Gerson Mora, Author at Chilling Solutions Training

Ammonia Water Chiller

The ammonia water chiller is an energy-efficient machine that excels in handling large thermal loads without environmental restrictions, as it utilizes a natural refrigerant.

How does the Ammonia Chiller System operate?

Ammonia chiller systems can operate with two types of cycles:

Ammonia chiller working with a compression refrigeration circuit.
Absorption chiller utilizing ammonia as the refrigerant.

Ammonia is an excellent option for industrial refrigeration as it does not harm the ozone layer or contribute to the greenhouse effect.
In chillers with high thermal loads, ammonia significantly reduces electricity consumption, making it a cost-effective choice compared to other synthetic refrigerants.
Additionally, ammonia is approximately 1.7 times lighter than air, enabling it to rise easily and form a cloud when in the presence of humid air.
Chiller installations working with ammonia are designed to detect leaks through security systems.
Ammonia leaks can often be detected by the human nose before becoming hazardous.
To prevent corrosion and leakage issues, ammonia chillers are constructed using robust steel or stainless steel materials, which can influence the initial cost of the equipment.
Ammonia chillers typically have zero overheating due to their use of flooded-type evaporators.
They also offer the possibility of total or partial heat recovery, further enhancing the energy efficiency of the installation.
These chillers often require less than 500 grams of ammonia per ton of refrigeration and are usually compact, assembled by the same machine manufacturers, and utilize various condensation methods, such as water, air, or evaporative.
For chillers produced in Northern Europe, R-717 (ammonia) is commonly used.
Specific engine rooms for ammonia chillers require dedicated mechanical ventilation systems, and ammonia leak detectors are set to values lower than established limits for safety purposes.
Ammonia is only flammable in the presence of a high source of ignition, and explosions can occur in flammable mixtures in confined spaces, provided that the ignition temperature exceeds 635°C.
However, in open spaces, ammonia rises and dissolves in the atmosphere, eliminating the risk of ignition and explosion.

Packaged Ammonia Chillers:

Packaged ammonia chillers generally operate on a compression refrigeration cycle with capacities ranging from 20 to 400 tons of refrigeration.
The ammonia load in packaged chillers is low, approximately 1 pound per ton of refrigeration.
Smaller capacity packed ammonia chillers use a piston compressor, while larger ones employ a screw compressor.
Packaged ammonia chillers are factory-assembled, enabling quick and easy installation of the system.

Where to learn all about chillers?

We offer comprehensive training in chilled water installations with chillers.

Chiller Training Courses

Chiller Training

We have chiller training, with everything that personnel working with chilled water systems need to know.

Part One Chiller Training:

The basic operation of the chiller.
Basic types of chillers.
Calculation of water chillers

Part two Chiller Training:

Efficiency study in chillers.

Part three Chiller Training:

Chilled water distribution systems.

Part Four Chiller Training:

Variants in cooling circuits in chillers.

Part Five Chiller Training:

Electronic control and electricity are applied to chillers.

Part Six Chiller Training:

Maintenance applied to chillers and ice water plants.

Rotary Screw Chiller

If you need a reliable and high-performance machine for cooling water flows, the rotary screw compressor chiller might be just what you’re looking for.

These machines are designed to operate using a compression refrigeration cycle, making them ideal for medium to high refrigeration power ranges. With cooling capacities ranging from 20 tons to 1,000 tons of refrigeration, there is a chiller available to suit your needs.

How do screw compressors work?

A screw compressor is a machine that increases the pressure of refrigerant gas that has been evaporated in the chiller. This high-pressure refrigerant is then sent to the condenser, where it is turned back into a liquid.
The screw compressor works by reducing its volume through the rotation of slotted helical screws within a tight tolerance housing.
The double rotor screw compressor is the most commonly used compressor in larger refrigeration installations, where the rotors rotate in opposite directions to draw gas into the rotors through an inlet port.
As the screws continue to turn, gas is trapped between the compressor housings and the rotors, and is released through an outlet port at a determined discharge pressure value.

What is the most common refrigerant used in screw chillers?

The most commonly used refrigerant in screw chillers is R-134A. However, due to environmental restrictions, newer refrigerants such as R513A have also been introduced.
Some screw chillers also use R410A, although this refrigerant has been replaced by more environmentally friendly options due to its high GWP value.

Which screw chiller is the best seller?

The best-selling chiller is the screw compressor with a water chiller in the range of 100 to 300 KW.

