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Several types of chillers differ in their design, operation and benefits. Before choosing a chiller for your equipment, consider the following types:
A water-cooled chiller pulls water into an evaporator through a primary return. The evaporator transfers heat from the water to a refrigerant, chilling the water before sending it through the primary supply to the system's water tank. A water pump then distributes chilled water to climate-controlled spaces.
As the chilled water flows through each space and reaches the air handler, it absorbs ambient heat. The second law of thermodynamics, which states that heat naturally flows from higher-temperature regions to lower-temperature regions, makes this heat transfer possible.
If this is an air conditioning application, after the heat transfers to the chilled water, the air inside the air handler cools down. A fan forces the air through ductwork and into each space, cooling the equipment's climate-controlled areas. When the warm water returns to the system's chiller, it cools again and repeats the process.
In order for the refrigerant to absorb more heat from the water in each cycle, it must transfer the heat it absorbed during the previous cycle. The evaporator moves the heated, low-pressure refrigerant to a motor-operated compressor. The compressor increases the temperature and pressure before sending the refrigerant to the condenser.
Inside the shell & tube condenser, the water surrounding the refrigerant pipes absorbs heat from the refrigerant. The water inside the condenser is pumped to a cooling tower where it releases its absorbed heat. As the refrigerant continues through its cycle, an expansion valve (much like a water spray bottle nozzle) reduces the refrigerant's temperature and pressure as it flows through on its way back to the evaporator where it restarts the process.
Water-cooled chillers provide the following benefits:
An air-cooled chiller operates similarly to a water-cooled chiller. The only difference between and Air Cooled & Water Cooled chiller is in the condenser section of the units. And air cooled chiller utilizes an air-over condenser coil to remove heat from the refrigerant while the water cooled chiller uses a water to refrigerant condenser coil. The way each chiller removes heat from the process remains the same.
The refrigerant then increases its temperature and pressure by moving through the compressor until it reaches the condenser where outside air circulates from a fan. The condenser absorbs the refrigerant's heat and expels it into the surrounding air. Finally, the refrigerant returns to the evaporator through the expansion valve to begin the process again.
Air-cooled chillers offer the following benefits:
A scroll chiller compresses refrigerant using a scroll compressor. It contains a stationary scroll plate and an orbiting scroll plate, which rotates around the stationary component and compresses the refrigerant to raise its temperature and pressure (Link: https://youtu.be/yNgqI4XPUZc). This process prepares the refrigerant for the rest of the cooling process.
Scroll chillers have the following benefits:
It's best to avoid choosing a tandem scroll compressor chiller unit. It's much better to choose a scroll compressor that applies a single compressor to each refrigeration circuit ' this eliminates the risk of burnouts damaging multiple compressors.
You can choose between industrial air-cooled scroll chillers, air-cooled portable scroll chillers and water-cooled portable scroll chillers for your applications.
When it comes to a scroll vs. a screw compressor, it's important to note that screw compressors handle larger capacities than scroll compressors. While scroll chiller tonnages vary between 2 and 140 tons (60HP maximum single compressor size), screw chillers vary between 30 and 400 or more tons. The main difference between screw and scroll chillers is that screw chillers use one or two rotating screws to apply force and compress refrigerant. Screw compressors are most commonly found in industrial process and petrochemical applications.
Some industrial machinery is susceptible to explosions, requiring industrial explosion-proof chillers to maintain safety. Explosion-proof chillers are manufactured with a reinforced, specialized design and contain features that protect their components from flammable materials. This design prevents potential explosions to protect employees, equipment and facilities.
For more information, please visit Screw Type Chiller Unit.
Few air-cooled chiller manufacturers have the expertise to provide reliable explosion-proof chillers. If your equipment operates in hazardous conditions, it's crucial to select an explosion-proof chiller from a reputable manufacturer that follows National Fire Protection Agency standards and codes.
