TopChiller Process Water Chiller Manufacturer and Supplier China

Process Water Chiller-An Ultimate Buying Guide by TopChiler

Are you looking for an excellent solution to maintain extra heat in your processes?

The purpose of a Process Water Chiller is to circulate process water at suitable pressure and temperature to allow the efficient functioning of machines, appliances, and devices.

Mostly, a Process Water Chiller is used in pharmaceutical, printing, medicinal, food, plastics, and other manufacturing industries.

Using a Process Water Chiller is undoubtedly an excellent solution to deal with the extra heat that is produced during different industrial or commercial processes.

This guide presents all about the Process Water Chiller, its functioning and usage, and how to deal with certain problems during functionality. So, let’s get started.

What is Process Water Chiller?

A Process Water Chiller is a refrigeration device that provides cooling for a process or industrial application using halocarbon or ammonia refrigerants.

At a bare minimum, a refrigeration circuit consists of compressors, condensers, thermal expansion valves, and evaporators.

These elements work together to form a whole component that drains extra heat from a process load to keep setpoint temperatures stable 24 hours a day, seven days a week.

Unlike industrial or HVAC, a Process Water Chiller is designed to withstand the harshest conditions.

What are the Components of Process Water Chiller?

Depending on the size, a Process Water Chiller is made up of a variety of components.

A compressor, condenser, evaporator, generator, tubing, high-pressure refrigerant relief valves, cooling towers, tanks, filters, and fans are all used in each Process Water Chiller.

What are the Features of a Process Water Chiller?

Here are some main features of a Process Water Chiller.

• Vertical in-line, end suction, or horizontal split-case centrifugal pumps
• Device controller based on a PLC (with color touchscreen interface)
• Drives with a constant speed or variable frequency (VFD)
• Auto pump staging on demand, depending on real device demand.
• Temperature sensors for the auto system
• Device restart on its own
• Bladder expansion tank and air separator
• Controls for device conductivity and auto-blow-down
• Controls for system pressure and differential pressure
• Key headers are made of carbon steel.
• Pumping several fluids at a regulated flow rate is possible with this device.
• Cooling medium: chilled water or glycol
• Flow rates of almost any kind

What is the Difference between Process Water Chiller and Process Air Chiller?

The distinction is that a Process Water Chiller uses a humid air stream (ambient air stream + water spray), while Process Air Chiller uses an ambient air current.

Process Water Chiller is typically less expensive and more effective, but it has the drawback of using a lot of water.

However, a Process Air Chiller is typically more expensive and a little less effective but works on air, which is all-time easily available.

How Does Process Water Chiller Work?

Process Water Chiller uses a cycle to transfer heat by sending liquids through the device. The heat from the machines is transferred to the Process Water Chiller by a vapor.

It shares heat with the refrigerant system to cool the process fluid, lowering equipment temperatures.

• Evaporator

The evaporator, also known as a heat exchanger, is the first stop for the process fluid. The fluid inside the heat exchanger transfers heat to the refrigerant.

Due to a drop in heat, the refrigerant evaporates. It becomes cold enough to cool the process fluid flowing by it as it transitions from a liquid to a gaseous state.

The process fluid then returns to its original location. Evaporators come in a variety of shapes and sizes.

Both these work by exposing the process liquid to the refrigerant, which collects the heat from the process fluid and converts it to a gas.

• Brazed plate heat exchangers (BPHE)

BPHE systems are smaller and need less maintenance. BPHEs weigh 85 to 90 percent less than equivalent shell and tube evaporators.

Place a filter at the return water inlet to keep these units running at their best.

As a result, the amount of particulate matter that may harm the heat exchanger is reduced. One of the drawbacks of this form of evaporator is that it produces a lot of heat.

• Evaporators with shells and tubes

Evaporators with shells and tubes are extremely effective. You will boost the Process Water Chiller cooling capacity by 10%.

This increased productivity will also be used to boost the evaporator temperature, increasing the unit’s energy efficiency and lowering potential operational costs.

Shell and tube evaporators also have the advantage of being fully self-contained personalizable. It is not a problem whether a consumer requests all-stainless steel or copra-nickel configuration due to the working conditions or fluid.