Popular Models of Screw Chillers:

Check out our table of the most commonly used models of screw chillers.

In this table, we have models of Screw Chillers and their main characteristics:

Chiller Model	Chiller Gas	Cooling Capacity	Cooling of Condenser
AquaForce 30XA	Carrier R134a	80 – 500 TR	Air-Cooled
AquaForce 30XV	Carrier R-134a	490 – 1755 TR	Air-Cooled
AquaForce 30HX	Carrier R-134a	75 – 265 TR	Water-Cooled
AquaEdge 23XRV	Carrier R-134a	175 – 550 TR	Water-Cooled
AquaForce 30XW	Carrier R-134a	150 – 400 TR	Water-Cooled
York YVAA	R-410A	150 – 575 TR	Air-Cooled
York YVFA	R-410A	150 – 500 TR	Air-Cooled
York YCIV	R-410A	150 – 400 TR	Air-Cooled
Trane RTAE	R134a	150 – 300 TR	Air-Cooled
Trane RTAC	R-134a	140 – 500 TR	Air-Cooled
Daikin Pathfinder	R-134a	100 – 565 TR	Air-Cooled
Daikin Navigator	R-134a	120 – 300 TR	Air-Cooled

Where to learn all about chillers?

We have prepared a complete training in chilled water installations with chillers.

Chiller Training Courses

Scroll Compressor Chiller

The scroll compressor chiller is a widely used cooling system in low-capacity applications.

This chiller operates on a compression refrigeration circuit and is suitable for low to medium thermal loads. It can be equipped with either an air-cooled or water-cooled condenser.
Each individual scroll compressor typically handles refrigeration capacities of less than 25 tons. To achieve higher cooling power, multiple scroll compressors can be used in parallel.
Scroll compressors boast high efficiency, and when combined with inverter technology, they can further optimize the efficiency of the chilled water plant.
The design of parallel scroll compressors requires meticulous lubrication control, which is ideally automated for ease of operation.
Characteristics of scroll chillers include a hermetic squirrel cage induction motor, cooled by suction gas, contributing to its longevity and stability. The elimination of suction valves in scroll compressors reduces valve losses and enhances efficiency.
By utilizing multiple scroll compressors, the chiller’s capacity can be adjusted according to the plant’s demand, offering a degree of redundancy in case of compressor failure.
However, the presence of more compressors may slightly increase the probability of failures, but the overall reliability of scroll compressors due to their few moving parts mitigates this concern.
Inverter-type scroll compressor chillers enable adaptability to varying cold needs within the plant, improving overall efficiency.
To maximize the chiller’s performance, an oil equalization system must be implemented to ensure consistent and reliable operation.
Chillers with scroll compressors are available in various refrigerants, including R22, R407C, R134a, R404A, and R410A.

For comprehensive learning on chilled water installations and chillers, we offer a complete training program.

Chiller Training Courses

Chiller Tonnage Calculator

Introducing the Chiller Tonnage Calculator: Your Handy Tool for Efficient Cooling

Are you looking for a way to accurately calculate the thermal load and water flow required for your chiller system? Look no further than our Chiller Tonnage Calculator!

Designed specifically for industrial processes and machine cooling applications, our calculator can help you determine the total chilled water flow your plant needs, the minimum water temperature required at the chiller outlet, and the outlet temperature at the chiller inlet.

Armed with this information, you can make informed decisions and accurate quotes before making any purchases.

Our user-friendly form makes it easy to input the necessary values for chiller calculation. Whether you need to determine pipe sizing, water flow rates, or glycol chiller sizing, our calculator has got you covered.

But what if you prefer to do things manually? No problem! Our calculator also provides the formula you need to manually calculate chiller tonnage.

With the Chiller Tonnage Calculator, you can ensure that your chiller system is properly sized for your application, leading to more efficient and effective cooling. Try it out today and see the difference it can make for your industrial processes!

Chiller Tonnage calculation formula:

For manual calculation the following information is required:

Specific Heat Table of Water:

	Kcal/Kg°C	J/Kg°C	Btu/lb°F
*Specific Heat of Water*	1	4186	1

NOTE: The specific heat of the water indicates the amount of heat that needs to be extracted from the water to decrease the temperature by one degree.

Water Density Table:

	Kg/L	Kg/m3	Lb/ft3
Water density	1	1000	62.43

NOTE: The density of the water allows us to transform the volumetric flow into the mass flow.

