A Quick Guide to Choosing the Correct Chiller

Heat is a common by-product of today's manufacturing machines, which include the advanced automation technology required for high-speed operation and high precision. Components such as spindle motors, variable frequency drives, lasers and X-ray sources all require cooling to operate properly and reliably - often in very harsh manufacturing environments.

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As manufacturing space is at a premium and machine packages become smaller and smaller, liquid cooling has become the most efficient and cost-effective method of removing process heat. Particularly suited to hot, dirty environments, liquid cooling provides a way to remove heat from the machine without contributing additional heat back into the environment.

A quick guide to choosing the right chiller.

As every industrial environment is different, a 6-step guide to help you choose the right chiller for your application:

 Water Cooled Screw Chiller

Step 1: Determine the thermal load

It is important to determine the thermal load of your application to ensure that the chosen chiller is large enough for the intended application. There are a number of ways to determine the thermal load (in BTU's) but understanding the process is essential to calculating an accurate thermal load.

Step 2: Determine coolant type, temperature and flow rate

When the heat load is known, the next step is to determine the coolant, its target temperature and the flow rate that the cooler must provide for the process. This depends on the method of heat transfer from the process to the coolant and the type of coolant used. Water, for example, has different properties to oil.

Step 3: Determine the installation environment

In what environment is the chiller to be installed? For example, indoor applications may encounter hot and dirty environments, while outdoor installations may encounter cold and hot environments. This can affect the size of the chiller and require accessories such as air filters, oil tank heaters etc.

 Air Cooled Screw Chiller

Step 4: Using chiller performance curves

Now use the available chiller performance curves to select a chiller model that meets or exceeds the required capacity based on the chilled water supply temperature and the maximum expected ambient air temperature. Application safety margins associated with available rack sizes should be considered to maximise the value of chiller selection. Find all Brannenberg chiller performance curves in the Thermal Management catalogue.

Step 5: Check pump performance curves

Check the available pump performance curves to ensure that the pump is able to deliver sufficient pressure at the design flow rate to meet the application. Some liquid cooling systems have smaller coolant flow paths or longer distances, so pressure losses may be higher than average.

Step 6: Final selection

Finally, consider the remaining application requirements such as power characteristics, control options, footprint, list of mechanisms, colours, etc. that have been met by the selected Standard Brannenberg chiller. Choosing a standard chiller will give you greater reliability, easier access to universal spare parts service and global support.

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Industrial chillers are an important part of many manufacturing and production processes. They are designed to cool process fluids, such as water, oil, and air, and can be used for various applications, such as cooling process equipment, removing heat from process fluids, and maintaining storage tanks at the desired temperature.

Selecting the right chiller for your application is critical to ensuring efficient operation and avoiding costly downtime. Choosing an industrial chiller can be a daunting task, but it is important to select a unit that will meet the specific needs of your application. 

Once you’ve determined your needs, you can begin narrowing down your options. Here are six considerations you need to make to help you choose the best industrial chiller for your needs:

1) Process Fluid Performance

What type of fluid will be cooled by the chiller? What are the specific temperature and flow requirements? Once you have determined the answers to these questions, your alternatives will be more limited, and you’ll be able to select a chiller that will perform as well as it possibly can for your application.

2) Cooling Fluid Temperature

The cooling fluid temperature is an important factor to consider because it will determine the type of chiller you need. For instance, if the cooling fluid temperature is between 32°F and 104°F, air-cooled chillers are used, while chillers that use water are utilised when the cooling fluid temperature is above 104°F.

3) Process Flow Rate

As we all know, the main function of a chiller is to remove heat from a process fluid. This is determined by the specific needs of the application. The higher the flow rate of the chiller, the larger it needs to accommodate the demand. If the chiller is too small, it will not be able to cool the fluid quickly enough, resulting in a decrease in performance.

4) Process Flow Pressure

The performance of the industrial chiller will be influenced by the process flow pressure. If the flow pressure is too high, it can cause the chiller to work harder than necessary and lead to increased energy consumption. Conversely, if the pressure is too low, it can result in reduced cooling capacity and efficiency.

5) Chiller Operating Environment

The operating environment of the chiller has to be appropriate for it to function properly, which is why it must be taken into account when selecting a unit. If the chiller will be located in a high-temperature environment, it is important to choose a unit that is designed for that specific condition.

6) Chiller Operating Space

Chillers exist in various sizes, so choosing a unit requires carefully considering the available space. It is quite important to select a chiller that is properly sized for the application. Making sure the chiller has enough space to operate effectively is crucial. If the chiller is too big or too small for the operating space, it can lead to inefficient operation.

Conclusion

Ultimately, choosing the right chiller for your needs is essential for its overall performance. Be confident that you’re selecting the ideal industrial chiller for your requirements by considering all of these factors.

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