These customizations, however, can incur extra costs.

• Compressor

The refrigerant enters the compressor and is compressed to a high-pressure state.

The temperature of the Process Water Chiller can be increased or decreased by changing the pressure of the refrigerant.

Compressors press the refrigerant from a gas to a liquid state using physical energy. The refrigerant is transported as a high-pressure gas to the condenser, where it is absorbed by air or liquids.

Compressors come in a variety of shapes and sizes. The process used to press the refrigerant down gives each compressor its name.

Mostly, Screw and Scroll compressors are available for a Process Water Chiller.

• Screw Compressor

The refrigerant flows through one or two rotating screws in a screw compressor. The gas is compressed as the screw is turned, resulting in higher pressure.

For better work, the Process Water Chiller with screw compressors has gas-cooled motors and an integrated lubrication system.

The operating temperature range of these compressors is extremely wide.

• Scroll Compressor

A scroll compressor is a device that compresses one scroll within another. The refrigerant travels between the two of them.

This room becomes narrower and smaller, compressing the refrigerant and increasing the pressure. Scroll compressors are available in some of the chillers.

A Process Water chiller with a scroll compressor is low in noise and high inefficiency.

• Condenser

Condensers change the refrigerant from a gaseous state to a liquid state. The high-pressure gas must release its heat for this to happen.

The heat from the refrigerant is normally absorbed by condensers using air or water. The refrigerant passes into the condenser, which is made up of heat-conducting coils.

• Air-Cooled

Condensers that extract heat from the refrigerant with water require a separate water supply.

While the condenser of Process Water Chiller is more efficient than air-cooled condensers, the need for a separate water tower can outweigh this advantage, especially in areas where temperatures are below zero.

Air-cooled condensers circulate ambient air over refrigerant-filled coils. Copper tube coils are used in our air-cooled systems to improve heat transfer.

Variable-speed fans are also available to change the necessary airflow on colder or warmer days.

If your plant is near a water source, we can have copper-copper coils (copper tubes and fins) or regular coils with a corrosion-resistant coating.

What are the Applications of A Process Water Chiller?

A Process Water Chiller can be used in a variety of industries. In reality, the applications are as diverse as the custom-designed chiller options.

Regardless of their various applications, they all have one thing in common: they all need to extract heat from a phase.

1. Plating and Anodizing

Both electrolysis plating and aluminum anodizing necessitate exceptionally high temperatures.

Process Water Chiller is used by factories to remove excess heat from machines and stuff.

The final result suffers if the plating bath is not at the correct temperature, particularly with zinc and chrome plating.

The temperature of the plating bath is optimized using a Process Water Chiller.

Find the BTUs of the heat load and split it by 12,000 to size the perfect chiller for metal plating and aluminum anodizing.

The heat load is calculated by multiplying the volts by the rectifier amps by 3.412.

Cooling Load = (12,000 volts x amps x 3.412)

To save money or cover device losses, some people who buy Process Water Chiller for metal plating minimize the estimated BTUs.

Any expected losses can be affected by factors outside your influence. Use the measured BTUs for plating and anodizing to prevent underestimating.

2. Plastics Industry

Process Water Chiller is used in the plastics industry for thermoforming, extrusion, and molding.

To mound a large sheet of plastic into your required shape, the thermoforming process heats it to a precise temperature.

Extrusion is the process of moving molten plastic into an extruder to produce long pieces of plastic. Molding involves the use of a series of molds to keep molten plastic in the right form.

All of these processes include temperature regulation. This is where a Process Water Cooler will help.

In certain cases, such as extrusion, the Process Water Chiller will need to be supplemented by external equipment such as a cooling liquid filter or a secondary heat exchanger.

3. Printing Industry

If you spend some amount of time near a copy machine, you’ll notice the heat produced by copying.

To speed up the printing process, the printing industry needs to get rid of the heat generated by the printers.

A Process Water Chiller is needed for rollers and printers to keep them cool during service and improve their performance.

4. 4. Food Processing

Both food processing and storage necessitate precise temperature regulation.

