The global demand for industrial process cooling remains at a steady high. Reliability and minimal downtime are key to consistent and profitable industrial and commercial processes.
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This article will consider the best methods to attain the optimal temperatures required to operate production processes in the metal finishing, medical, brewing, and agricultural industries.
So, how does a chiller work? The process works in a loop, but we will start where the cooling medium interfaces with your process equipment.
The system's coolant absorbs thermal energy from your process, typically causing a phase change into a gas. The gaseous refrigerant is then circulated to a condenser which expels the heat through evaporative condensation or a cooling tower. This heat exchange condenses the cooling medium back into a cooler liquid that is sent back to process heating source to begin the cycle again.
The type of coolant utilized in a chiller is based on process needs and cost considerations. The most popular coolants used are either water or a mixture of water and another substance with suitable heat conduction properties ' like glycol compounds.
The use of water as chiller fluid is an economical one as in most cases the water can be easily sourced with minimal costs. Alternatively, purified (deionized water, reverse osmosis) water can be used in a water-based chiller to achieve a higher cooling efficiency.
Glycol based coolants are either composed of ethylene glycol or propylene glycol. While these two variants have similar physical properties, they should never be mixed. The major advantages which glycol coolants confer are an improved resistance to corrosion as well as antifreeze properties.
Using a glycol-water mix as a chiller coolant has various benefits over the use of plain water as a chiller fluid. These advantages are due to its unique physical properties which include a lower freezing point than water.
For water free of impurities, the freezing point is 32°F which is much higher compared to pure ethylene glycol which changes to its solid-state at 8.9°F. When a glycol-water mixture is altered, the freezing point of the coolant also changes. To cite an example, 10% ethylene glycol will freeze at 25.9°F while a 60% glycol solution will freeze at -63°F.
From the above analysis, it's clear that glycol has refrigerant properties that are more suited for use in chillers expected to function in low-temperature environments. In these thermal conditions, a water coolant will freeze and obstruct chiller circulation while diminishing overall efficiency.
By contrast, utilizing a glycol-based chiller will take advantage of its antifreeze properties ensuring the coolant remains in a desirable fluid state.
Both glycol and water chillers can be used to satisfactorily dissipate the heat being generated by your production process. The fundamental difference between both chiller types lies in variations in their freezing points as well as their heat conduction capacities.
Pure glycol or a mix of glycol and water has a much lower freezing point than that of pure water. By implication, glycol-based chillers are better suited to low-temp environments. Conversely, water has a better ability to retain and conduct heat from an associated process than a glycol mixture can. As a result, the efficiency of heat transfer for a water chiller will be higher than that of a glycol chiller.
Overall, operators need to consider the ambient temperatures for the siting environment before choosing a chiller type.
A glycol chiller plant is composed of a refrigeration component and tubing containing a glycol-water mixture as coolant. Chilled fluid from the refrigeration unit is channeled through the piping associated with a thermal exchanger surrounding a heated process. After absorbing heat from the associated process, the warmed coolant is returned to the refrigeration unit for cooling after which the process is repeated.
For many chiller types, ethylene glycol is mixed with water at a ratio of 60/40. This higher percentage of glycol boosts the mixture's antifreeze properties significantly. This is useful in cases where rapid cooling is required. In these situations, a process can be cooled to very low temperatures without freezing the coolant within its piping.
A conventional water chiller works on the principles of heat transmission between various mediums both fluid and solid. These cooling systems work either by heat absorption or vapor compression. The basic components of a water chiller system include a refrigeration unit and a piping system that circulated chilled coolant.
For the last thirty years, Cold Shot Chillers has been manufacturing premium industrial chillers. With an impressive line of water- and air-cooled chiller units, your industrial cooling needs are sure to be met.
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A glycol chiller is an industrial cooling system that utilizes a mixture of glycol and water to achieve temperatures significantly below the freezing point of water. Glycol types used are either ethylene glycol or propylene glycol. The antifreeze properties of glycol help maintain the coolant in a liquid state at these low temperatures. Typically, the mixture consists of 60% glycol and 40% water in most chiller systems.
Increasing the concentration of glycol in the mixture enhances its antifreeze properties, which is particularly beneficial for achieving rapid cooling. This improvement in heat transfer efficiency is crucial for maintaining precise temperatures, which is often essential for the success of specific production processes.
