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Recent changes A chiller is a machine that removes heat from a liquid via a
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vapor-compression or absorption refrigeration cycle. This
Tools liquid can then be circulated through a heat exchanger to cool
equipment, or another process stream (such as air or process
What links here
Related changes water). As a necessary by product, refrigeration creates waste
Upload file heat that must be exhausted to ambient or, for greater
Special pages efficiency, recovered for heating purposes.[1]
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Chilled water is used to cool and dehumidify air in mid- to
Page information York International water-cooled
Wikidata item large-size commercial, industrial, and institutional facilities. chiller
Cite this page Water chillers can be water-cooled, air-cooled, or
evaporatively cooled. Water-cooled systems can provide
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efficiency and environmental impact advantages over air-cooled systems.[2]
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Download as PDF Contents
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Printable version 1 Use in air conditioning
2 Use in industry
In other projects
3 Vapor-compression chiller technology
Wikimedia Commons
4 How absorption technology works
Languages 4.1 Industrial chiller technology
5 Industrial chiller selection
‫العربية‬
6 Refrigerants
Čeština
Deutsch 7 See also
Español 8 References
‫فارسی‬ 9 External links
हिनद
Italiano

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Chiller - Wikipedia

മലയാളം Use in air conditioning [ edit ]

Nederlands
In air conditioning systems, chilled water is typically
日本語
Polski distributed to heat exchangers, or coils, in air handling units
Português or other types of terminal devices which cool the air in their
Русский respective space(s). The water is then re-circulated back to the
Српски / srpski chiller to be cooled again. These cooling coils transfer sensible
Türkçe
heat and latent heat from the air to the chilled water, thus
Українська
cooling and usually dehumidifying the air stream. A typical
Tiếng Việt
Edit links chiller for air conditioning applications is rated between 15
and 2000 tons , and at least one manufacturer can produce Rental chiller mounted on a trailer
chillers capable of up to 5,200 tons of cooling.[3] Chilled water
temperatures can range from 35 to 45 °F (2 to 7 °C),
depending upon application requirements.[4]

When the chillers for air conditioning systems are not operable or they are in need of repair or
replacement, emergency chillers may be used to supply chilled water. Rental chillers are mounted on a
trailer so that they can be quickly deployed to the site. Large chilled water hoses are used to connect
between rental chillers and air conditioning systems.[5]

Use in industry [ edit ]

In industrial application, chilled water or other liquid from the chiller is pumped through process or
laboratory equipment. Industrial chillers are used for controlled cooling of products, mechanisms and
factory machinery in a wide range of industries. They are often used in the plastic industries, injection and
blow molding, metal working cutting oils, welding equipment, die-casting and machine tooling, chemical
processing, pharmaceutical formulation, food and beverage processing, paper and cement processing,
vacuum systems, X-ray diffraction, power supplies and power generation stations, analytical equipment,
semiconductors, compressed air and gas cooling. They are also used to cool high-heat specialized items
such as MRI machines and lasers, and in hospitals, hotels and campuses.

Chillers for industrial applications can be centralized, where a single chiller serves multiple cooling needs,
or decentralized where each application or machine has its own chiller. Each approach has its advantages.
It is also possible to have a combination of both centralized and decentralized chillers, especially if the
cooling requirements are the same for some applications or points of use, but not all.

Decentralized chillers are usually small in size and cooling capacity, usually from 0.2 to 10 short tons
(0.179 to 8.929 long tons; 0.181 to 9.072 t). Centralized chillers generally have capacities ranging from ten
tons to hundreds or thousands of tons.

Chilled water is used to cool and dehumidify air in mid- to large-size commercial, industrial, and
institutional (CII) facilities. Water chillers can be water-cooled, air-cooled, or evaporatively cooled. Water-
cooled chillers incorporate the use of cooling towers which improve the chillers' thermodynamic
effectiveness as compared to air-cooled chillers. This is due to heat rejection at or near the air's wet-bulb
temperature rather than the higher, sometimes much higher, dry-bulb temperature. Evaporatively cooled
chillers offer higher efficiencies than air-cooled chillers but lower than water-cooled chillers.

Water-cooled chillers are typically intended for indoor installation and operation, and are cooled by a
separate condenser water loop and connected to outdoor cooling towers to expel heat to the atmosphere.

