Industrial Process Chillers Manufacturers | GESON Chiller
This guide will help you in getting the best Process Chiller Manufacturers.
Indeed, it specifies every aspect.
That you have been searching for.
Hence, it identifies a version, kind, advantages, price, and maintenance, among other important points.
So before you buy a Process Chiller, go through this guide.
What is the Process Chiller?
Figure 1 Process Chiller
A process chiller is a thermal appliance that eliminates heat produced by a given process.
Hence, this cooling device continuously conducts chilled water via a closed loop.
Subsequently, to permit a drop in increasing process temperatures.
· What are the kinds of Process Chiller?
GESON REFRIGERATION EQUIPMENT CO. is one of the leading Industrial Water Chiller Manufacturers. We categorize our Process Chillers into two main categories.
- Central Process Chiller
- Compact Process Chiller
Central Process Chillers have a performing range of -30°F to 65°F.
Thus it can handle from under ten to over 200 tons.
To know more about our Central Process Chillers, view our table of products or contact a GESON REFRIGERATION EQUIPMENT CO., representative.
Figure 2 Central Process Chiller
Compact Process Chillers are smarter models of our central chillers.
Thus, they are unique, ranging from one to 40 tons.
Moreover, these chillers are fully integrated turnkey systems.
Though, if physical space is limited, this is a perfect choice.
To get to know more about our Compact Process Chillers?
Please look at our selection of compact process chillers or contact GESON REFRIGERATION EQUIPMENT CO., the representative.
Figure 3 Compact Process Chiller
· What Are The Parts of A Process Chiller?
Process Chillers consist of many different parts depending upon the structure.
Hence, each process chiller has a
- High-pressure refrigerant relief valves,
- Cooling towers,
Contact GESON REFRIGERATION EQUIPMENT CO.
So, one of our technical engineers will assist you design one to achieve your custom requirements.
Figure 4 Parts of a Process Chiller
· How Do Industrial Chillers Work?
A process chiller may utilize an air or water condenser in its cooling method.
Thus, a thermostatic expansion valve causes the pressure and temperature to drop.
As the subcooled fluid, the refrigerant moves from the condenser to the evaporator.
The refrigerant gas then picks up the heat from the liquid flowing through the evaporator.
Thus, changing from a fluid to a vapor.
Moreover, it moves in a constant cycle, continually cooling the process.
· What Are The Advantages Of A Process Chiller?
The capability of a industrial process chiller to perform across a range of ambient situations at variable loads make them ideal for providing effective process cooling,
Hence, Advantages of using Process chillers include:
- The capability to retain continuous and accurate control of the process temperature.
- The cooling liquid can be provided directly to the application heat source.
- Cooling is not dependent on ambient situations.
- The capability to lower potential contamination of the process via a closed-loop water circuit.
- The cooling liquid is recirculated, reducing waste and price.
- High heat exchange potential.
- Capacity to combine into existing free cooling systems.
- Process chillers can be combined into most applications.
Industrial Process Water Chiller
· What Causes Low Suction Pressure On A Process Chiller?
This can be caused by low air movement.
This can be a
- Dusty filter,
- Slipping belt,
- Undersized or limited ductwork,
- Dust and dirt buildup on blower wheel,
- The dusty or plugged evaporator coil,
Thus, assessing superheat will specify if the low suction is caused by inadequate heat getting to the evaporator.
· What Are the Applications Of A Process Chiller?
Process Chillers are applicable in a variety of industrial applications.
- Plastics Industry: The plastics industry utilizes process chillers to lower cycle times in injection molding cooling and blow molding by modulating temperatures.
- Baking Industry: The baking industry may utilize process chillers in its procedure of mixing.
Thus, the chilled water from a process chiller may be used to allow larger mixing times.
Hence, this enhances the final quality for any grade of flour.
- Food Industry: The food industry utilizes a process water chiller system to cool any procedure.
For instance, chocolate production, vegetable processing, meat massagers/injectors, and confectionary producing.
- Pharmaceutical Industry: The heat from emollient vats requires to go somewhere.
This is where a GESON REFRIGERATION EQUIPMENT CO. Process Chiller assists pharmaceutical firms to save money by lowering the total producing time, leading to price savings in labor expenses.
