it is the daily decisions faced by a small family firm, we know what works and what does not.
We put our proposals into action for you.
In this guide, we have highlighted and mentioned the important detail regarding Process Chiller.
In the end, we conclude by highlighting that Process Chiller is a good source of removing heat from a process to avoid any issues.
Your good choice can result in and help you reduce the unusual costs and gain maximum advantage from Process Chiller.
100% Quality Tested Process Chiller
FAQ of Process Chiller
- What Happens if the Heat Load of a Process Chiller Swings Large Amounts?
If the heat load of your application turns to large amounts, the Process Chiller will provide the coolant at a consistent level.
- What Refrigerant, a Process Chiller uses?
Process Chiller uses HFO refrigerants to regulate the temperature of the process. Such as R407c, R410a, etc. As it eliminates the factors of Ozone Depletion and global warming.
- What is the Purpose of Process Chiller in UV Printing and UV Lighting (UV stands for Ultraviolet)?
The Process Chiller is used to control the temperature of the UV LED lamp to keep the reliability of the UV lighting source.
It includes UV equipment like UV screen printing machines, UV-LED curing equipment, etc.
- What Safety Protection Devices are Used by the Process Chiller?
The Process Chiller is mostly equipped with the following protection devices;
- Water flow protection device
- High/Low Protection device
- Overheating protection device
- Overload compressor protection device
- What is a Barrel in a Process Chiller?
Every Process Chiller has a barrel. A barrel consists of a big volume, storage tank made up of stainless steel with an immersed evaporator.
Process Chiller Barrel