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Air-cooled and evaporatively cooled chillers are intended for outdoor installation and operation. Air-
cooled machines are directly cooled by ambient air being mechanically circulated directly through the
machine's condenser coil to expel heat to the atmosphere. Evaporatively cooled machines are similar,
except they implement a mist of water over the condenser coil to aid in condenser cooling, making the
machine more efficient than a traditional air-cooled machine. No remote cooling tower is typically
required with either of these types of packaged air-cooled or evaporatively cooled chillers.

Where available, cold water readily available in nearby water bodies might be used directly for cooling,
place or supplement cooling towers. The Deep Lake Water Cooling System in Toronto, Ontario, Canada ,
is an example. It uses cold lake water to cool the chillers, which in turn are used to cool city buildings via a
district cooling system. The return water is used to warm the city's drinking water supply, which is
desirable in this cold climate. Whenever a chiller's heat rejection can be used for a productive purpose, in
addition to the cooling function, very high thermal effectiveness is possible.

Vapor-compression chiller technology [ edit ]

There are four basic types of compressors used in vapor compression chillers: Reciprocating
compression, scroll compression, screw-driven compression, and centrifugal compression are all
mechanical machines that can be powered by electric motors , steam , or gas turbines . They produce their
cooling effect via the "reverse-Rankine " cycle, also known as 'vapor-compression'. With evaporative
cooling heat rejection, their coefficients-of-performance (COPs) are very high; typically 4.0 or more.

COP

Current vapor-compression chiller technology is based on the "reverse-Rankine" cycle known as vapor-
compression. See the attached diagram which outlines the key components of the chiller system.

Key components of the chiller:

Refrigeration Compressors - are essentially a pump for

refrigerant gas. The capacity of the compressor, and hence the
chiller cooling capacity is measured in kilowatts input (kW),
Horse Power input (HP), or volumetric flow (m3/h, ft 3/h). The
mechanism for compressing refrigerant gas differs between
compressors, and each has its own application. Common
refrigeration compressors include Reciprocating, Scroll,
Screw, or Centrifugal. These can be powered by electric
motors, steam turbines or gas turbines. Compressors can have Diagram showing the components of
a water-cooled chiller
an integrated motor from a specific manufacturer, or be open
drive - allowing the connection to another type of mechanical
connection. Compressors can also be either Hermetic (welded closed) or semi-hermetic (bolted together).

In recent years, application of Variable Speed Drive (VSD) technology has increased efficiencies of vapor
compression chillers. The first VSD was applied to centrifugal compressor chillers in the late 1970s and
has become the norm as the cost of energy has increased. Now, VSDs are being applied to rotary screw
and scroll technology compressors.

Condensers can be air-cooled, water-cooled, or evaporative. The condenser is a heat exchanger which

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allows heat to migrate from the refrigerant gas to either water or air. Air cooled condenser are
manufactured from copper tubes (for the refrigerant flow) and aluminium fins (for the air flow). Each
condenser has a different material cost and they vary in terms of efficiency. With evaporative cooling
condensers, their coefficients-of-performance (COPs) are very high; typically 4.0 or more.

The expansion device or refrigerant metering device (RMD) restricts the flow of the liquid refrigerant
causing a pressure drop that vaporizes some of the refrigerant; this vaporization absorbs heat from nearby
liquid refrigerant. The RMD is located immediately prior to the evaporator so that the cold gas in the
evaporator can absorb heat from the water in the evaporator. There is a sensor for the RMD on the
evaporator outlet side which allows the RMD to regulate the refrigerant flow based on the chiller design
requirement.

Evaporators can be plate type or shell and tube type. The evaporator is a heat exchanger which allows the
heat energy to migrate from the water stream into the refrigerant gas. During the state change of the
remaining liquid to gas, the refrigerant can absorb large amounts of heat without changing temperature.

How absorption technology works [ edit ]

The thermodynamic cycle of an absorption chiller is driven by a heat source; this heat is usually delivered
to the chiller via steam, hot water, or combustion. Compared to electrically powered chillers, an absorption
chiller has very low electrical power requirements - very rarely above 15 kW combined consumption for
both the solution pump and the refrigerant pump. However, its heat input requirements are large, and its
COP is often 0.5 (single-effect) to 1.0 (double-effect). For the same tonnage capacity, an absorption chiller
requires a much larger cooling tower than a vapor-compression chiller. However, absorption chillers, from
an energy-efficiency point of view, excel where cheap, high-grade heat or waste heat is readily available.
In extremely sunny climates, solar energy has been used to operate absorption chillers .

The single-effect absorption cycle uses water as the refrigerant and lithium bromide as the absorbent. It is
the strong affinity that these two substances have for one another that makes the cycle work. The entire
process occurs in almost a complete vacuum.