Chillers In Pharmaceutical Industry
- Printing Industry: Process chillers can be utilized to modulate temperatures in presses and rollers, which results from descending in stretching and bleeding.
Thus, this, in turn, reduces the time required to print.
Subsequently, which enhances efficiency and results in higher quality products at money savings.
- Other industries that get benefits from the uses of a process chiller include:
- Boat & airplane producing,
- Metal finishers,
- Skating rinks,
- Chemical industry,
- Composite producers,
- Laser cutting machines,
- Dry cleaners,
- The United States government utilizes many for military applications,
Figure 5 Applications of a Process Chiller
· What is Process Chiller Safety?
Usually, a Process chiller consists of a compressor, an evaporator, and condensers.
Moreover, every Process chiller generally has safety modulators.
Thus, they are designed to protect the cooling system from danger.
It is because of low refrigerant temperature, low oil pressure, or high condensing pressure.
water-cooled Process Chiller Components
· Where Can A Process Chiller Be Placed?
Depending upon your place and the size of your Process Chiller, this chiller may be placed directly beside your procedures, in a separate room, or even outdoor.
A GESON REFRIGERATION EQUIPMENT CO. representative will be happy to cope with you to recognize which will best fit your needs.
· What Are The Common Problems and Possible Causes of A Process Chiller?
- CHILLER DOES NOT POWER UP
- Inappropriate line voltage or loose connection
- Improper phase connection (three-phase units)
- The blown circuit breaker or fuse
- Power switch in “off” position
- NO PUMPING OR INADEQUATE LIQUID FLOW
- Inappropriate or fluctuating line voltage
- The inadequate liquid in the reservoir
- Pinched or limited process line
- Close or partially closed process valve
- Coolant liquid unsuitable for temperature needs
- Clogged liquid filter
- Process piping too narrow
- Process limitation
- Pump failure
- NO COOLING OR INSUFFICIENT COOLING
- Inappropriate or fluctuating line voltage
- Blocked air filter or condenser
- Coolant liquid unsuitable for temperature needs
- Heat transfer features of the coolant liquid have declined
- Refrigerant gas leak
- High surrounding temperature
- Evaporator freeze-up
· Does the Process Chiller Pose Any Risks to One’s Health?
Properly retained Process chiller will not transfer the disease.
Because they generate no diffusers.
However, they should not be mixed with cooling towers or evaporative condensers.
Because they have different technology.
· What Are The Maintenance Steps And Schedule For A Process Chiller?
Essential Steps for Optimized Working of a Process Chiller are:
- Assess the process chiller quarterly
- Routinely assess for refrigerant leaks.
- Confirm compressor performing pressures are within a reasonable extent
- Assess all motor voltages & amps
- Examine all electrical starters, contactors, and relays
- Observe all hot gas and unloader functions
- To reach maximum effectiveness, utilize superheat and sub-cooling temperature analysis.
- Line analysis from Discharge lines should also be gathered
For a custom sustenance schedule for your process chiller, please contact the GESON REFRIGERATION EQUIPMENT CO. representative, and they will be happy to negotiate maintenance packages with you.
Daily Maintenance Check List for Process Chillers
|Chiller use & Sequencing
||Turn off or sequence unnecessary chillers
|Overall Visual Inspection
||Complete overall visual assessment to be sure all parts are performing and that safety systems are in place.
||Assess all set points for proper setting and operation
Monthly Sustenance Check List for Process Chillers
|Evaporator and Condenser Coil Fouling
||Check evaporator and condenser coil fouling as needed.
|Compressor Motor Temperature
||Assess temperature per producer’s instructions
||Conduct leak checking on all compressor fittings, oil pump joints and fittings, and relief valves
|Assess all Insulation
||Observe insulation for condition and appropriateness
||Verify proper control operation, including:
· Hot gas bypass
· Fluid injection
Semi-Annually Sustenance Check List for Process Chillers
|Assess Process Chiller Lockout Points
||Assess settings for manufacturer’s instructions
Annual Sustenance Check List for Chillers
|Compressor Motor & Assembly
||Assess all alignments according to guidelines. Examine all seals and provide lubrication where necessary.
|Compressor Oil System
||Conduct observations on oil & change as necessary. Test oil pump and seals. Examine the oil heater and thermostat. Assess all strainers, valves, etc.
||Assess all electrical connections and terminals for contact and tightness
||Check precise water flow in the evaporator and condenser.
|Assess Refrigerant Level and Condition
||Record amounts and mention leakage problems.