Glycol-based industrial chillers circulate a glycol-water coolant through heat exchanger systems, where the coolant absorbs heat from industrial applications. The heated coolant is then processed through the chiller, where it is cooled down before being recirculated to absorb additional heat from various industrial processes. Glycol chillers are widely utilized due to their reliable performance in preserving frozen foods and supporting food production processes.
Glycol, an organic alcohol compound, is commonly known for its antifreeze properties. Its key feature is its superior ability to transfer heat, which makes it particularly effective for cooling and chilling applications. Glycol mixtures in industrial chillers are adept at rapidly removing substantial amounts of heat, which is essential for maintaining reaction stability during chemical processes. Due to their rapid heat transfer capabilities, glycol chillers are crucial in scenarios where quick temperature control is necessary.
There are two primary types of glycol chillers: ethylene glycol and propylene glycol. Despite both being glycol compounds, they should not be mixed due to their distinct properties related to fluid characteristics, toxicity, and heat transfer efficiency. Mixing them could lead to system malfunctions or inefficiencies.
Ethylene glycol serves as an antifreeze in industrial cooling systems, offering protection against freezing and acting as a rust inhibitor. The concentration of ethylene glycol in a water mixture is based on the lowest expected outdoor temperatures and the specific temperature requirements of the application. With a high flashpoint of 240°F, ethylene glycol is suitable for various industrial processes. However, its toxicity prevents its use in food processing applications.
Propylene glycol, known for its low toxicity, is a food-grade antifreeze often used in environments where safety is a priority. It is more environmentally friendly than ethylene glycol and readily biodegradable. Propylene glycol chillers are suitable for use in the food industry and refrigeration systems where direct contact with the substance might occur. Despite being a synthetic compound, propylene glycol mixes well with water. The Food and Drug Administration has deemed it safe for use in maintaining moisture in medicines, cosmetics, and food products.
Portable glycol chillers are small, compact, and self contained, with all of their components included in the unit. They have a capacity of 1 to 40 tons of cooling and are ideal for small loads or where special fluids, flows, pressure, or temperature are necessary. Due to the compact size of portable glycol industrial chillers, they can be used for test applications or positioned for temporary use.
A modular glycol industrial chiller system consists of multiple chillers connected to create a comprehensive cooling solution. This setup is highly adaptable, allowing for the addition of more chillers as demand grows. The system is designed to ensure uninterrupted cooling, even during maintenance periods.
Modular glycol industrial chillers feature oversized processing pumps and large glycol reservoirs with extra ports for system expansion. As new modules are added, the chilling capacity of the system increases significantly. This design is particularly advantageous for industries that cannot afford downtime, as it allows for backup chillers to take over if one unit fails.
One notable advantage of modular glycol industrial chiller systems is their ability to operate partially during periods of low heat load, which saves costs and enhances control. While the term "modular glycol industrial chiller" encompasses a broad range of designs, these systems are available in various configurations to suit different industrial needs.
When selecting a glycol industrial chiller, several crucial factors must be taken into account. Their distinctive performance characteristics and high efficiency have made them a preferred choice for cooling critical production processes.
Process cooling systems are crucial for industrial applications, where heat accumulates during material blending, mixing, or chemical reactions. A cooling system helps maintain stable temperatures, allowing other manufacturing processes to proceed efficiently.
One significant advantage of a glycol industrial chiller is its precise temperature control. Glycol's antifreeze properties prevent pipes from freezing, with both ethylene and propylene glycol being suitable for cooling systems but not interchangeable due to their differing properties.
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Glycol is an effective additive in cooling systems because of its compatibility with water. While the freezing point of water is 32°F, which can hinder or damage a cooling system, glycol lowers the freezing point to '60°F, enhancing the system's operational temperature range.
The lower temperatures achievable with glycol allow a cooling system to remain effective longer than with water alone. These benefits have made glycol a crucial component in modern cooling systems.
Glycol industrial chillers operate as closed-loop systems, where the coolant continuously circulates without exposure to the environment. This closed system keeps the glycol coolant clean and uncontaminated, preventing fouling or scaling and eliminating water loss from evaporation. As a result, closed-loop systems are exceptionally efficient and durable.
Closed-loop systems also require less pumping power, which helps lower installation costs. The glycol coolant is circulated through tubing connected to the input and output sections of the chiller.
The heat exchanger allows the transfer of heat between the glycol water coolant and the refrigerant gas. It uses the flowing glycol to collect heat from the refrigerant and move the heat away from the area being cooled. The heat exchanger and glycol pipes are small since glycol is capable of removing more heat.
