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Process Chiller-The Ultimate FAQ Guide By TopChiller

What is Process Chiller?

Process Chiller is a type of refrigeration unit or a cooling system that is used in a wide range of industrial processes.

It is used to cool down the products, the production process, and the production machinery.  A Process Chiller uses different kinds of refrigerants like glycol, water, air, and oil.

Its applications are very widespread, from food industries to huge automotive parts manufacturing industries.

Process Chiller comes in Air-cooled and Water-cooled designs and different models based on the different types of compressors.

What are the Major Components of a Process Chiller?

The number of major components may differ according to the design, model, and applications. However, below four are the major components found in every Process Chiller.

1. The Evaporator:

In the evaporator, the refrigerant absorbs all the excessive heat content from the system. This absorption of heat converts liquid refrigerant into a gaseous state.

2. The Condenser:

The major function of a condenser is to discard the excessive heat collected by the refrigerant in the refrigerator.

This heat extraction lowers the temperature and provides the desired chilling in a Process Chiller.

3. The Compressor:

A compressor is responsible for the increase in the pressure of the refrigerant. This change of pressure happens without compromising the gaseous state of the refrigerant.

4. The Control Unit:

This being the heart of the Process Chiller is made of a modern microprocessor that controls all the functions, programming, and other activities.

What are the Additional Components of a Process Chiller?

Following are the certain additional components that can be added for specific functions for particular applications.

1. Double Power System:

This is used when there are two refrigeration units in a Process Chiller. It is used to provide power to both refrigeration units individually.

2. Electrical Additions:

These are circuit breakers, power meters, voltage meters, resistant meters, etc.

3. Vibration Eliminator:

These are certain plastic, wood, or other pads that are used below the Process Chiller to overcome the vibrations.

What are the Characteristics of an Ideal Process Chiller?

1. An Efficient Compressor:

The most important characteristic that makes it ideal is the efficient compressor. There are many types of compressors like scroll, centrifugal, and screw type.

A good compressor is a key to the efficiency of the Process Chiller.

2. The Advanced Control Unit:

Advanced control unit based on the most innovative microprocessor is the second most important characteristic of an ideal Process Chiller.

As it controls all the components and operations, its efficiency can make a great impact on the process.

What are the Outstanding Advantages of a Process Chiller?

1. Uniform and Continues Cooling:

A Process Chiller can perform heat extraction continuously for a long time without any mistake. It will provide a uniform flow of chilling without any kind of fluctuations in the temperature controls.

2. High Product Quality:

The uniform and accurate temperature control make the production process highly efficient. This makes you produce any kind of product with the highest level of quality.

3. Economically Beneficial:

Because of its features, it saves a lot of time, energy, and resources for your industry, making the production processes economic.

How a Process Chiller Saves Energy, Time, and Cost of your Industrial Processes?

1. In Process Chiller, you don’t need to add water every time for every cycle. The water is recirculated in the system, hence saving a lot of the cost of refrigerant.
2. It makes your production process successful and products full of quality. This increases the production and ultimately you can save a lot of money.
3. The process of Process Chiller is fast and efficient. This uniform process does not cause any kind of problem or hurdle. This process is completed faster, saving your time and energy.
4. It provides a high level of heat extraction at lower power sources. This allows you to save a lot of electric energy.

How does a Process Chiller Work?

The working principle is simple and based on heat extraction by compression and refrigeration of the refrigerant used.

Stage 1: The refrigerant, either water or air is cooled to a particular temperature.

Stage 2: This refrigerant is sent to the compressor. Here it gets the suitable flow rate and pressure for further process.

Stage 3: After passing through the compressor, it enters the evaporator. Here it collects the excessive and unwanted heat and proceeds towards the compressor.

Stage 4: In the compressor, all the heat is discarded out of the system, and the desired cooling is achieved.

Stage 5: After the completion of heat extraction, refrigerant is sent back to the system and another cycle begins instantly.

What is the Importance of Process Chiller for your Industry?

The process of every machine is mechanical and involves the generation of heat during the process.

This excessive and unwanted heat is a threat to the process and regulation of temperature to a set-point becomes vital.

A Process Chiller is an efficient and accurate chiller that is the best choice to overcome this unwanted heat. As it has unlimited applications, it can be used in almost every process and every industry.

Process Chiller not only facilitates heat extraction but also keeps your machine safe and sound from the adverse effects of excessive heat.

What are the Applications of a Process Chiller?

1. Plastic and Polymer Industries:

It is used in processes like injection molding, blow molding, thermoforming, etc for the reduction of temperature.