1. Solution Pump : A dilute lithium bromide solution (63% concentration) is collected in the
bottom of the absorber shell. From here, a hermetic solution pump moves the solution through a
shell and tube heat exchanger for preheating.
2. Generator : After exiting the heat exchanger, the dilute solution moves into the upper shell. The
solution surrounds a bundle of tubes which carries either steam or hot water. The steam or hot
water transfers heat into the pool of dilute lithium bromide solution. The solution boils, sending
refrigerant vapor upward into the condenser and leaving behind concentrated lithium bromide. The
concentrated lithium bromide solution moves down to the heat exchanger, where it is cooled by the
weak solution being pumped up to the generator.
3. Condenser : The refrigerant vapor migrates through mist eliminators to the condenser tube
bundle. The refrigerant vapor condenses on the tubes. The heat is removed by the cooling water
which moves through the inside of the tubes. As the refrigerant condenses, it collects in a trough at
the bottom of the condenser.
4. Evaporator : The refrigerant liquid moves from the condenser in the upper shell down to the
evaporator in the lower shell and is sprayed over the evaporator tube bundle. Due to the extreme
vacuum of the lower shell [6 mm Hg (0.8 kPa) absolute pressure], the refrigerant liquid boils at
approximately 39 °F (4 °C), creating the refrigerant effect. (This vacuum is created by hygroscopic

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action - the strong affinity lithium bromide has for water - in the Absorber directly below.)
5. Absorber : As the refrigerant vapor migrates to the absorber from the evaporator, the strong
lithium bromide solution from the generator is sprayed over the top of the absorber tube bundle.
The strong lithium bromide solution actually pulls the refrigerant vapor into solution, creating the
extreme vacuum in the evaporator. The absorption of the refrigerant vapor into the lithium bromide
solution also generates heat which is removed by the cooling water. Now the dilute lithium
bromide solution collects in the bottom of the lower shell, where it flows down to the solution
pump. The chilling cycle is now completed and the process begins once again.[6]

Industrial chiller technology [ edit ]

Industrial chillers typically come as complete, packaged, closed-loop systems, including the chiller unit,
condenser , and pump station with recirculating pump, expansion valve, no-flow shutdown, internal cold
water control. The internal tank helps maintain cold water temperature and prevents temperature spikes
from occurring. Closed-loop industrial chillers recirculate a clean coolant or clean water with condition
additives at a constant temperature and pressure to increase the stability and reproducibility of water-
cooled machines and instruments. The water flows from the chiller to the application's point of use and
back.[citation needed]

If the water temperature differentials between inlet and outlet are high, then a large external water tank
would be used to store the cold water. In this case the chilled water is not going directly from the chiller to
the application, but goes to the external water tank which acts as a sort of "temperature buffer." The cold
water tank is much larger than the internal water goes from the external tank to the application and the
return hot water from the application goes back to the external tank, not to the chiller.[citation needed]

The less common open loop industrial chillers control the temperature of a liquid in an open tank or sump
by constantly recirculating it. The liquid is drawn from the tank, pumped through the chiller and back to
the tank. In industrial water chillers is the use of water cooling instead of air cooling. In this case the
condenser does not cool the hot refrigerant with ambient air, but uses water that is cooled by a cooling
tower. This development allows a reduction in energy requirements by more than 15% and also allows a
significant reduction in the size of the chiller, due to the small surface area of the water-based condenser
and the absence of fans. Additionally, the absence of fans allows for significantly reduced noise
levels.[citation needed]

Most industrial chillers use refrigeration as the media for cooling, but some rely on simpler techniques
such as air or water flowing over coils containing the coolant to regulate temperature. Water is the most
commonly used coolant within process chillers, although coolant mixtures (mostly water with a coolant
additive to enhance heat dissipation) are frequently employed.[7]

Industrial chiller selection [ edit ]

Important specifications to consider when searching for cumond industrial chillers include the total life
cycle cost, the power source, chiller IP rating, chiller cooling capacity, evaporator capacity, evaporator
material, evaporator type, condenser material, condenser capacity, ambient temperature, motor fan type,
noise level, internal piping materials, number of compressors, type of compressor, number of fridge
circuits, coolant requirements, fluid discharge temperature, and COP (the ratio between the cooling
capacity in RT to the energy consumed by the whole chiller in KW). For medium to large chillers this
should range from 3.5 to 7.0, with higher values meaning higher efficiency. Chiller efficiency is often

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specified in kilowatts per refrigeration ton (kW/RT).