What Are the Breakthroughs In Cost Control And Energy Efficiency Of A Process Chiller?
- Newer lines of Industrial Process Water Chillers have been displaying extraordinary innovations in terms of accuracy in temperature control.
While also requiring only half the power of conventional appliances.
Moreover, newer process chillers are coming out with unique characteristics to the industry or have not been utilized across the board in differing configurations.
- A recent improvement in this direction is the use of compressor technologies that can perform at variable speeds.
However, earlier such technology was limited solely to HVAC Chiller.
Thus, it is for the first time being used in process chilling applications.
- Such technologies control the real time process temperatures.
Moreover, accordingly, transmit signals to the compressors to either speed up or slow down.
However, such components will not only provide an advantage from lower wear and tear, by the reduction of cycling in compressors.
Hence, this equipment will also result in reductions of up to 50 percent of energy needs.
Thus it will assist in recovering much of the significant investments made in such equipment.
- Other technologies that are expected to have a bright future in the industrial process water chillers sector include:
Variable speed condenser fans with real-time controlling abilities.
As well as electronic expansion valves, which can boost variable speed compressors.
Thus to adjust the valve to performance needs based on pressure and temperature sensors.
· How Do You Troubleshoot A Process Chiller?
Even when your process chiller gets checked and retained regularly.
Its execution can decrease or decline with time.
However, pumps can stop working.
Process lines can get the block.
Refrigerant gas can leak.
Further, many issues can occur.
It can be related to component aging or changing climate conditions.
Following are some essential measures which can help troubleshoot the problem:
- Ensure that the process chiller is working.
Your process chiller may stop performing due to a puffed circuit breaker or fuse.
Moreover, loose wiring or merely a switch that’s might put in the “off” position. It might also stop the process chiller from running.
- Make sure whether the process chiller is cooling.
Thus, examine the temperature of the coolant at the process chiller’s outlet to the process.
If it isn’t at or near the preferred temperature?
The evaporator might get freezes.
However, it is also possible that the heat transfer properties of the coolant fluid might be declining.
What Is Industrial Process Cooling?
Industrial process cooling is the method that is used by process chiller manufacturers to provide large-scale cooling solutions for businesses and industries. It utilizes a cooling system that uses a heat transferring process designed to diffuse heat to the ambient environment. In some cases, the heat is transferred to a liquid that is pumped from different sources, such as a river or sea. The product is called an industrial process chiller.
What Types Of Compressors Are Used In An Industrial Process Chiller?
There are three types of compressors that are commonly used in an industrial process chiller. The reciprocating compressor is the first type of compressor. This type of compressor is operated using a piston that is driven with the use of a crankshaft. This enables a small amount of coolant at high pressure. The piston compressor can range from 3 to 60 horsepower.
Chiller Temperature Setting
The centrifugal compressor is another one commonly used by process chiller manufacturers. In fact, this is the first choice for many companies or industries. The main reason why it is popular is that the centrifugal compressor has fewer moving parts. This uses up less energy to achieve the right pressure and higher cooling power. As a result, this type of compressor is known to be more energy-efficient.
Centrifugal compressors are ideal for low-pressure applications such as cooling units and volume ventilation fans. This type of compression functions by applying centrifugal force to an air mass in order to achieve compression. This type of compression can support up to hundreds of tons in cooling capacity.
The screw compressor is the final type of compressor commonly used in an industrial process chiller. It is made up of two screws that are assembled in a fixed body. Once the rotors begin to rotate, it causes gas to compress. Most types of screw compressors have up to 1000 horsepower.
Process Chiller Design
How Does An Industrial Chiller Work?
