Glycol Cooling System for Beer Lines and Beverage Industry | GESON Chiller

 

In the global landscape, there is a consistently high level of demand for industrial cooling processes such as with the use of a glycol cooling system. This type of system is used in numerous commercial and industrial water chillers processes, which explains the level of demand. Choosing the right type of system, many benefits to use can significantly increase productivity and lower operational costs.

This type of chiller system is unique because it requires the use of antifreeze. It has plenty of uses and the most common is in the brewery industry.

If you are in the market searching for the best system to use, you have come to the right place. You will learn many benefits from this guide about glycol condenser and how it works. You can use the information available in the article to help you choose the system that would bring about the highest level of efficiency and performance.

Below is a list of the most frequently asked questions about this type of cooling system that you can use to suit your intended purpose, or the type of industry you operate in.

What Is A Glycol Cooling System?

A glycol cooling system is an industrial-grade refrigeration system. glycol mixture is used in order to achieve the cooling effect with this system. glycol mixture is a type of food grade antifreeze. It goes through numerous processes in order to achieve the ideal freezing point needed for this chiller system to operate.

There are different components involved that operate in synchronization with each other in order to achieve the ideal temperature control for a specific application. It is important to understand what these components are in order for you to maintain and keep them running at all times.

The chiller function goes through an unending loop. It’s cooling systems medium is the most vital component, though, as it facilitates the chilled effect. The cooling systems medium goes through every component wherein it is processed until you can produce the desired chilling effect.

Why Is Glycol Used For Cooling Systems?

Glycol mixture is a type of food grade antifreeze coolant that is water-miscible. This particular property makes it ideal for use in the glycol condenser. It is also widely used in many cooling systems applications or ones that require heat transfer.

This organic compound slows the rate of freezing when it is combined with water. From there, it is piped throughout the system for further processing and to release the cooled air in a given space. The loop function ensures that the ideal temperature control is achieved consistently.

What Type Of Glycol Is Used For Chillers?

There are two types of glycol water cooled screw chiller that are available for use in chiller systems: ethylene and propylene. The latter – propylene glycol – is more commonly used because it has a lower toxicity level. It is, therefore, safer when exposed to humans as compared to pure ethylene glycol that can be hazardous to humans.

How Does Water Glycol Chiller Differ From Water Chiller?

Both glycol chiller and water chillers are systems， that are developed to dissipate heat from your production facility or to maintain a cool very low temperatures. Whatever your needs, it is important to identify the differences between the two systems in order to determine the best one for your intended application.

The primary difference between cooling systems and water chiller is in their freezing points. They also differ in terms of heat conduction capacity.

Figure 2 Ethylene Glycol Chiller

What Types Of Piping Are Used In Glycol Cooling System?

There are numerous options when it comes to piping used for a glycol condenser. Copper pipes are the most popular option. The initial cost of acquiring the copper pipes is higher, but this is a rigid pipe so it will pay off in the long run since they tend to last longer even with regular maintenance.

The pre-insulated schedule 80 PVC is another type of pipe used in a glycol water cooled screw chiller. It is the most popular choice for breweries. PVC should never be used for piping for this system. The pre-insulated ones work best.

Cross-linked polyethylene or PEX is another common material used for piping in a glycol condenser. While it is not as common as the first two materials, it is easy to install and quite economical.

The ABS plastic piping is the next option in the list of materials used for piping a glycol chiller. This one is similar to PVC in terms of its properties. You can also find pre-insulated variants. This one is expensive to acquire but has been engineered to be suited for chilled water applications. Hence, it is also a popular choice among breweries.

Figure 3 Glycol Refrigeration System

How Does Glycol Cooling System Works?

A glycol cooling system is made up of various refrigeration components and a piping system that contains the glycol and water mixture as a refrigerant. The fluid is first processed and chilled from the refrigeration unit before it is transferred through the pipes. From there, it goes through a heat exchange process in order to eliminate heat from the water. This process is repeated in a loop to produce a cooled very low temperatures in various settings.