Process pump specifications that are important to consider include the process flow, process pressure,
pump material, elastomer and mechanical shaft seal material, motor voltage, motor electrical class, motor
IP rating and pump rating. If the cold water temperature is lower than −5 °C, then a special pump needs to
be used to be able to pump the high concentrations of ethylene glycol. Other important specifications
include the internal water tank size and materials and full load current.

Control panel features that should be considered when selecting between industrial chillers include the
local control panel, remote control panel, fault indicators, temperature indicators, and pressure indicators.

Additional features include emergency alarms, hot gas bypass, city water switchover, and casters.[6]

Demountable chillers are also an option for deployment in remote areas and where the conditions may be
hot and dusty.[8]

Refrigerants [ edit ]

Main article: Refrigerant

A vapor-compression chiller uses a refrigerant internally as its working fluid. Many refrigerants options
are available; when selecting a chiller, the application cooling temperature requirements and refrigerant's
cooling characteristics need to be matched. Important parameters to consider are the operating
temperatures and pressures.

There are several environmental factors that concern refrigerants, and also affect the future availability for
chiller applications. This is a key consideration in intermittent applications where a large chiller may last
for 25 years or more. Ozone depletion potential (ODP) and global warming potential (GWP) of the
refrigerant need to be considered. ODP and GWP data for some of the more common vapor-compression
refrigerants (noting that many of these refrigerants are highly flammable and/or toxic):[9]

Refrigerant ODP GWP

R12 1 2400
R123 0.012 76
R134a 0 1300
R22 0.05 1700
R290 (propane) 0 3
R401a 0.027 970
R404a 0 3260
R407a 0 2000
R407c 0 1525
R408a 0.016 3020
R409a 0.039 1290
R410a 0 1725
R500 0.7  ???
R502 0.18 5600

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R507 0 3300
R600a 0 3
R744 (CO 2)[10] 0 1
R717 (ammonia) 0 0
R718 (water) [11] 0 0

R12 is the ODP reference. CO 2 is the GWP reference

The refrigerants used in the chillers sold in Europe are mainly R410a (70%), R407c (20%) and R134a
(10%).[12]

See also [ edit ]

Architectural engineering
BTU
Building services engineering
Chemical engineering
Cooling tower
Evaporative cooling
Free cooling
Heat Pump
HVAC
Mechanical engineering
MOKON
Pipefitter
Seasonal thermal energy storage

References [ edit ]

1. ^ "The Science Behind Refrigeration" . Berg Chilling Systems Inc. Retrieved 2016-02-24.
2. ^ III, Herbert W. Stanford (2016-04-19). HVAC Water Chillers and Cooling Towers:
Fundamentals, Application, and Operation, Second Edition . CRC Press. p. xvii.
ISBN 9781439862117.
3. ^ TITAN Multistage Industrial Chillers (FORM 160.72-EG1) (PDF). York International.
Retrieved 23 February 2015.
4. ^ American Society of Heating, Refrigerating and Air-Conditioning Engineers
http://www.ashrae.org/publications/page/158
5. ^ Request for Proposal #946 - Emergency Chillers Rentals (PDF). Montclair State University.
Retrieved 23 July 2015.
6. ^ a b http://matsu.com.au/chiller-range/chiller-range-2
7. ^ III, Herbert W. Stanford (2016-04-19). HVAC Water Chillers and Cooling Towers:
Fundamentals, Application, and Operation, Second Edition . CRC Press. p. 113.
ISBN 9781439862117.
8. ^ "Summit Matsu Chillers - Chillers for Mining - Summit Matsu Chillers" . Summit Matsu Chillers.
9. ^ "Refrigerants" . Archived from the original on 5 July 2013. Retrieved 5 July 2013.
10. ^ "R744 (Carbon dioxide)" . Archived from the original on 5 July 2013. Retrieved 5 July 2013.

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11. ^ Kilicarslon, Ali; Müller, Norbert (18 July 2005). "A comparative study of water as a refrigerant
with some current refrigerants" (PDF). Int. J. Energy Res. Wiley. 29: 947–959.
doi:10.1002/er.1084 .
12. ^ Eurovent Market Intelligence https://www.eurovent-marketintelligence.eu/

External links [ edit ]

Glossary of Basic Chiller Terms

Chiller Energy Consumption Calculator (requires Java)

Authority control GND: 4133762-1

Categories : Cooling technology Heating, ventilating, and air conditioning

Mechanical engineering Chemical equipment

This page was last edited on 6 May 2017, at 11:48.

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