How Does 3 ton water chiller Work?

A water-cooled chiller is a type of chiller from which heat is removed to cool water used in a project or industrial or domestic structure, and which puts the water back into the operating cycle. In effect, the chiller is transferring heat from one space that needs temperature control to another. The chiller is therefore not a means of generating cold, but a means of dissipating heat, its task being to facilitate the transfer of unwanted and undesired heat caused by the activity to a place outside the system.

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Cooling towers are specifically designed for water-cooled chillers. This is because the condenser of a water-cooled chiller uses water as stimulant and coolant. The efficiency of a water-cooled chiller is increased because the wet surface is more successful in transferring heat and can work in compression even at wetter bubble temperatures.

 Water-Cooled Screw Chiller     

How do water-cooled chillers work?

The water cooled chiller cycle, like any other chiller, consists of four main components: the evaporator, the compressor, the condenser and the expansion valve, each of which undergoes a thermodynamic process. The chiller works by delivering refrigerant at different pressures and temperatures to the different phases of the material to cool the water, which is then pumped out of the chiller. In fact, the main work of a chiller is based on the phase change or physical state of the refrigerant or refrigerant. Meanwhile, the work of a water-cooled chiller is based on the condensation of a vapour or gas.

First step in chiller operation.

The starting point of this cycle is where the water from the production process enters the evaporator into the chiller cycle.

In this part of the cycle, the heat absorbed by the refrigerant first manifests itself in the form of a change from the liquid to the gas phase. As the refrigerant absorbs heat from the water, the ambient temperature in contact with this part drops, so the water leaves at a lower temperature. This water enters the fan coil and brings the cool air to the desired space.

 Box Type Water-cooled Chiller         

In fact, the evaporator is where another cycle is involved in addition to the current one and that cycle is between the evaporator and the outlet of the cooling unit. In effect, the hot water enters the chiller evaporator, which then cools it and pumps it to the desired location throughout the building.

Second stage.

The gaseous refrigerant, which has reached the gaseous phase before the liquid state, then enters the compressor. In the compressor, the gas condenses and the temperature and pressure increase, thus moving to the next high pressure stage. The increase in pressure and temperature as the refrigerant leaves the compressor is important because the refrigerant needs to release heat from inside the condenser and it must therefore carry enough heat to the condenser.

Another key function of the compressor is to draw the refrigerant into the evaporator at the right time so that the pressure inside the evaporator remains high enough to absorb the heat again.

Third stage.

The third step takes place inside the condenser. The high temperature gas enters the condenser. In the condenser, the gaseous refrigerant is converted into a saturated, high-pressure liquid. This is a constant pressure process.

GEA BOCK Low Temperature Water Cooled Condensing Unit (-35~-25℃)

On the other hand, the water enters the cooling tower after the temperature has risen because the condenser exists in another cycle between the cooling towers. Since the main task of the cooling tower in a water-cooled chiller is to cool the water consumed, the condenser uses this water as its drive material.

This is where the excess heat from the water disappears and the water temperature returns to the required low temperature. The heating process we mentioned earlier takes place in the condenser to release the heat of the gaseous refrigerant itself, which is the source of heat that now needs to be eliminated by the cooling tower. In this way, the water entering the chiller cooling tower from the condenser comes into contact with the gas stream and transfers its heat to the air, which then returns to the condenser.

Fourth and final step.

The expansion valve is the final stage through which the refrigerant passes. This milk, as the name implies, expands and reduces the refrigerant. These processes take place with the refrigerant in the expansion valve, resulting in the refrigerant becoming a mixture of liquid and gas. Eventually, the same compound re-enters the evaporator to resume the cycle and the hot water re-enters the evaporator from the other direction.

Our innovative chiller solutions are designed to provide efficient, reliable cooling for all types of large commercial applications.

What is a Chiller & How Does it Work?

If your facility uses process fluids or heavy-duty machinery that generates heat, you’ll need an industrial chiller system to cool your processes and internal machine components. Understanding how an industrial chiller works and the various types of chillers available will help you choose the right cooling needs.

What is a Chiller?

An industrial chiller is a refrigeration system used to lower the temperature of machinery, industrial spaces, and process fluids by removing heat from the system and transferring it elsewhere. Industrial chillers are essential for temperature regulation in several industrial processes, such as injection molding, metal plating, oilfield production, and food processing.