For most chiller types, the ratio between glycol and water is 60/40. For applications wherein rapid cooling is required, it is important to use a higher percentage of glycol. This will significantly boost the cooling properties of the glycol.

What Are The Applications For Chilled Glycol Cooling System?

There are numerous applications for a chilled glycol condenser.

As mentioned above, it is commonly used in glycol condenser beer lines, gclosed loop glycol cooling system brewery, closed loop glycol cooling system for ice cream machine, closed loop glycol cooling system frozen yogurt, glycol beer lines cooling system.

You can also find it used in many other industries such as wineries, distilleries, food industry processing, and more.

Figure 4 Glycol Water Chiller

How Are Glycol Chiller Used In Breweries?

Glycol cooling system is a specific type of glycol water cooled screw chiller that is used in order to provide refrigeration for different kinds of liquids. In particular, it is commonly used for cooling alcohol family and beverages. This goes without saying that a closed loop glycol cooling system is commonly used in the brewery industry.

This type of chiller uses glycol as a refrigerant so that it can lower the very low temperatures of the said product/s within a given time. There are different types of glycol to choose from that you will know more about later.

In the brewery industry, cooling is necessary for many different processes. For instance, very low temperatures is needed to aid in the fermentation of beer lines (since the fermentation process itself generates heat) or to cool off the wort following the initial boiling procedure.

What Refrigerant In Glycol Cooling System?

Adopt R-404A, R134A, R410A environmentally friendly refrigerants as refrigerants in closed loop glycol cooling system,

Meet the requirements of the current society on the environment.

What Are The Components Of Glycol Cooling System Design?

A glycol cooling system design has different components such as the compressor, evaporator, condenser, and metering device. You can also get a buffer tank to go with the chiller unit in order to provide additional system capacity. This is designed to keep the closed loop glycol cooling system stable amidst erratic system operation or temperature fluctuations.

How Do You Determine How Much Glycol Your System Needs?

It is often a question for breweries and other industries that rely on ethylene glycol cooling system as to how much of this coolant to use for their chiller system. The freezing point is an important indicator as to how much glycol to use. It is important that the glycol burst protection level must be considerably lower than the anticipated ambient temperature.

The freezing point of glycol mixed with water is normally at 8 degrees Fahrenheit (versus 32 degrees Fahrenheit for pure water). This is very important you achieve the ideal freezing conditions; otherwise, the system could burst and it will not be working properly as it should. Too much glycol is a bad thing because it can inhibit system efficiency.

Video: Glycol Chiller

What Are The Types of Glycol?

There are two types of glycol that are available in the market that are used to operate a ethylene glycol cooling system. It is important to note that these two types of glycol should never be mixed. The two types of glycol are propylene and ethylene.

Both of these types of glycol can provide the same level of freeze protection. At the same time, they have the ability to protect the pipes of the chiller system against corrosion. A few other types of glycol, they have the ability to prevent the growth of bacteria.

The glycol is moderately toxic although it is still harmful when swallowed. Therefore, you should never use glycol in industries such as food processing systems or water processing. When there is a leak, it can contaminate the food industry and water that can be harmful to human consumption.

Propylene glycol is the other type of glycol that is used in chiller systems. This one has a lower toxicity level and is the choice for ethylene glycol cooling system used in the food processing systems industries or other industries wherein there is a possibility of human contact with the liquid. It is also relatively safer to handle (in comparison to ethylene) and is easier to dispose of.

If you were to use glycol for a chiller system, make sure to avoid combining these two. Otherwise, it can congeal the chiller systems and result in the filters being clogged.

How Safe Is Glycol?

When handled properly, glycol is safe. However, glycol has a higher level of toxicity as propylene glycol. Therefore, the former is rarely used in industrial applications that come into contact with humans, food industry, or water.

glycol, therefore, is rarely used in chiller systems. It can be broken down and lead to forming toxic compounds that cause fatality.

How Long Does Glycol Last?