An industrial process chiller works based on the principle of either vapor absorption or vapor compression. It involves the heat transfer from one medium to another and the evaporation of the refrigerant. In some cases, it also involves the conversion of low-pressure liquid into vapor form to reduce the temperature of the coolant.
From the above step, the refrigerant goes through the compressor wherein it is further processed to achieve its function.
What Are The Types Of Industrial Cooling Systems?
A cooling system, such as the ones used by process chiller manufacturers for industrial applications, works by transferring thermal energy one medium (such as gas or liquid) to another. Cooling is a critical component in an industrial process to ensure that products or equipment maintain a certain temperature level.
Most types of industrial process chiller use water as a medium as it can absorb heat more effectively. In general, there are three basic types of cooling systems available in the market.
The once-through cooling system is the simplest of all types of systems. In this system, the coolant (mostly water) is pumped and passes the system only once (as the name implies) after it has absorbed heat. After that, the coolant is discharged back to its source. This system is employed in areas wherein there is access to low-cost water at high volume.
The closed recirculating system is the next type of cooling system used by process chiller manufacturers for industrial process chiller. In this system, the heat that is absorbed by the liquid coolant is transferred to another coolant or released back into the environment. In this system, evaporation is not used but rather a series of small tubes that contain a circulating coolant.
The open recirculating system is the most common type of system employed in most industrial applications. It involves the use of cooling towers that uses the same coolant (water) over and over again throughout the system in an endless loop. It uses evaporation in order to release heat that is absorbed by the water back into the atmosphere. An industrial process chiller consists of three main equipment: water pump, heat exchanger, and the cooling tower.
Industrial Water Chiller Application
What Are Industrial Chillers For?
Process cooling systems are developed by process chiller manufacturers for a wide variety of applications. It has many uses and includes processes such as cooling metals and plastics, or for the industrial sector such as fabricating glass, electronics, metal products, and data centers.
How Chiller Works With Diagram
What Does Process Cooling Mean?
Process cooling is the term used to describe the method of removing heat from a process. It uses mechanical refrigeration in order to achieve the ideal temperature for a given industrial setting regardless of the load.
There are many uses for process cooling such as the direct cooling of a product, like cooling metal products for machining or plastic for molding. Another use for process cooling is to facilitate a specific process, such as the fermentation of beer. In some cases, process cooling is also used for machine cooling such as for welding and laser cutting machinery.
What Type Of Refrigerant Is Used In Industrial Chillers?
Hydrofluorocarbon (HFC or R134A) is the most common type of refrigerant used by process chiller manufacturers. It is more commonly known as Freon 134A. It is used as a refrigerant because of its stable thermal properties and low toxicity level. And it is also a non-combustible substance.
The R744 CO2 is another non-toxic and non-flammable refrigerant common in industrial process chiller. The main drawback for this refrigerant is that it requires a massive system to avoid potential leaks. It also requires a high maintenance cost.
Hydrocarbons (HCS) are another example of refrigerants used for an industrial setting (as well as domestic purposes). You can find two common variants of this: propane and isobutene. These are highly flammable; thus, it takes a specialized expert to conduct the installation to ensure safety of your industrial chiller unit.
There are more types of refrigerants used by process chiller manufacturers such as R717 Ammonia, R407C, R404A, and R448A.
What Are The Components Of Industrial Process Chiller?
Process chiller manufacturers use a number of components in order to build the cooling system for industrial use. It is important to know what these components are and their corresponding functions so you can ensure that they are working properly. At the same time, it is beneficial when doing maintenance so that you can troubleshoot any issues.
The four basic components of an industrial process chiller are as follows: 1) compressor, 2) condenser, 3) expansion valve and 4) evaporators. Each of these components plays a vital role in achieving the desired cooling effect to maintain an industrial or manufacturing facility.
Water-cooled Process Chiller Connection Details
Is Industrial Process Chiller Packaged Or Split?
An industrial process chiller is typically complete and packaged. When you install them for your industrial or commercial space, they will come with the main chiller unit along with the pump station, recirculating pump, condenser, expansion valve, and other components.
How To Choose A Cooling Solution?
It is important that give proper care and consideration when choosing an industrial cooling solution for your business. To choose the best industrial process chiller, these are some factors you need to consider.