Why Use a Chiller?

Air-cooled chillers and water-cooled chillers alike are beneficial for industrial processes where strict operational temperatures are required. When integrated with heat-sensitive processes, chillers will prevent thermal damage to process equipment and ensure no alterations to the final products from exposure to unsuitable temperatures.

Working Principles

Industrial chillers work based on the following principles of operation.

1. Phase Change: When heated, a liquid coolant undergoes a phase change into a gas, and when the gaseous coolant is supercooled, it condenses back into a liquid.
2. Heat Flow: Heat energy always flows from an area of high concentration to an area of lower concentration.
3. Boiling Point: Reducing the pressure over a liquid decreases its boiling point, and increasing the pressure increases its boiling point.

How Does a Chiller Work?

So, exactly how does a chiller work? An industrial chiller system is driven by one of two operational principles: heat absorption and vapor compression.

Heat absorption chillers integrate heat exchangers that pull heat away from any associated processes and dissipate them exteriorly. Heat exchangers typically comprise piping containing coolant fluids (air, water, or a mixture of water and other liquids).

Vapor compression chillers achieve a cooling effect by circulating coolant in pipes through the processes requiring cooling. This will pull heat from any associated processes into the coolant, which is then circulated to a refrigerant system that cools the chiller fluid and prepares it for a new cycle of process cooling.

Chillers consist of four key components: an evaporator, a compressor, a condenser, and an expansion unit. In addition, every chiller system contains a refrigerant.

The process starts with a low-pressure refrigerant entering the evaporator. Inside the evaporator, the chiller refrigerant is heated, causing it to undergo a phase change into a gas. Next, the gaseous refrigerant goes into the compressor, which increases its pressure.

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The high-pressure refrigerant goes to the condenser, which rejects the heat using cooling water from a cooling tower or ambient air from the surroundings, condensing it into a high-pressure liquid. The condensed refrigerant then goes to the expansion unit, which has a valve that acts as a metering device to limit refrigerant flow. Learn about new chiller refrigerants.

Consequently, this lowers the pressure of the refrigerant and begins the cooling process again. The entire process is known as the refrigeration cycle.

Basic Chiller Components

The central chiller components include the following:

• Condenser
• Compressor
• Evaporator
• Expansion valves
• Power unit
• Control unit
• Water boxes

Condenser

The function of a chiller condenser unit is to eliminate heat from the refrigerant being circulated through the chiller unit. This is achieved by circulating water between a cooling tower and the condenser for water-cooled variants or blowing cool air over condenser piping for air-cooled chiller units.

Compressor

The compressor is the driving unit of any chiller system. It generates the pressure gradient necessary to push refrigerant around the chiller unit to achieve process cooling. Various condensers are available, with the most popular types including centrifugal, screw, and reciprocating compressors.

Evaporators

An evaporator is placed between the expansion valve, and the condenser removes heat from any associated process into circulating refrigerant. Depending on the chiller configuration, this is then channeled to a cooling tower or air-cooled.

Thermal Expansion Valves

Thermal expansion valves between the compressor and the evaporator expand refrigerant passing through them. This action diminishes the pressure and improves the heat elimination from the evaporator.

Power Unit

All air-cooled chillers and water-cooled chillers incorporates a power unit that controls electrical energy flowing through the system. Power unit components usually include starters, power monitoring panels, and circuit breakers.

Control Panels

Control panels serve to regulate the entire cooling operation process. They usually integrate sensors, alarms, and display screens that allow operators to adjust system settings for optimal thermal control.

Water Boxes

These devices may be mounted on the chiller system evaporator or its water-cooled condenser. Their purpose is to conduct water flow effectively.

Types of Industrial Chillers

The three main types of chillers in use today are air-cooled chillers, water-cooled chillers, and absorption chillers. We will also briefly touch on cooling towers (an alternative or supplemental cooling system) and special chillers like glycol and centrifugal.

Selecting the right chiller for your industrial application will help you save costs, reduce downtime, and improve operational efficiency.

Water-Cooled Chillers

Water-cooled chillers use water from an external cooling tower to reject heat from a gaseous refrigerant in the condenser before it changes into a liquid.