A Process Water Chiller may sustain the low temperatures needed for cooling ingredients or building cool storage environments.

5. Pharmaceutical Industry

To get the formulations correct, drug manufacturing often necessitates temperature control during the process. In addition, after processing, certain medications must be processed at low temperatures.

In the pharmaceutical industry, Process Water Chiller may assist with these and other features.

6. Medical Industry

Large medical equipment will quickly overheat if not properly maintained. MRIs, PET scanners, and CAT scanners all produce a lot of heat when they’re in operation.

The high temperatures could impact the consistency of the test results if the heat is not removed with a Process Water Chiller.

A Process Water Chiller may be used for a variety of purposes, including those mentioned above. A Process Water Chiller, on the other hand, will help any industry that needs lower temperatures to make the machinery run more effectively.

What are the Advantages of Process Water Chiller for your Applications?

• Longer Life Expectancy

A Process Water Chiller doesn’t need to be replaced as much as an air-cooled one. They are durable because they are not exposed to outdoor conditions such as rain, snow, ice, and heat.

• Operation in Silence

A Process Water Chiller is quieter than Air Cooled Chiller, which has ducts and fans that make noise.

The water moves through the Process Water Chiller does not produce the same loud expansion and contraction as Air Cooled Chiller does.

• Efficiency of Energy

Process Water Chiller has an energy coefficient that is 10 to 100 times higher than the Air Cooled Chiller.

This means the Process Water Chiller is more effective at transferring heat. Many businesses save money on electricity as a result of using this machine.

• No need for open space

To run, the Air Cooled Chiller must be held outside in an open area with plenty of fresh air. While the process Water Chiller is installed indoors, making them suitable for businesses with little outdoor space.

• Safety

Process Water Chiller uses water instead of toxic additives as a refrigerant. This makes using the Process Water Chiller a safer option for all.

How to Maintain Your Process Water Chiller?

To help sustain high performance, here are six maintenance tips that relate the most to Process Water Chiller.

• To ensure effective heat transfer, keep tubes clean.

Heat transfer efficiency has the greatest single impact on Process Water Chiller output, so retaining high efficiency requires clean heat transfer.

Minerals, size, dirt, algae, and other impurities raise thermal resistance while lowering overall efficiency. The temperature of the approach is a strong predictor of heat transfer efficiency.

Higher approach temperatures are strong indicators of a drop in heat transfer performance.

Brush clean the condenser tubes at least once a year, or according to the demand repair plan, to keep them free of pollutants.

• Avoid size and corrosion by treating condenser water.

Water treatment is needed for all condenser water loops that use open cooling sources (such as atmospheric cooling towers) to prevent size, corrosion, and biological growth.

Both of these things cause condenser fouling, which obstructs heat flow and reduces the efficiency of tubes and piping.

Once a year or daily, inspect chilled water loops.

• Reduce the temperature of the water entering the system.

The performance of the Process Water Chiller can be improved by lowering the temperature of the condenser water entering the chiller.

To solve air handler shortcomings such as filthy coils, the operator can lower the chilled water set point on certain building systems.

This treats the symptom but not the underlying issue and makes the Process Water Chiller work harder to achieve the same net cooling result.

• Make sure there’s enough refrigerant in the system.

The amount of refrigerant that a Process Water Chiller can pass through the compressor determines how much ventilation it can produce.

Maintaining the correct refrigerant amount for optimal conditions is critical.

Leaks in the refrigerant, as well as air and moisture added into the system, would reduce the system’s performance and reliability—the use of a minimal refrigerant fee.

• Prevent non-condensable from causing inefficiencies.

Since their evaporators run in a vacuum, non-condensable such as air and moisture escape into low-pressure chillers.

Non-condensable can reduce the actual efficiency of Process Water Chiller by as much as 4% at 60% load and 7% at 100% load when compared to the rated output.

Non-condensable are minimized by purge units. If the oil charge is replaced, inspect the oil filters for pressure drop and replace them.

Traditional chillers require very different maintenance and operations than new magnetic-bearing frictionless chillers.

The use of oil in the construction of these chiller systems has been discontinued, lowering repair costs even further.