With a proper care and maintenance, a glycol cooling system can last for up to 15 years or more. But when used at a very high temperature, glycol can only be kept for a few years. To extend the life span of your glycol chillers, it is important to observe proper storage conditions.

How Often Must You Replace Glycol Refrigeration System?

The ideal time frame to replace glycol in your chiller system is approximately 3 to 5 years. This type of antifreeze can degrade over time. Hence, it should be replaced as often as needed or instructed in the manufacturer’s manual.

How Does Chilled Glycol Cool System Transfer Heat?

Glycol is a type of coolant that is used in numerous heat transfers and cooling applications.

This substance is known for its heat transfer efficiency.

In general, it is up to 10% less efficient than water when it comes to transferring heat.

However, glycol is a better option because it does not cause dirt buildup or corrosion to the system like water does.

Therefore, glycol is chosen to use in the chilled glycol refrigeration system.

Because it facilitates better system efficiency by preventing scaling and corrosion. Without this, it can increase the cost of operating the system over time.

How Much Glycol Is Needed In Chilled Water Systems?

You must first determine the amount of water your system holds in order to get an approximate dose of the glycol to be used. In most systems, the ratio between glycol and water is 35% to 65%. You can get the exact measurement with the use of a glycol refractometer.

How to Mix Water With Glycol For Chillers?

Glycol is often mixed with water in chiller systems in order for the system to work and function properly. However, you cannot simply any water source. You need to consider closely where you get the water from and how much to use.

Before you mix glycol with water, it is best to check the manufacturer’s recommendation on which water to use. Most water sources from the city are good for this. However, experts suggest that you must refrain from the use of de-ionized water as it can cause damage to the metal parts of the chiller over time.

To be safe, you must use distilled water or reverse-osmosis water for your chiller. Always take precautions and make sure you follow the manufacturer’s instructions.

In terms of the amount of water to use, the manufacturer will also have a recommendation on the ideal ratio. You can also compute it by knowing the coolest temperature that can be achieved by the glycol solution while operational. In general, a glycol cooling system used indoors has a smaller chance of freezing so you would need less glycol for this.

It is important that both glycol and water are applied in the correct ratio. If there is too much water, it can make the system inefficient. If there is too much glycol, it can freeze the entire system leading to burst pipes.

What Are The Characteristics Of the Glycol Cooling System?

The glycol used in chilled water systems, as the refrigerant to run the refrigeration system.

Glycol cooling systems are widely used,

In pharmaceutical, chemical, cold storage, and other industries.

What Compressor of Glycol Cooling System?

The imported compressors used at different temperatures of -50~150℃ and -45~150℃ are different.

-50~150℃ glycol refrigeration system adopts: semi-hermetic compressor;

-45~150℃ pure ethylene glycol refrigeration system adopts Ai Vortex flexible compressor, which is more reliable in use. Running smoothly.

What Condenser for Glycol Refrigeration System Design?

The water-cooled condenser that can be cleaned is a double-pipe heat exchanger.

It is connected to the tube plate and equipped with a safety valve to ensure the safe operation of the glycol refrigeration system design.

Is The Glycol Chiller System Design a Closed System?

The entire refrigeration system of the g glycol chiller system design is a fully closed loop glycol cooling system,

There will be no oil mist at high temperatures,

Does not absorb moisture in the air at low temperatures,

The closed-loop glycol refrigeration system will not increase in pressure due to high temperature during operation,

Automatically replenish heat transfer medium at low temperature.

What Expansion Valve For Glycol Water Cooling System?

Adopt imported Emerson expansion valve,

Its function is to throttle and cool the low-temperature and high-pressure supercooled liquid into a low-temperature and low-pressure liquid, and automatically adjust the flow of refrigerant into the evaporator according to the evaporation temperature.

And maintain a certain pressure to ensure the evaporation rate in the evaporator.

What Evaporator For Glycol Water Cooling System?