Air-Cooled Chillers

In place of the cooling water, air-cooled chillers use ambient air to reject heat from the refrigerant in the condenser. Learn more about air-cooled chillers vs. water-cooled chillers.

Vapor Compressor Chillers

This type of chiller uses refrigerants to cool process fluids and spaces. A compressor is used as the driving force to pump refrigerant around the system.

Vapor Absorption Chillers

Vapor absorption chillers have no compressor in the unit. Instead, they use a heat source, e.g. solar energy or waste heat to drive the coolant through the system.

How does an absorption chiller work?

The process starts with liquid coolant in an evaporator, which turns it into gaseous form. Next, the gaseous coolant is absorbed by a concentrated absorbent such as Lithium Bromide or Ammonia, provided by a generator. Finally, the diluted solution absorbs the coolant while the cooling water absorbs heat.

The diluted solution of coolant and absorbent flows through a heat exchanger to the generator, where it is heated. The coolant vaporizes out of the solution, condenses, and is sent out for cooling again. The now-concentrated absorbent is recycled as well.

Glycol Chillers

Glycol chillers are special types that use propylene glycol, an anti-freeze, in the system. They are widely used in food-grade applications such as in the production of alcohol and for brewery chilling systems.

How does a glycol chiller work?

The mode of operation of glycol chillers is the same as that of standard air and water-cooled chillers.

Centrifugal chillers

Centrifugal chillers consist of the usual evaporator, compressor, condenser, and expansion device set-up but with additional rotating impellers which compress the refrigerant and transport it around the system.  They benefit medium to large-scale cooling operations (from 150 – tons of refrigeration).

Uses of Industrial Chillers

Water-cooled chillers and air-cooled chillers can be used for cooling operations in diverse industries. Below are some of the most common industrial processes:

• Food Processing – Industrial chillers are used extensively in food production and processing operations, which require a high degree of precision in temperature control. For instance, winery chillers are used for temperature control during the fermentation and storage of wine. Likewise, bakery chillers help with mixer cooling, potable water cooling, and cooling jacketed tanks of yeast, which are all critical bakery components.
• Metal Finishing – Temperature control is essential in metal finishing processes such as electroplating or electroless plating to remove the excess heat, as they typically require very high temperatures (several hundred degrees) to bond the metals. Some industries use metal-finishing chillers to cool the anodizing liquid in a heat exchanger or use glycol/water as a cooling medium to lower the temperature inside the tank.
• Injection Molding – Injection molding is a mass-production technique for creating plastic parts using an injection molding machine, thermoplastic pellets, and a mold. The process and melt must be maintained within precise temperature limits to prevent problems such as cracks, warping, and internal stresses in the final product. An injection molding chiller can supply a stream of supercooled fluid to cool the mold at an ideal rate to ensure optimum product quality.
• Space Cooling – In manufacturing plants that generate a lot of heat from heavy-duty process equipment, water-cooled chillers and air-cooled chillers can help prevent temperature extremes in offices and other working spaces. They also help save costs on purchasing separate HVAC systems for cooling.

Determining the Right Size of Chiller for Your Needs

An adequately sized chiller is critical for efficient and cost-effective processes, machinery, and space cooling. Cold Shot Chillers’ easy-to-use sizing tool can help you quickly determine your optimal chiller capacity, tonnage, and size.

Getting The Most Out of Your Chiller

The cost of installing and operating air-cooled and water-cooled chillers can be pretty high. Chiller units must be run as efficiently as possible to avoid additional charges during routine operations. Scheduling and conducting proper maintenance regularly for your system will prevent costly chiller repairs in the long term. Applicable chiller maintenance should include condenser coil inspection and cleaning, condenser water, and refrigerant maintenance. Real-time monitoring apps like Cold Shot Guardian® can be used to monitor equipment, predict system failures, and suggest pre-emptive interventions.

Trust Cold Shot Chillers for All Your Chiller Needs!

With over three decades of expertise in manufacturing air-cooled chillers and water-cooled chillers, Cold Shot Chillers provides cooling equipment and expertise for the most challenging process cooling needs.

The company is the world’s best 10 Ton Air Cooled Water Chiller supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.