In water chillers, liquid is kept separate from the refrigerant by sealed tubes or coils. The liquid, in this case water, is passed through a series of sealed tubes containing a compressed refrigerant. As the refrigerant comes in contact with warm water, a heat exchange takes place. The heat from the warmer water is passed through the metal sealing tubes (holding the refrigerant). The gas is then sucked off by a compressor. The refrigerant again flows over the chilled water coils absorbing more heat and completing the cycle. The heat exchanger is a sealed chamber that contains both gas refrigerant and water coils.
Why use a water chiller?
Reason 1 - Protect your equipment: The most compelling reason for a water chiller is expensive equipment protection. A chiller keeps equipment from running too hot. It provides insurance against heat related equipment failures.
Reason 2 - Production speed: production speed can increase as long as you maintain proper cooling temperature in your equipment. A chiller will reduce the number of rejected parts due to excess heat. A water tower may provide adequate cooling during fall and winter, but fail (go out of range) during the summer. A water chiller will immediately eliminate this problem.
Reason 3- Temperature consistency: Does your company depend on the flow of city water to provide enough cooling? Water chillers take care of this problem. A properly sized water chiller will maintain a constant source of properly chilled water.
Reason 4 - Cost of city water: What is the cost of that water in your city? What are your sewage costs? What about water shortages? In Southern California there is a growing recognition of the cost of using city water to cool process equipment. A water chiller pays for itself. Then it saves you money for years to come.
What type of water chiller should I use?
Industrial water chillers combine the properties of both cooling towers and air-cooled heat exchangers. Externally they appear similar to a cooling tower. However, an industrial water chiller has some of the cooling tower replaced by a tube coil. Water is pumped to the top of the water chiller and distributed to a cooling tower. Water is cooled by passing air through the cooler (absorbing heat from the fluid) and as well as using the tube coil. As the name suggests, industrial water chillers are used where fluid that cannot be exposed to the atmosphere must be cooled.
The selection of a cooling tower, water chiller, or air-cooled heat exchanger, depends on the capacity of the system and the design ambient wet and dry bulb temperatures. Dykier Engineering will determine these properties for you and recommend a perfectly sized system for your needs.
In some cases we may suggest an air-cooled heat exchanger for your system. Air-cooled heat exchangers offer no risk and no requirement for water treatment. They have some significant disadvantages when compared to water chillers. In climates with low dry bulb temperatures or high wet bulb temperatures, air-cooled heat exchangers can work well. The Pacific Southwest (California, Arizona, and Nevada) have a good climate for heat exchangers. Typically air-cooled heat exchangers occupy twice the area of a water chiller.
Large industrial water chillers are commonly located in mechanical equipment rooms. They are generally located close to the process equipment they are cooling. Some industrial water chillers may be located directly beside the process, depending on the size of the chiller and compressor. Some may even be placed completely outdoors.
Dykier Engineering will work with you to determine which will best fit your requirements.