Heat Power Units Conversion Table:

Heat Power Unit	Equals	Equals	Equals
1W	0.86 Kcal/h	3.41 Btu/h	0.00028435 TRF
1 Btu/h	0.25 Kcal/h	0.29 W	0.00008333 TRF
1 Kcal/h	3.96 Btu/h	1.16 W	0.00033069 TRF
1 TRF	12000 Btu/h	3516.85 W	3023.95 Kcal/h

Note: The table shows the common units for measuring heat output in the refrigeration sector.

Volume Flow Conversion Table:

*Volumetric Flow*	*Equals*	*Equals*	*Equals*
1 m3/s	0.01 ft3/s	16.67 L/min	4.4 GPM
1 L/min	0.26 GPM	0.000589 ft3/s	0.06 m3/s
1 ft3/s	101.94m3/h	1699 L/min	448.83 GPM
1 GPM	0.23 m3/h	3.8 L/min	0.000589 ft3/s

Chiller Calculation International System of Units:

Chiller Calculation made easy with the International System of Units!

So you need to calculate the power required for your chiller? No problem! Here’s what you’ll need to get started:

Maximum water flow = 18 m3/h Chiller water inlet temperature = 14°C Chiller water outlet temperature = 8°C

Step One: First things first, we need to calculate the change in temperature of the water inside the chiller. Easy peasy!

T water inlet – T water outlet = 14°C – 8°C = 6°C Temperature change = 6°C

Step Two: Next, we’ll use the specific heat to determine the amount of heat required to achieve the desired temperature change.

Specific heat is the amount of heat required to raise the temperature of 1 kg of water by 1°C. In this case, our specific heat is 1 kcal/kg°C.

Total heat to be extracted = Specific heat x Temperature change Total heat to be extracted = 1 kcal/kg°C x 6°C = 6 kcal/kg (that’s 6 kcal for each kg of water that enters the chiller)

Step Three: Now it’s time to calculate the power. We’ll need to know the mass flow that the chiller will receive.

Chiller water flow = 18 m3/h

Using table 4, we have: 18 m3/h x 16.67 = 300 liters/minute = 5 liters/second

Mass flow = Volumetric flow x Density Mass flow = 0.5 l/s x 1 kg/l = 5 kg/s

Chiller power = Total heat x Mass flow Chiller power = 6 kcal/kg x 5 kg/s = 30 kcal/s

Step Four: The final result needs to be converted to units of heat for use in refrigeration.

We’ll convert 30 kcal/s to kcal/h by multiplying by 3600.

30 kcal/s x 3600 = 108000 kcal/h

This value can be converted to different units:

108000 x 3.96 = 427680 Btu/h 108000 x 1.16 = 125280 W 108000 x 0.00033069 = 35.7 TRF (Tons of Refrigeration)

Step Five: To be on the safe side, we recommend applying a safety factor of 20%. This compensates for losses due to insulation deficiencies.

Chiller power = 35.7 TRF x 1.2 = 42.84 TRF

And there you have it, your chiller power calculation is complete!

Where to learn all about chillers?

We have prepared a complete training in chilled water installations with chillers.

Chiller Training Courses

Air Cooled Chiller Vs Water Cooled Chiller

Air-cooled packaged chillers are typically available in capacities between 8 to 550 tons of refrigeration, while water-cooled packaged chillers are typically available in 10 to 5,000 tons.

In the following table we have a comparison between the initial investment for each chiller, according to the condenser cooling:

Investment initial chiller	150 TRF	300 TRF	450 TRF	600 TRF	750 TRF
Cooled by air	100%	100%	100%	100%	100%
Cooled by water	150%	140%	130%	120%	95%

This means that the condenser, compressor, and evaporator are included within the machine and are designed and configured from the factory for optimum performance and reliability, reducing design and lead time and simplifying installation.
Water-cooled condenser chillers have the added complexity of condenser piping, pumps, cooling towers, and water controls, and their performance is highly installation-dependent.
Most air-cooled condenser chillers are “packaged systems”.
This means that the condenser, compressor, and evaporator are included within the machine and are designed and configured from the factory for optimum performance and reliability, reducing design and lead time and simplifying installation.
Water-cooled condenser chillers have the added complexity of condenser piping, pumps, cooling towers, and water controls, and their performance is highly installation-dependent.