The low viscosity of glycol is why high-powered pumps are not required for operating a glycol chiller. Small pumps are essential for circulating the glycol and maintaining a consistent cool temperature. Depending on the chiller unit's design and the application's needs, the cooling system may require multiple pumps.
The compressor takes low pressure and temperature refrigerant and compresses it into high pressure and temperature. There are several different types of compressors that a glycol industrial chiller can use with ones designed to fit the needs of the chiller and the applications for which it was developed. The different types of compressors include positive displacement, screw, diaphragm, screw, diaphragm, rotary, and centrifugal.
The condenser absorbs the excess heat from the chiller's compressor, which it has received from the evaporator. This heat is transferred to water circulating around the condenser, which then releases the heat into the surrounding air.
Water plays a crucial role in glycol systems, as glycol must be mixed with water for the system to function effectively. Key factors in the process include the type and quantity of water used, which can vary. Although city water can be used in a glycol industrial chiller, it is generally not recommended.
Manufacturers recommend the use of distilled or reverse osmosis water to mix with glycol. Deionized water can initiate the chiller process but should be replaced since it can attack metals in the chiller and damage other components. Reverse osmosis or hyperfiltration removes contaminants through the use of pressure that forces water through a semipermeable membrane. The process can be seen below.
Several factors must be considered when determining the ratio of water to glycol. The primary consideration is the location of the chiller and the ambient temperature of the environment. Indoor chillers, which are less likely to experience freezing conditions, typically require less glycol.
For systems operating at very low temperatures, such as below 20°F, the glycol-to-water mixture should be adjusted similarly to that of an outdoor chiller system, corresponding to the saturated suction temperature in the evaporator or 10°F below the chiller's setpoint temperature.
Determining the correct ratio of water to glycol depends on the coldest temperature the glycol system will encounter during operation. It is crucial to get this ratio right, as excessive glycol can lead to inefficiency, while insufficient glycol can cause the system to freeze or burst pipes.
Once the appropriate type of water and glycol are selected, the chart below provides an approximate percentage of water to glycol for both outdoor and indoor glycol chiller applications.
Glycol Chiller Applications Applications Percent of Water to Glycol Freeze Protection Burst Protection Indoor 30% to 70% 5°F or -15°C -20°F / -29°C Outdoor 50% to 50% -35°F or -37°C -60°F / -60°CMaintaining clean water and proper glycol content are critical factors in regard to the life of the cooling system as well as an important part of reducing downtime. To keep the water and glycol free of suspended solids, it is important to have a filtration system as part of the chiller.
Automatic self-cleaning screen filters act as a barrier to suspended solids and are energy-efficient, although they can result in some coolant loss.
A commonly used filtration method for glycol chillers is the side stream filter. This system removes a portion of the fluid flow to filter out solids and contaminants before returning the cleaned fluids to the system. Side stream filtration is effective in controlling suspended solids and helps maintain the integrity of the glycol and water mixture.
Glycol industrial chillers are highly regarded for their efficiency in cooling systems, thanks to the precision control they offer and the low temperatures they can achieve. They are commonly used in beverage production, where maintaining specific cooling levels is crucial for ensuring the quality of the final product.
Maintaining products at a consistently low temperature can be costly and necessitate frequent monitoring. The introduction of glycol systems in various sizes has streamlined the process, making it more affordable to produce high-quality products without the need for constant oversight of the cooling process.
A common concern with refrigeration systems is the risk of leaks that can lead to temperature increases and potential crop damage. This issue is mitigated with glycol chillers, as glycol contains inhibitors that make the system resistant to corrosion, scaling, and rust, thereby reducing the likelihood of leaks and damage to pipes.
Propylene or ethylene glycol acts as an anti-freeze, preventing freezing inside the coils. The glycol and water mixture also helps protect the chiller from the buildup of algae and bacteria.
Another safety feature of glycol chillers is their low maintenance requirements. These chillers can store and keep products cool for extended periods without the need for expensive upkeep. They are designed to last for years, delivering exceptional performance with minimal maintenance needs.
Glycol industrial chiller pipes are capable of running longer distances, servicing multiple processing locations from a single cooler and pump package. These pipes come in various types, with PVC80 being a common choice. Proper installation is crucial, and using a reverse return method helps balance the flow across the equipment by ensuring that the cooling medium travels the same distance to and from the chiller. The size of the piping is determined by the flow requirements of the equipment, considering factors like pressure drop and velocity.