Process Chiller in plastic industries is mostly used to control the temperature of plastic manufacturing machines and molds.

2. Food Industries:

All the processes in food industries like; chocolate manufacturing, baking of bread, soup making, juice making, etc are temperature-based.

In these processes, a Process Chiller is used to manage the temperature so that quality food can be made.

3. Pharmaceutical:

Process Chiller in pharmaceutical industries helps in the extraction of process heat that is generated from the exothermic chemical reaction of drug manufacturing.

What are the Different Types of the Process Chiller?

1. Central Process Chiller:

This is a heavy-duty one and can perform chilling up to 300 tons. This one is used on a high level to control the temperature of the whole area in which the process is taking place.

2. Glycol Process Chiller:

In this, glycol is used as the refrigerant to eliminate excessive heat. This one differs slightly from others, as it has glycol.

3. Centrifugal Process Chiller:

Centrifugal are the ones in which centrifugal type of compressor is used. The only difference is of the compressor, otherwise, the whole working principle is the same.

4. Screw Process Chiller:

In screw type, the compressor used is based on two or more rotating screws that regulate the pressure and flow rate of the refrigerant.

5. Scroll Process Chiller:

In these scroll type of compressor is used to provide chilling.

What is the Difference Between HVAC and a Process Chiller?

1. Refrigeration Unit:

The most basic difference between a Process Chiller and HVAC is the refrigeration unit or refrigeration circuit.

HVAC has a combined refrigeration circuit for water and refrigeration. On the other hand, a Process Chiller has separate circuits.

2. The Applications:

HVAC is used for environmental cooling in a large area like rooms, halls, etc. while Process Chiller is used for the chilling in industrial processes.

3. Additional Components:

In the case of an HVAC system, usually, no additional component can be added to it for any specific function.

While in the case of Process Chiller you can add different components like monitor, computer, sensors, etc for particular functions.

What is the Difference Between Water-Cooled Process Chiller and Air-Cooled Process Chiller?

1. Kind of Refrigerant Used:

The first and most important difference is the use of refrigerants. A Water-cooled uses water as a refrigerant and an Air-cooled Process Chiller uses ambient air as the refrigerant for cooling.

2. The Working Principle:

With the change of refrigerants, the mechanism of working changes slightly. In Water-cooled the refrigerant is circulated within the circuit of the Process Chiller.

On the other hand, in an Air-Cooled ambient air from the surrounding is sucked and used as the refrigerant.

3. Applications:

Both types have specific applications. In some cases, both can be used for similar purposes, but mostly these are applied to separate applications.

Like a Water-Cooled is preferred for the industrial process while an Air-Cooled is used for cooling of wide areas in which processes are taking place.

What Type of Coolant is used in a Process Chiller?

Water, Air, Glycol, and Oil are four major coolants, that are generally used in them. Glycol due to its anti-freezing and lubrication properties used for very low-temperature applications.

It is used in Glycol Process Chiller. Oil coolant is used in metal cutting and manufacturing properties where hydraulic oil is chilled and provided to the machines to keep the process heat low.

The ambient air from the environment is sucked to the Process Chiller and chilled and provided to the process to lower the temperature.

Water is chilled in the system and circulated over and over again to control the temperature.

What Type of Factors should be Considered while Selecting a Process Chiller for your Industry?

1. Type of Process Chiller:

It is the most vital factor that should be considered while making the selection for your industry. Every type has its merit and applications.

Like; a glycol Process Chiller is used for the applications where very low temperature chilling is needed.

2. Type of Compressor:

You should decide which type of compressor is suitable for your processes. Either it is scroll type or screw type. It can be centrifugal or another type that fits best to your requirements.

3. Increase in Compressor units:

You should select a Process Chiller in which you can add more than one compressor while needed in some cases.

What Type of Compressors Are Used in a Process Chiller?

1. Rotating Screw Compressor:

This type of compressor is made of cylindrical screws that rotate and creates the required flow rate and pressure. Generally, this type has 2 to 3 rotating screws.

2. Centrifugal Type Compressor:

Centrifugal type compressors use centrifugal force to create the required pressure, flow rate, and speed of the refrigerant.

3. Scroll Type Compressor:

This type of compressor is made of a set of two compressors. One compressor scroll rotates while the other remains stationary.

4. Centrifugal Frictionless Compressor:

This one is the same as the centrifugal compressor, except it is specifically made to produce less amount of friction while moving and performing.