Liquid Cooling vs Air Cooling Electric Power Costs:

Water-cooled chillers and refrigeration systems are generally more energy efficient than air-cooled ones.
Since the wet bulb temperature is often significantly lower than the dry bulb temperature, the condensation temperature and pressure of the refrigerant in a water-cooled refrigeration system can be lower than in an air-cooled cycle.
This means that the compressor needs to do less work and therefore consumes less energy.
This efficiency advantage may decrease during a night operation because the dry bulb temperature tends to drop faster than the wet bulb temperature when the sun sets.

Where to learn all about chillers?

We have prepared a complete training in chilled water installations with chillers.

Chiller Training Courses

Industrial Water Chiller System

Are you ready to chill with the Industrial Water Chiller System ? These liquid chillers are designed to cool machinery and processes with special temperature requirements.

But wait, what temperatures are we talking about here?

Let’s break it down. The Industrial Refrigeration Chiller can be classified according to the temperature range they handle.

We’ve got the Conventional Industrial Refrigeration Chiller for temperatures above 35°F.
Industrial Refrigeration Chiller for medium-low temperatures for values between 20°F and 35°F.
Low-Temperature Industrial Refrigeration Chiller generally between 20°F and -59°F.
Ultra-Low Temperature Industrial Refrigeration Chiller for ranges between -60°F and -112°F.

Why do we need Industrial Chillers for Special Refrigeration, you ask?

Well, some processes require an outlet fluid temperature below 35°F. For this, we use industrial chiller systems with multiple cooling stages that can reach even lower temperatures by using a mixture of water and glycol. Some chillers even use different fluids for each cycle to meet temperature demands.
When it comes to low-temperature industrial chillers, the oil management system must consider all necessary measures to guarantee the oil returns to the compressor, even at low viscosity levels. And, let’s not forget about the interior components of the ultra-low temperature industrial chiller, which need to be more efficient, stronger, and durable.
While industrial air-cooled chillers are great for most applications, they are not recommended when an outlet fluid temperature below -30°F is needed.
For this, we use two- and three-stage coolers that can use a variety of heat transfer fluids containing silicone oils, inert fluorinated fluids, hydrofluoroethers, or alkylated aromatic fluids. Some chillers even work with the environmentally friendly R507 Refrigerant Gas.
When it comes to capacity, low-capacity industrial chillers use a scroll-type compressor, while low-temperature industrial screw chillers are ideal for quick freezing of food and prepared meals in the food industry.

So, there you have it, the Industrial Water Chiller System is here to chill with special temperature requirements.

Where to learn all about chillers?

We have prepared a complete training in chilled water installations with chillers.

Chiller Training Courses

Industrial Water Chiller Price

The price values of the industrial water chiller depend on the criteria used in the design of the installation, thus we have:

Chillers with high initial investment vs low running costs:

Chillers with fixed initial investment vs high running costs:

Chiller and Cooling Tower

Water Cooled Centrifugal Chiller

The Water Cooled Centrifugal Chiller is a fantastic machine that uses a compression refrigeration cycle to generate massive amounts of ice water for applications with high thermal loads.

The best part? It’s surprisingly simple to understand!

This chiller uses a centrifugal compressor with an impeller wheel that spins at a high speed.
As the coolant enters, it acquires the speed of the impellers and moves radially under the effect of centrifugal force.
The refrigerant then leaves the impeller and enters the compressor volute, which is a curved funnel that increases in area as it approaches the discharge port. By doing this, it increases its cross-sectional area to convert the speed of the refrigerant into pressure. This results in coolant that has high pressure and is ready for use!
Centrifugal chillers are perfect for handling large amounts of thermal load and typically have a water-cooled condenser.
They also have few friction parts, which means they’re very efficient and easy to maintain. Plus, the frictionless operation means that the vibration of the chiller is close to zero.
To control the capacity of the compressor, vanes at the inlet of the centrifugal compressor are used. As the blades close, the flow of refrigerant entering the compressor reduces, and the compressor revolutions are reduced to generate the required pressure.
Magnetic bearings improve the efficiency and increase the life of the machine, and some centrifugal chillers do not require oil.
Not using oil increases the efficiency of the chiller heat exchangers. The partial load efficiency indicator “IPLV” can reach 13, and the chiller can consume 30 to 50% less energy. Centrifugal chillers can have a useful life of up to 30 years.
In summary, the Water Cooled Centrifugal Chiller is a reliable and efficient machine that can handle large amounts of thermal load. Its simple operation, low maintenance, and energy efficiency make it an excellent option for any application with high thermal loads.