How does an industrial chiller work?

Ⅰ. Working Principle of Industrial Chillers

The basic function of an industrial chiller is to take the heat from the process fluid and throw it out into the atmosphere. The refrigeration cycle has four major steps: evaporation, compression, condensation, and expansion. As an initial step, low-temperature and low-pressure refrigerants are introduced inside an evaporator, where they gain energy from the process fluid being cooled by releasing their own energy; hence, vaporization occurs. The gaseous refrigerant then flows to a compressor, where it is converted to high temperature and high pressure as a gas.

The next stage gives way for this newly heated and pressurized refrigerant gas to enter a condenser in where it gives off heat, thereby cooling down into liquid form. Finally, before re-entering the evaporator at reduced pressure as well as temperature to start once more with another set of cycles of refrigeration, this liquid refrigerant passes through an expansion valve, which reduces its pressure as well as temperature too.

II. Core Components of Industrial Chillers

The efficient operation of industrial water coolers relies on their precisely designed core components. These components not only determine the equipment’s performance but also impact its reliability and maintenance costs. Below are several key components of industrial water coolers and their functions.

1. Evaporator

The evaporator is the component from which the refrigeration cycle begins by getting enough heat from the process fluid to vaporize the refrigerant. The design and materials used account directly for cooling efficiency. Common evaporator types include shell-and-tube evaporators and plate evaporators. Shell-and-tube evaporators have simple construction and easy maintenance, so they may be suggested for medium-sized industrial water coolers. Higher heat exchange efficiency is attained with plate evaporators, but their structure is relatively complex, and the cost of maintaining them is also high. The appropriateness of a type that best suits a particular industrial application within budget constraints defines its choice.

2. Compressor

The compressor serves as the power core of industrial water coolers, driving the refrigerant cycle. Its performance directly impacts the efficiency and energy consumption of the refrigeration cycle. Common compressor types include screw compressors, piston compressors, and centrifugal compressors.

• Screw compressors offer compact design and smooth operation, making them suitable for medium to large industrial water coolers.

• Piston compressors provide high compression efficiency but feature relatively complex structures and higher maintenance costs.

Centrifugal compressors work well in large industrial water chillers. They are efficient and quiet. When choosing a compressor, you need to think about how much cooling you need, the size of the equipment, and how much it costs to run.

3. Condenser

The condenser cools high-temperature, high-pressure refrigerant gas into liquid while releasing heat into the environment. Its performance directly impacts the efficiency and energy consumption of the refrigeration cycle. Common condenser types include air-cooled and water-cooled condensers.

Air-cooled condensers use air as a cooling medium. They have simple construction, easy maintenance, and relatively lower cooling efficiency, hence mostly used for small industrial chillers. Water-cooled condensers apply water as a cooling medium in their operation, thus providing high cooling efficiency but requiring a stable supply of water. This makes them best for large industrial water chillers. The type of condenser to be selected depends on the specific industrial application and the condition of cooling.

4. Expansion Valves

The expansion valve is a critical control component in the refrigeration cycle. It regulates refrigerant flow and pressure to ensure the refrigerant reaches the appropriate state before entering the evaporator. The performance of the expansion valve directly impacts the efficiency and stability of the refrigeration cycle.

Common expansion valve types include manual and automatic expansion valves. Manual expansion valves require manual adjustment, which is relatively cumbersome but lower in cost. Automatic expansion valves can automatically adjust based on the actual demands of the refrigeration cycle, offering convenient operation but at a higher cost. Selecting the appropriate expansion valve type requires consideration of specific industrial applications and operational requirements.

III. 産業用チラーの種類

Industrial water chillers come in multiple types, each optimized for distinct application scenarios. Understanding different industrial water chiller types and their uses helps users better select equipment suited to their needs.

1. Air-Cooled Industrial Chillers

Air-cooled industrial chillers utilize air as the cooling medium, making them suitable for locations with limited space or lacking cooling water sources. This type features a simple structure, easy installation, and lower maintenance costs. However, due to air’s relatively low cooling efficiency, the refrigeration capacity of air-cooled chillers is somewhat limited. Consequently, they are typically used in small-scale industrial applications or settings with modest cooling demands. For instance, in small electronics manufacturing workshops or laboratories, air-cooled chillers can effectively cool equipment to ensure its proper operation.

2. Water-Cooled Industrial Chillers

Water-cooled industrial chillers utilize water as the cooling medium and are typically deployed in large-scale industrial facilities. They offer high cooling efficiency, capable of meeting the cooling demands of extensive industrial production. The condensers of water-cooled chillers require a stable water supply, necessitating careful consideration of cooling water supply and drainage systems during equipment selection.

Water-cooled chillers need more maintenance. You have to check and maintain the cooling water system regularly to avoid problems like scale and rust. But they cool very well, so many big industries use them. For example, in chemical production, they cool reactors. This helps chemical reactions happen at the best temperature. As a result, production is more efficient and the quality of the products is better.

3. Absorption Chillers

Absorption chillers belong to a special class of industrial water chillers that use heat energy for operating the refrigeration cycle. It is best applied in situations where electrical energy is fairly limited or massive amounts of waste heat can be recovered. Cooling absorption units do not use chemical reactions between an absorbent and a refrigerant, similar to the standard compression unit; however, common absorbers are lithium bromide and ammonia. Perhaps the greatest advantage of absorption cooling units lies in very little consumption of electricity, hence gaining very specific conveniences under conditions when the supply of energy is hampered, but exhibiting low refrigeration efficiency with high equipment costs, besides periodic maintenance, as well as a constant need for charging additives. Therefore, their use has been restricted mainly to selected industrial applications, like solar refrigeration systems or waste heat hand installations.

IV.結論

Industrial chillers are a key part of modern industrial production. They have complex working principles and many uses. By understanding how they work, their main parts, different types, and how to maintain them, we can choose and use this equipment better. This helps meet cooling needs in all kinds of industrial settings. In food processing, chemical manufacturing, and electronics production, industrial water coolers work efficiently and steadily. They support smooth industrial operations. As technology keeps improving, industrial water chillers will work even better and more efficiently. This will bring more convenience and benefits to industrial production.