- Type of fluid that must be cooled.
- Check the ideal temperature of the fluid.
- Check the maximum volumetric flow.
- Amount of heat to be dissipated.
- Check the wet and dry bulb temperature in the summer and winter.
- Availability of power supply.
- Check the recommended location for the cooling system.
Process water chiller
What Is The Difference Between AHU And FCU?
The AFU and FCU are two components of industrial process chiller but they serve a different purpose so they must not be confused with each other. AHU is the air handling unit, which is a component of an HVAC responsible for cooling and distributing air into a given space. The cooled air is released through a duct system.
On the other hand, the FCU or fan coil unit is a standalone component. It is responsible for circulating the air that exists within a small space. Some HVAC systems do come with a fan coil unit, though.
Which Industries Rely On Process Cooling?
There are several industries that can benefit from the use of industrial process chiller. Among these industries served by process chiller manufacturers are the following:
- Food processing and storage
- Data Centers
- District Cooling
What Are Challenges With Industrial Refrigeration Systems?
There are many challenges that are faced when dealing with the operation and maintenance of an industrial process chiller. These challenges must be taken into account in order to achieve optimal performance for the entire system.
The first challenge is how to establish the key measuring and control needs for the whole operation of the system. The basic elements that must be taken into account during the operation are temperature, pressure sensors, humidity, and controllers for the user.
The next challenge lies in terms of troubleshooting the system in the event of any issues. Most process chiller manufacturers will provide remote troubleshooting for users when necessary. However, it is also important for the user to know how to detect the problem, control the equipment, and perform basic troubleshooting.
Finally, the biggest challenge when using an industrial process chiller is in overcoming the common mistakes with its use. The installation must be done by an expert and based on the instructions provided by the process chiller manufacturers. The same level of care and attention must be given towards the maintenance, usage, and supervision of the system.
How Do You Maintain Industrial Process Chiller?
The type of maintenance work required on each system will depend on instructions from the process chiller manufacturers. Proper maintenance is crucial to ensure that the system is working efficiently. You can take a few maintenance steps to ensure an optimized efficiency level.
First off, the industrial process chiller must be located within a mechanical equipment chamber. It should be placed inside the building and close to the site being cooled. There are some systems that must be placed outdoors, though.
You can also perform preventive maintenance on your industrial process chiller. Keep the chiller tubing clean at all times. Make sure to inspect the condenser to prevent scaling. It is also recommended that you maintain an adequate refrigerant charge. It is important to hire an expert if you are not sure about how to do maintenance on the industrial chillers.
How Do You Keep Industrial Process Chillers Energy-Efficient?
There are two approaches you can take if you want to achieve energy efficiency with the use of an industrial process chiller: component- and system-level.
The component level entails looking into every part of the system to make sure they are working efficiently. On the system level, you must look at the overall interaction of these individual components so that they must be configured in the most effective way.
Process chiller manufacturers recommend a few energy-efficiency measures for an industrial process chiller to ensure that you can reach optimal efficiency level. Here are some of those measures:
- Hydronic loops must be near the design temperature differential to operate efficiently.
- Use the variable speed control settings on the system’s compression along with the ideal water condenser reset.
- Optimize control of the cooling towers especially when dealing with low condenser temperature settings.
- Make sure to reset the chilled water supply temperature according to the process load.
- Adjust the condensing water temperature according to the ambient temperature.
Why Choose Geson As Process Chillers Manufacturers?
If you are looking for the best process chiller manufacturers, make sure to consider Geson Chiller. We are an expert water chiller manufacturer for more than 15 years. We offer a wide range of products and solutions that can meet all of your refrigeration needs – from domestic to industrial process chiller.
Process Chillers Manufacturers
· How Can You Start A Process Chiller Business?
Much of the Industrial Process Chiller in the market produce in China.
To start an Industrial Process Chiller?
You will require to approach the producers.
Moreover, you may look for a local supplier.
Given the fact that all over the world. Everyone is switching to environmentally friendly items.
So, you can never be wrong with the Industrial Process Chiller business.
I hope you got all facts and figures you were looking for in this guide.
However, if you have more queries on Industrial Process Chiller.
You should feel free to contact us.