What is Portable Process Chiller?

This one is a unique type due to its unique and innovative features. It has the most vital advantage over other types of Process Chiller that is its portability.

It can be easily handled and relocated where is needed. It needs low footprints and can be used in industries that have confined spaces and areas.

Its lightweight feature allows you to operate it with ease. A Portable Process Chiller is used in industrial processes where random chilling is needed.

Portable Process Chiller is used in metal forming, automotive, food industries, breweries, etc.

What is the Cost of a Process Chiller?

Process Chiller cost varies a lot. It can be different for different kinds of compressors or different kinds of designs and models.

Usually a small size single compressor Water-cooled and Air-Cooled costs around 3200-4000 USD.

While a double compressor Water-cooled or Air-cooled cost around 4000-7000 USD. A 100 to 150-ton Process Chiller cost in the range of 22000-30000 USD.

How to Install your Process Chiller?

The ease of installation is one of the advantages. It can be installed properly by the below-given guidelines.

Step One: The foremost thing for installation is the selection of the proper location. Select the suitable location and make it vibration-free by using damping pads, vibration-resistant materials, etc.

Step Two: Secondly, install the Process Chiller by following the instruction and standard guidelines from the manufacturer or expert.

Step Three: Check every part in detail and clean it before starting it.

Step Four: Install all the power wires, components and start the Process Chiller.

Step Five: Make a trial run by running it for 15 to 30 minutes on your specific parameters.

Step Six: When everything looks good, apply it to the temperature control of the process.

What Type of Factors should be Considered for the Surrounding of a Process Chiller?

When it comes to the surrounding considerations, the most important factors to be considered are moisture content and dust.

The higher moister content affects negatively the performance of the Process Chiller and reduces it.

In order to avoid these types of mistakes, always install it where there is less amount of moister in the environment.

The excessive amount of dust in the surrounding can accumulate in the internal components of the Process Chiller over time and may cause a huge failure in it. The surrounding of it should be free from dust.

What Type of Quality Certificates you Should Consider While Choosing Process Chiller?

Quality certification is the standard certification for the quality provided by the local, national or international organizations.

For a Process Chiller following certifications, you should consider while making your selection.

1. DIN EN ISO 9001 Quality Management Certification.
2. DIN EN ISO 4001 Environmental Management System Certification.
3. Air Conditioning, Heating and Refrigeration Institute (AHRI) Standard 550/590.

What Type of Safety Certifications Should Be Consider While Choosing Process Chiller for your Industry?

The safety standards are generally provided by the manufacturer. Mostly these are provided by the local agencies on the national level.

Following are some basic certifications you should consider while buying a Process Chiller for your Industry.

1. DIN EN ISO 4001 Environmental Management System Certification.
2. Accredited Disposal Operations for Cooling Equipment (ADOCE) QSK.
3. US EPA Safety Standard for Environmental Protection.
4. Local agency certification for occupation health and safety.

What are the Operational Mistakes that should be Avoided while Operating your Process Chiller?

1. The most common operational mistake is the improper filling of the refrigerant tank. Always keep it to the optimum level. Low or high levels of refrigerants can damage the tank and Process Chiller.
2. The Air-cooled should not be operated in an environment that contains a high amount of dust.
3. Improper flow rate and pump pressure are reasons for big failure in the Process Chiller. Always fix them to the optimum values for your process.
4. Always use vibration-free ground. Make your ground vibration less with proper applications of, plastic pads, clothes, etc.

What are the Safety Precautions for a Process Chiller?

1. As there is very low-temperature exposure, the workers should not touch the Process Chiller with bare hands.
2. Proper PPE should be worn while working with it. PPEs like gloves, goggles, shoes, etc should be made compulsory for all workers.
3. Proper precautions should be taken for electric safety. As it involves water circulation and moister, it may cause electric tripping of shock. Always operate it with safety gloves.

How to Customize your Process Chiller?

Customization can be made through the customization of the following components:

1. Refrigerant Tanks and Heat Exchanger:

Through these parts, you can customize the refrigerant level of the tank, tank dimensions, and capacity.

You can install a meter to monitor fluid levels and an alarm system that can notify your while refrigerant level is very high or very low.

2. Control Unit:

You can customize the level and ranges of temperatures. You can connect it to the computer and transfer data along with making changes in the parameters.

You can customize parameters like flow rate, speed, and pump pressure by using Control Unit.

How to Train your Personals for Proper Operating of Process Chiller?