• Inspect the starters and motors for proper operation.

Check the protection and sensor calibrations on microprocessor controls for effective starter and motor operation (consult manufacturer’s guidelines).

Then, look for hot spots and worn contacts in the chiller’s electrical ties, wiring, and switchgear.

Check electrical motor windings for insulation resistance to ground and winding-to-winding to avoid insulation faults.

Check for potential refrigerant leakage in open drive motor shaft seals and clean motor cooling air vents to ensure optimum cooling impact.

What Are Some Main Challenges of Process Water Chiller?

The Process Water Chiller is not without flaws. There are several issues regarding new processes.

However, future chiller technologies aim to solve some of the current issues, making a Process Water Chiller more reliable and competitive.

Hold the temperature at 45 degrees F or above and use the maximum possible water flow rate to minimize the risk of freezing while retaining the most cost-effective model.

Still, water has a lower chance of freezing than moving water.

Switch off the cooling fans to avoid circulating cold air over the water and further chilling it.

Particulate Matter Cooling Liquid

Some procedures, such as plastic extrusion, can cause particulate matter to contaminate the cooling liquid.

The particles will clog the system, reducing the efficiency of the Process Water Chiller. Use a filter for the process liquid to prevent this problem.

Before the cooling liquid enters the heat exchanger, it should be filtered to dissolve any debris.

Water Use in Process Water Coolers

Water shortages are popular in drought-prone regions. These limitations often apply to industrial water use, making it impossible to use a Process Water Chiller also.

However, by repurposing wastewater for cooling towers and other beneficial uses, the facility will be able to save millions of gallons of water.

Reclaimed wastewater in Process Water Chiller, rather than using fresh water, may help reduce the environmental effects of these units.

Bacteria in Water Towers

The life of a Process Water Chiller can be extended by testing and removing bacteria from the water in the cooling tower.

Bacteria may create a slime that clogs the system’s workings if it isn’t tested, necessitating more regular repairs.

Another source of risk is Legionella bacteria, which can infect humans who inhale the bacteria. People are protected from disease transmission by testing for bacteria and handling it.

Stainless steel mesh biofilm is more effective at detecting Legionella and other bacteria than the traditional research approach of using dip slides.

Researchers discovered bacteria using this process on a Colorado HVAC cooling tower where normal tests had come up empty.

Better bacteria control is possible with more accurate monitoring, which saves chiller equipment and humans.

Despite these obstacles, the Process Water Chiller continues to be an efficient means of heat removal from machinery during processing and storage.

To meet these challenges, many businesses have embraced new Process Water Chiller trends.

How to Install Your Process Water Chiller?

• Make a surface for mounting.
• Make preparations for rigging.
• Fluid piping is given, as well as a power drop.
• From the chiller to the MRI operator’s work station, run a 34″ conduit with a pull loop.
• De-mineralized water in the range of 65 to 95 gallons is needed.
• At four corner paws, rig and anchor your Process Water Chiller
• Fill reservoir through the fill tube/site glass after connecting fluid piping.
• Connect the power drop and double-check the polarity.
• Connect the Carrel Display to the remote
• Enable 5-10 minutes for the pumps to purge air from the fluid piping after turning on the unit to ensure proper pump rotating path.

How to Troubleshoot your Process Water Chiller Problems?

The following are some preliminary measures to take to help isolate the issue.

• Check to see if your Process Water Chiller is switched on.

The Process Water Chiller will not be able to work due to a blown circuit breaker or fuse, loose wire, or even a control switch that has been turned off.

• Check to see if the Process Water Chiller is cooling.

Check the temperature of the coolant at the product’s outlet. The evaporator could be iced up if the temperature isn’t at or above the set point.

• See if the pump is on.

A partially or fully closed valve, a faulty pump, insufficient coolant capacity, or a process line constraint could be preventing adequate liquid flow through the process coolant loop.

• Examine the mechanism and the surrounding climate. Because of variations in the phase or the atmospheric temperature, the Process Water Chiller can be overloaded.

If you change the position of your Process Water Chiller, this will affect the working.

Also, the loose or broken wires or improper insulation will decrease the functioning of your Process Water Chiller.