Using the evaporator of the top international brand Emerson,

Vaporize the compressed and liquefied refrigerant,

Change from liquid to gas while absorbing heat at the same time,

The function is to reduce the temperature of the surrounding medium and play a cooling role.

How to use a glycol systems chiller?

When using a water chiller, you can choose water for circulating cooling,

But if the temperature is too low,

The circulating water will freeze,

At this time, the glycol mixture is a very good refrigerant.

The glycol chiller is also very efficient and stable.

The biggest advantage of the glycol chiller is that the glycol mixture has an antifreeze effect.

In the case of OC°,

Avoid freezing of circulating water during use,

Will not cause malfunctions during operation.

Glycol chiller is a kind of constant temperature, constant current and constant pressure cooling water equipment,

The main function is to cool the water inside the working host to ensure a constant temperature.

Generally speaking, a glycol chiller is composed of a refrigeration system, water system, and control system. The cold system is composed of an independent compressor refrigeration system, including compressor, condenser, thermal expansion valve, plate heat exchanger, and refrigerant pipeline.

What should be paid attention to when purchasing？

The brands of these accessories in the refrigeration system also need to be paid attention to.

Generally, the most popular choice is the accessories of international first-line brands.

It is more stable in use and has fewer failures.

When you choose, you can look at the brand information of these accessories.

After purchasing a glycol chiller, you need to pay attention to maintenance.

Ensure stable working voltage,

The normal operation of the chiller can be guaranteed. for

Pay attention to protect the pump,

Can’t run the chiller without water,

So as not to cause the failure of the circulating water pump of the glycol chiller.

Ensure that the inlet and outlet channels of the chiller fan are smooth,

The filter is recommended to be cleaned regularly to avoid clogging by the ash layer

Stuffed,

when the water temperature is lower than the ambient temperature,

Increase the water temperature or heat the water pipe cooler,

In order to avoid water condensing.

it is not conducive to the operation of the chiller.

Glycol chillers have many applications in terms of industrial process cooling. It is best used with a cooling water temperature of 5 degrees Celsius. This type of chiller is best suited for beverage processing, such as in breweries. It also has applications in food processing systems, ice rinks, and cold storage.

As glycol chiller manufacturers, we ensure that our chiller units can deliver stable performance under all conditions. This is made possible by our rational design approach and strict production process.

We supply glycol chillers in China and other parts of Asia. We can offer low temperature cooling solution for up to 3000 KW. Our range of glycol chillers include both air-cooled and water-cooled unit types. These models operate at a range of -40 to 5 degrees Celsius.

Our experienced team can design the most suitable chiller system for your unique need. As trusted glycol chiller manufacturers, we understand the importance of a correctly sized glycol chiller. This is how we can deliver systems that offer better performance and have a longer operation.

We have air-cooled glycol chillers that operate in as low as -35 degrees Celsius. It has a cooling capacity range of 1KW to as much as 900 KW. We also offer water-cooled glycol chillers with a maximum cooling capacity of 2000KW. We have a wide range of options if you need high-quality, low-temperature cooling for your industrial processes.

Before we can design a system, our team of engineers will study your cooling demand. They will calculate the cooling capacity based on the information provided. We will then customize the design to meet your exact demands.

With over 15 years experience as glycol chiller manufacturers, we use our expertise in industrial cooling to offer turn-key solutions for your needs. With the customized design, we can guarantee that our glycol chillers are ready to use and operate upon installation.

What is the principle of glycol refrigeration?

When it comes to refrigeration in the refrigeration industry, people may first think of Freon, ammonia, carbon dioxide, etc.

Because many refrigeration systems and closed-loop glycol cooling systems are currently using these three types,

E.g:

beer lines

homebrew

system

for ice cream machine

With the increasing intensity of national supervision,

Freon and other refrigerants that are harmful to the environment are gradually being replaced.

So, can pure ethylene glycol used as a refrigerant be used in glycol refrigeration system design?

What is the principle of refrigeration? Next, analyze for everyone.

In fact, the principle of glycol refrigeration is very simple.