1. The most important thing for the training of a person is the complete knowledge of your Process Chiller. For this, you may use manual, guides, and information provided by the manufactures.
2. Request manufacturer to conduct a training session for the personals of your industry and train them properly.
3. The most common type of training used is the training of new personal is by training him or her under experts of the industry already working on Process Chiller.

New and juniors should spend time under their supervisor and learn everything.

How to Maintain your Process Chiller for Longer Life?

Any type of unpredictable fault or failure can create disaster for your industry. Proper maintenance of your Process Chiller can make it long-lasting.

Following tips can help you to keep it well-maintained.

1. The most important thing in this regard is the inspection. Inspection should be done thoroughly and on regular basis. This inspection is a visual inspection with the naked eye.
2. Always keep it leakage-free. All the leakages can be found while inspection or from any kind of unusual performance incident.
3. Always keep flow rate, pump pressure, temperature, and power voltages accurate with the specification of your Process Chiller. Improper parameters can cause permanent damage.
4. Use clean and suitable refrigerant. Refrigerant health and levels should be checked daily.

After What Period Maintenance of Process Chiller Becomes necessary?

The maintenance can be done on regular basis or while in case of any failure. Regular maintenance is preferred to keep your Process Chiller up to date and healthy.

Regular-based maintenance includes mainly inspection. This inspection is a visual inspection done thoroughly.

A detailed inspection of the components should be done on weekly basis. This includes a detailed inspection of every component, its cleaning, inspection, and repairs for corrosion and leakages.

How to Keep your Process Chiller Safe from Corrosion?

1. The use of contaminated water is the most common cause of internal corrosion. Use clean and safe water for the refrigerant.
2. Do not clean your Process Chiller with improper chemicals or cleaners.
3. Inspect regularly for any kind of corrosion and get rid of it as soon as possible.
4. Leakages in pipes can cause water to trip to other parts and cause corrosion. Always keep pipes free from every kind of leakage.
5. Excessive moister in the surrounding also causes corrosion. Install your Process Chiller where the surrounding is dry.

How to Optimize Performance of your Process Chiller?

1. Regular inspection should be done and performance records should be kept daily. These records and inspections help you to find any kind of mistake.
2. Always keep it clean and leakage-free.
3. Use clean and safe water for the refrigerant.
4. Keep the parameters to their optimum values.
5. Do not overload the Process Chiller.
6. You can use pre-cooled water to optimize the cooling performance.
7. It should be operated by skilled personals.

What Is the Average Life of a Process Chiller?

The average lifetime of it can be too short or long-lasting. The lifespan of a Process Chiller highly depends upon how you keep it maintained and optimized.

A good maintenance practice can make it last longer. On average a screw compressor Process Chiller has an average lifetime of 18-20 years.

While scroll compressor type has an average life of around 12-18 years. Air-cooled Process Chiller is the most durable and can last up to 22-25 years.

How to Overcome Scaling and Fouling Problems in a Process Chiller?

When it is running regularly for a long time, the dust and other types of contaminations accumulate in the edges, bottom, and sides of internal components.

This type of problem is called scaling and fouling. Scaling can be catastrophic for a Process Chiller. First thing is to use clean water. Water should be used according to the standards.

Secondly, regularly clean the components. Especially the refrigerant tank, evaporator, compressor, and pipe assembly.

What are the Practices that Reduces the Efficiency of Process Chiller?

1. Improper operational protocols and practices.
2. Unskilled personals operating Process Chiller.
3. Delayed maintenance and inspection of the components.
4. Fault in the control unit, or improper programming of the parameters.
5. Overfilling of the refrigerant tank.
6. Too small diameter pipes used for pipe assembly.

How can you Increase the Production using the Process Chiller?

It is made to operate continuously for a long period. It can be operated 24/7 while retaining its full performance efficiency.

This efficient and continuous cycle allows you to conduct nonstop production for a long time and increase your production.

Secondly, due to its accuracy and efficiency of the temperature control, it can make your process faster than previous. Hence, increasing the rate of production of your industry.

What are the Troubleshooting Guidelines for your Process Chiller?

1. Leaking Refrigerant or Tripping Refrigerant from Tank:

It can be because of overfilling of the refrigerant tank by water. It also happens when there is some kind of leakage in the tank.

Prolonged corrosion in the bottom of the tank may also cause holes and tripping. Inspect the tank and repair it. Always keep refrigerant to the standard levels.

2. Pipe Assembly Clogging:

It happens because of the deposition of dust and other particles in the pipes. Regular cleaning of pipes can be a great solution to this kind of problem.