Category: Chiller Information

The Chiller System Components are divided according to their location into:

• Chiller System components: located in the refrigeration circuit, for its operation and control.
• Chiller system components: located in chilled water distribution.

Chiller Parts of Refrigeration Circuit for its Operation and Control:

The basic components of a chiller are the following:

• Evaporator Chiller: to transfer the heat from the water to the refrigerant in the circuit, thus generating ice water.
• Chiller compressors: to receive the refrigerant from the evaporator, raise its pressure and drive it to the circuit condenser.
• Chiller condenser: to dissipate the heat of the refrigerant into the environment.
• Expansion valve chiller: to recover low pressure and return low temperature to the refrigerant.
• Chiller cooling towers: They are responsible for cooling the water that goes to the chiller condenser.
• Chiller control board: It is in charge of controlling and optimizing the operation of the chiller’s refrigeration cycle.

Evaporator Chiller:

The evaporators used in chillers are:

• Shell and Flooded Tube Chiller Evaporator.
• Shell and Dry Tube Chiller Evaporator.
• Shell and Coil Type Chiller Evaporator.
• Double Tube Chiller Evaporator.
• Baudelot type chiller evaporators.
• Plate Chiller Evaporators.

Shell and Tube Chiller Evaporator Flooded.

• A shell and tube evaporator consists of a shell, and a large number of straight tubes parallel to each other.
• The coolant is inside the casing, and the water is inside the pipes. The coolant is fed through a float. The float is in charge of maintaining the constant level of refrigerant inside the casing.
• The refrigerant outlet of the evaporator is located at the top, To exit the casing, the refrigerant must be in a vapor state, in order to reach the exit point.
• They can be single-pass tubing or multi-pass.
• Use fins out of the tube.
• Steel pipes are used with ammonia.
• Copper tubes are used with freons.
• Ammonia has a high heat transfer coefficient, while Freons have a rather lower heat transfer coefficient, therefore fins are used on the refrigerant side.
• In case of freezing, the water freezes in the tube, which causes the tubes to burst, as the water expands when it freezes.
• They are not recommended for applications where the temperature of the liquid to be cooled may be below 3 ° C.

Shell and Dry Tube Chiller Evaporator:

• It is made up of a shell and a large number of tubes parallel to each other.
• A thermostatic expansion valve feeds the refrigerant to the evaporator.
• The refrigerant supply is carried out according to the superheat at the outlet of the exchanger.
• The refrigerant is inside the tubes.
• This evaporator requires less refrigerant charge.
• Fins are used inside the tubes.
• Water flows through the casing.
• The presence of baffles creates turbulence in the water, enhancing the transfer of heat.
• The deflectors increase the residence time of the water in the housing.
• In the case of freezing, the water has enough space in the shell for expansion.

Expansion valve chiller

Water cooled chiller parts

Chiller system componentes

chiller control board

chiller compressors

Where to learn all about chillers?

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

Chiller Training Courses

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.

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:

Water Density Table:

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

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

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 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

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

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 high initial investment vs low running costs:

If you need to cool a large area with less electrical energy consumption, then a Chilled Water Air Conditioning System is an ideal solution for you.

• This type of air conditioning system uses a refrigeration cycle to cool water, which is then carried through pipes to cool the air in the environment.
• It’s a central system that provides the right amount of cold air needed for the space, reducing the likelihood of failure and saving energy.
• Chilled Water Air Conditioning Systems are designed to match the cold air requirements of the facility, reducing maintenance costs, and allowing for efficient air filtration.
• This type of air conditioning system also makes it possible to renew the air inside the room with external air and avoids the need for high-power electrical installations.
• One of the significant advantages of a Chilled Water Air Conditioning System is its low noise generation.
• The iced water temperature is usually maintained at 7°C (44°F) at the outlet of the chiller and 12°C (54°F) at the return, which chills the air to condition the environment.
• The components of a chilled water central air conditioning system include a chiller, water distribution system, and air distribution system, which are responsible for generating low-temperature, transporting water to the area, and handling and carrying the air to the rooms.

Compared to conventional air conditioning equipment, Chilled Water Air Conditioning Systems are more efficient, require less maintenance, and are designed to match the specific cooling requirements of a facility.

Condition:	Splitt	Aire Tipo Paquete (Ducts)	Chiller
Number Of Equipements	High	Low	Low
Electric Consumption	Medium-Hight	Low-Medium	Low
Maintenance frequency	Medium	Low-Medium	Low-Medium
Initial investment of money	Low	Medium	Hight
Noise	Medium-Low	Medium-Low	Low
Quality of air	Low	Hight	Hight
Experience of designer.	Low	Medium-Hight	Hight
Required area by installation	Low	Medium-Low	Medium-Hight

Where to learn all about chillers?

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

Chiller Training Courses