Some industrial operating conditions require the leaving fluid temperature to remain below 35 degrees Fahrenheit. Low-temperature chillers ensure equipment operates efficiently for applications such as petrochemical processes and ice rink cooling that require low leaving fluid temperatures. Some units can run down to as low as -40 degrees F leaving fluid temperature. At these conditions, special heat transfer fluid is required.
An industrial glycol chiller features a reliable digital temperature controller. This controller makes it possible to maintain ideal temperatures for food and drink products. Wineries and breweries often use glycol chillers for this reason.
The main chiller components are the Compressor, Condenser, Evaporator, Expansion Valve, Power Panel, Controls unit and the Water Box. In this article we will learn how to locate these on the chiller and briefly what their purpose is.
YouTube video tutorial at the bottom of the page
Chillers can be found in most medium to large buildings and will produce the chilled water that is used to provide air conditioning. There are many different types of chillers but essentially they all have the same main components.
The compressor is the the prime mover, it creates a pressure difference to move the refrigerant around the system. There are various designs of refrigerant compressors, the most common being the centrifugal, screw, scroll and reciprocating type compressors. Each type has it's own pro's and con's. It is always located between the evaporator and the condenser. It's usually partly insulated and will have an electrical motor attached as the driving force, this will be either mounted internally or externally. Compressors can be extremely noisy, usually a constant deep droning sound with an overlaying high pitch, hearing protection should be worn when in close proximity to the chiller.
Centrifugal type compressorScrew type compressorReciprocating type compressorScroll type compressorThe condenser is located after the compressor and before the expansion valve. The purpose of the condenser is to remove heat from the refrigerant which was picked up in the evaporator. There are two main types of condensers, Air cooled and Water cooled.
Water cooled condensers will repetitively cycle 'Condenser water' between the cooling tower and the condenser, the hot refrigerant which enters the condenser from the compressor, will transfer its heat into this water which is transported up to the cooling tower and rejected from the building. The refrigerant and the water do not mix they are kept separated by a pipe wall, the water flows inside the pipe and the refrigerant flows on the outside.
Condensers on air cooled chillers work slightly differently, they do not use a cooling tower but instead blow air across the exposed condenser pipes with the refrigerant flowing this time on the inside of the tube.
The expansion valve is located between the condenser and the evaporator. It's purpose is to expand the refrigerant reducing its pressure and increase it's volume which will allow it to pick up the unwanted heat in the evaporator. There are many different types of expansion valve, the most common at the thermal expansion vale, the pilot operated thermal expansion valve, the electronic expansion valve and the fixed orifice expansion valve.
Electronic expansion valvePilot operated thermal expansion valveThermal expansion valveThe evaporator is located between the expansion valve and the compressor, its purpose is to collect the unwanted heat from the building and move this into the refrigerant so that it can be sent to the cooling tower and rejected. The water cools as the heat is extracted by the refrigerant, this 'chilled water' is then pumped around the building to provide air conditioning, This 'Chilled water' then returns to the evaporator bringing with it any unwanted heat from the building.
Evaporator on an air cooled chillerEvaporator on a water cooled chillerThe power unit is either mounted directly to the chiller or it can be seperated and mounted to the wall of the plant room with power cables running between them. The purpose of the power unit is to control the flow of electrical power to the chiller. These usually contain a starter, circuit breakers, speed controller and power monitoring equipment.
Electrical power unitThe controls unit is typically mounted on the chiller. It's purpose is to monitor the various aspects of the chillers performance and control these by making adjustments. The controls unit will generate alarms for the engineering teams and safely shut the system down to prevent damage to the unit. BMS connections are also usually present to allow remote control and monitoring.
Chiller controls unitWater boxes are mounted to the evaporators and also the condensers of water cooled chillers. The purpose of the water box is to direct flow as well as as to segregate the entrance and exit. Depending on the number of passes in the evaporator and condenser, water boxes may have 1-2 flanged entrance or exit holes or they can be completely capped and just redirect flow back into the next pass.
Chiller water box, open endedChiller water box, closed end
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