There are currently two common methods for preparing frozen water at 1-4°C:

1. Ammonia refrigeration system using ammonia as the refrigerant and open steel pipe as evaporator;
2. Use Freon as the refrigerant and ethylene glycol as the carrier refrigerant.

Shell and tube heat exchanger is used as a Freon refrigeration system for heat exchange equipment.

According to actual usage,

The ammonia refrigeration system of A scheme adopts open steel pipe as the evaporator,

The cooling capacity of ammonia is transferred to chilled water when chilled water flows through the evaporator.

In this process, the water flow velocity is too small, that is

Add a stirrer,

The flow rate of chilled water is also difficult to control and the distribution is very uneven.

Therefore, the surface of the open steel tube evaporator often freezes and the water temperature is difficult to drop to the design value.

At the same time, after a long time of use, the steel pipe evaporator is corroded by chilled water and leaks.

Due to icing on the surface of the open steel pipe,

Although it will not damage the open steel tube evaporator,

But because the cooling capacity of ammonia cannot be transferred to the chilled water in time,

After a long time, the compressor will be unloaded and shutdown or even alarm

In severe cases, liquid compression will destroy the compressor,

Cannot meet production needs.

Plan B uses Freon as the refrigerant,

Ethylene glycol is used as a refrigerant,

Increase the shell and tube heat exchanger.

During installation, the ethylene glycol goes through the shell side and the chilled water goes through the pipe side.

Since the water system uses a circulating water pump for forced heat exchange,

And the chilled water is piped,

Therefore, the flow rate of chilled water is fast, stable, and has no dead ends.

Can prevent icing.

On the other hand, due to the addition of refrigerant,

Therefore, the evaporation temperature of Freon is lower,

Therefore, the energy efficiency ratio of this freon refrigeration system is relatively low,

But it can prepare 1-2℃ frozen water.

Therefore, this solution is suitable for occasions where 1-2℃ chilled water needs to be provided.

So ethylene glycol refrigeration is still through indirect production of cold capacity,

The real substantial cooling capacity still requires professional refrigeration with refrigerants.

Then the cooling capacity is transferred through the refrigerant.

Common Refrigerant Use Temperature And

Glycol Used In Chilled Water Systems %

Temperature℃	Refrigerant	Mass Concentration %	Initial Solidification Temperature℃	Density kg/m3	Specific Heat kj/kg.K	Dynamic Viscosity k Pa.s
0℃	Ethylene Glycol Aqueous Solution	12	-7.2	1111	3.465	2.5
	Ethylene Glycol Aqueous Solution	16	-7	1020	3.89	2.84
-5℃	Ethylene Glycol Aqueous Solution	16	-12	1140	3.2	3.14
	Ethylene Glycol Aqueous Solution	23.6	-13	1030	3.77	5.10
-10℃	Ethylene Glycol Aqueous Solution	20	-17	1180	3.06	4.88
	Ethylene Glycol Aqueous Solution	31.2	-17	1040	3.64	6.67
-15℃	Ethylene Glycol Aqueous Solution	22	-22	1200	2.95	5.8
	Ethylene Glycol Aqueous Solution	40	-22	1070	3.35	11.7
-20℃	Ethylene Glycol Aqueous Solution	24.5	-27	1230	2.85	8.1
	Ethylene Glycol Aqueous Solution	45	-27.5	1080	3.23	19.0
-25℃	Ethylene Glycol Aqueous Solution	26	-32	1240	2.81	12.9
	Ethylene Glycol Aqueous Solution	50	-33.8	1088	3.11	30.5
-30℃	Ethylene Glycol Aqueous Solution	27.5	-38.6	1260	2.74	13.6
	Ethylene Glycol Aqueous Solution	53	-37.9	1100	3.05	50.5
-35℃	Ethylene Glycol Aqueous Solution	28.5	-43.5	1270	2.7	24.5
	Ethylene Glycol Aqueous Solution	57	-44	1103	2.95	83.5