The economizer feature in glycol industrial chillers leverages cold ambient air for cooling when the temperature is suitable. A control switch deactivates the compressor and utilizes the chilled environmental air to meet the thermostat's setpoint. This feature enhances efficiency and reduces operating costs by integrating ambient air into the cooling process.
Glycol industrial chillers can operate at temperatures well below the freezing point of water, with control over these temperatures achieved by adjusting the glycol mixture percentages. For example, a 10% ethylene glycol mixture freezes at 26°F, whereas a 60% mixture freezes at -60°F. Glycol's antifreeze properties ensure that the coolant remains in a fluid state, even at extremely low temperatures.
Opting for a glycol industrial chiller can be significantly more cost-effective compared to multiple self-contained refrigeration units. A single glycol chiller unit, which includes a chiller compressor to cool the glycol and water, often costs less than half of what it would cost to purchase several separate refrigeration units.
Over the years, cooling systems have evolved significantly, moving away from outdated and harmful methods. The chiller manufacturing industry has become more environmentally conscious, developing cooling solutions that comply with environmental agency regulations.
These advancements in cooling technology have expanded their use across various industries and provided solutions for applications that previously lacked effective cooling options. A key aspect of this progress is the incorporation of glycol as an additive in cooling systems, which has enhanced their efficiency and versatility.
With increasing environmental safety restrictions, grocery stores need chilling units that meet eco-requirements while providing long-lasting and durable solutions. Propylene glycol industrial chillers, which are food grade, are ideal for frozen food chiller cases. They are specifically engineered to efficiently remove heat while being robust enough to withstand constant use.
Maintaining the freshness of fruits and vegetables is crucial in the produce packing industry. Failures, downtimes, and maintenance delays can ruin a shipment of products. Like grocery stores, cooling units must comply with food grade requirements while being robust enough for continuous use. Propylene glycol industrial chillers are engineered to meet the stringent demands of the produce shipping industry, making them an ideal choice for ensuring reliable and effective cooling.
One of the areas where glycol industrial chillers are used the most is the brewing industry, which requires precisely controlled temperatures and conditions. The maintenance of temperature has to be consistent since any fluctuations can have extremely negative effects on the quality of the final product. It is for these reasons that propylene glycol industrial chillers help to precisely regulate and maintain container temperatures.
Engineering an outdoor ice rink in a warm climate presents unique challenges. However, glycol chillers, which can cool below the freezing point of water, make it feasible. In such installations, glycol is pumped through mats placed beneath the ice rink surface. Water sprayed over these mats then freezes upon contact, allowing the rink to maintain ice even in warmer temperatures.
Similar to breweries, the quality of dairy products heavily depends on an effective cooling system, as inadequate or unsuitable systems can lead to bacterial growth. Consistent temperature control throughout the dairy manufacturing process is essential. Milk is pumped directly from cows into cooling units, which store it until further processing.
Maintaining a stable temperature at every stage of the process is crucial to prevent spoilage and bacterial growth in raw milk.
The few examples of glycol chiller applications provided are just a fraction of their extensive uses. Any industry where heat is a factor in the process relies on glycol chillers to effectively remove and dissipate heat.
There are specific actions and considerations to avoid in order to keep a glycol chiller operating at peak performance. Failing to follow these guidelines can result in damage or complete system failure. Glycol chiller manufacturers provide clients with essential information during installation to ensure the system performs optimally.
While automotive antifreeze contains similar chemicals to glycol coolants used in chillers, it is formulated differently. Using automotive antifreeze can lead to reduced flow rates, pressure issues, and a significant decrease in heat transfer efficiency.
Inhibited glycol contains additives that protect against corrosion, scale, and rust, unlike uninhibited glycol. For effective protection, glycol must be used in concentrations of 25% or higher to ensure that the inhibitors are present in sufficient quantities.
Manufacturers strongly advise against mixing ethylene and propylene glycol or different brands of glycol. The incompatibility of various formulations can result in clogged filters, strainers, and pumps, as well as problems with transfer properties.
Different states, counties, and cities have varying regulations regarding the use of glycol and antifreeze to protect water tables, drainage systems, and fluid disposal. It is crucial to check with local authorities before installing a glycol chiller to ensure compliance with municipal regulations.
The ratio of glycol to water must be regularly checked and tested to maintain the correct percentages and prevent corrosion issues.
Glycol chillers perform best when using distilled or reverse osmosis purified water, as city water often contains contaminants that can interfere with the glycol-water mixture. Other pure water options include demineralized water, which eliminates the unpredictability associated with municipal water.
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