What are Safety Tips for the Process Water Chiller?

The device includes refrigerant vapor and liquid under pressure, which can cause damage if released.

To prevent damage to the pressure device, the user should exercise caution during installation, service, and repair.

Only suitably educated and skilled employees should seek to obtain access to the parts of the pressure system.

Using electricity

The device has to be grounded. Without first turning off the electricity, isolating, and locking off the power source, no construction or repair work on the electrical equipment can be attempted.

It is not a good idea to want to service or maintain live appliances. During regular operation of the Process Water Chiller, no effort should be made to obtain access to the control panel or electrical enclosures.

Oils and refrigerants

The refrigerants and oils used in the device are nontoxic, nonflammable, and non-corrosive and pose no special safety risks.

When working on the device, gloves and protective glasses are recommended.

In confined or sealed spaces, the buildup of refrigerant vapors, such as from a spill, poses a possibility of asphyxiation, so proper ventilation should be prioritized.

Cleaning with high temperatures and pressure

Cleaning techniques involving high temperatures and pressures (e.g., steam cleaning) should not be used on any aspect of the pressure system because they may cause the pressure relief device to malfunction.

Detergents and solvents can also be avoided because they can induce corrosion.

Shutdown in an emergency

If the Process Water Chiller is equipped with an optional circuit breaker or non-fused disconnect button, it can be turned off from the control panel in the event of an emergency.

How to Increase Efficiency of Your Process Water Chiller?

The reliability of a Process Water Chiller is determined by how well the device functions. The cooling capacity of the system is reduced as refrigerant leaks.

Continuous leak detection can help avoid problems by alerting repairs when a problem arises.

Additionally, even though the ambient temperature varies dramatically, the device can need modifications to operate as effectively as possible.

Here are a few things you can do to increase the efficiency of your Process Water Chiller

• Always clean your Process Water Chiller to keep bacteria and germs away.
• Make sure to dry the Process Water Chiller after using.
• Properly read the manual and guide that comes in the package to understand the working of the Process Water Chiller.
• Also, always maintain your Process Water Chiller either by yourself or either by calling an expert for help.

FAQ of Process Water Chiller

How to Drain Your Process Water Chiller?

The best way to drain your Process Water Chiller is to attach the inlet and outlet points with a hose. Then, allow maximum water to get out of your Process Water Chiller. Finally, make sure to dry your Process Water Chiller for the best results.

What Do You Mean By TR of A Process Water Chiller?

TR of a Process Water Chiller is the refrigeration ton (RT), a unit that describes the capacity of the air conditioner and refrigerator to absorb excess heat.

What is the Process Cooling in Your Process Water Chiller?

Process cooling refers to the extraction of extra heat from any process. The purpose of removing this heat is to maintain the temperature leading to an efficient, protected, and better functioning of the process.

How Do You Choose Between the Process Water Cooled Chiller and the Process Air-Cooled Chiller?

A Process Water Cooled Chiller is a better option than the Process Air Cooled Chiller.

The reason behind this is that less energy is required when using water as the basics of removing due to the high heat capacity of water.

Also, a Process Water Cooled Chiller is durable and efficient than the Process Air Cooled Chiller.

How to Choose the Chiller Pump of Your Process Water Chiller?

While choosing a chiller pump for your Process Water Chiller, make sure to consider the pressure loss, efficiency, flow rate, and cost in mind.

What is the Durability of Your Process Water Chiller?

The average life of a Process Water Chiller exists around 10 to 15 years. However, the maintenance, usage, and care of the Process Water Chiller affect this life accordingly.

What Causes Your Process Water Chiller to trip?

The low-pressure trip of a Process Water Chiller occurs due to less refrigerant or broken tubing.

Moreover, badly working evaporators because of mud accumulation, or the decreased flow of water, are also responsible for the Process Water Chiller to trip.

How Does the Compressor of the Process Water Chiller work?

The function of the compressor in the Process Water Chiller is to compress a refrigerant in a gaseous state with less temperature and less pressure into a refrigerant with higher pressure and temperature.

Then the water in the condenser will remove the excess heat from the refrigerant.