Vaporizer System
An in depth explanation of process cooling applications and types of cooling systems. by Smart Cooling
What is Process Cooling?
Process cooling can entail a process chiller and/or a cooling tower system being used to cool a process line or manufacturing line. Normally, something is being made or built. During the production process, heat is generated either by the product itself (molten plastic for example), by the hydraulics needed to move the product, or by some other means. Typically, process chillers are used to cool the manufactured product while cooling towers typically cool auxiliary equipment, like hydraulics. This is true because the products being cooled require a lower temperature cooling water than the auxiliary equipment.
What types of industries use Process Cooling?
Most manufacturing processes involve process cooling and process chillers.
These include:
Petrochemical Industry
Food & Bakery Industries
Laser & Waterjet cutting
Plastics Industry
Medical & Pharmaceutical Industries
Printing Processes (newspapers, paper plates, etc)
There are many specialty industries that utilize process chillers but may not be viewed as true process cooling applications. These include: Ice Rinks, dry cleaners, purified water cooling (for military), and cooling for frozen yogurt machines.
What are typical Process Cooling Systems?
A process cooling system will consist of either a cooling tower package or a process chiller (or chilled water system). Each cooling system has its temperature limits and in some cases, a process cooling application may require both a cooling tower system and a chilled water system.
Cooling Tower System
The cooling tower system features an evaporative cooling tower, a tower water tank, process and recirculation pumps, and depending on the cleanliness of the process water, a secondary plate and frame heat exchanger. At Smart Cooling Products, we feature Fiberglass cooling towers from 3 to 660 tons. We offer both a commercial counter-flow fiberglass cooling tower as well as a CTI certified industrial cross-flow cooling tower.
Smart Family of Cooling Products use only the highest quality, corrosion resistant 304 stainless steel in the manufacture of our water tanks. This corrosion resistant construction and overall industrial design will provide the end user with many years of trouble-free service. Our engineers design the tower water tank to accept the full cooling tower drain down volume so during plant shut downs there is no water loss. The pump package and tank walls rest on an industrial grade structural steel welded frame.
When the cleanest process water is required, we utilize a secondary plate and frame heat exchanger to isolate the dirty tower water from the clean process water. Because of its design, the heat exchanger is both compact and fully cleanable. Keeping the system as factory complete as possible, the heat exchanger comes pre-piped on the water tank skid for easy install.
Different Types of Process Chiller Designs
A process chiller is labeled air cooled, water cooled, or evaporative condensed. That description simply denotes how the system’s heat is being removed. Trying not to get too involved in the technical aspect, we will briefly explain the refrigeration cycle:
Refrigerant enters the compressor and is compressed. During compression, heat is also added to the refrigerant. Upon exiting the compressor, the superheated vapor refrigerant goes to the condenser where both the sensible and latent heat is removed. The refrigerant leaves the condenser at high pressure but it is now in the (sub-cooled) liquid state. Before entering the evaporator, the refrigerant passes through an expansion valve that contains a very small orifice. As it crosses through this valve, both the pressure and temperature decrease. Then the refrigerant enters into the evaporator where it absorbs the heat from the process fluid. During this time, the refrigerant changes state yet again back to (saturated) vapor. It then goes back to the start and enters the compressor.
Air Cooled Chillers
Air cooled process chillers are typically the least expensive system and most popular. They are a standalone piece of equipment. Air cooled chillers consist of a compressor (or multiple compressors), an evaporator, an air cooled condenser, and an electrical control package. Although air cooled chillers are the easiest to install, they are the least efficient of the choices as well. Typical EER (Energy Efficiency Ratio) values range from 9 up to 11 for standard air cooled units. Smart Family of Cooling Products offers air cooled scroll chillers from 1/4 ton up to 115 tons and air cooled screw chillers from 30 ton to 300 tons.
Water Cooled Chillers
While Air Cooled Chillers are standalone pieces of equipment, water cooled process chillers rely on a secondary cooling source, typically a cooling tower, to cool its condenser. They are more efficient than air cooled chillers but require additional piping, a cooling tower, and a tower water recirculation pump, which adds extra cost overall. Water cooled chillers consist of a compressor (or multiple compressors), an evaporator, a water cooled condenser, and an electrical control package. While the typical EER values for a water cooled chiller can range from 13 to almost 17, that does not incorporate the kW value that the cooling tower fan and recirculation pump add to the system. Smart Family of Cooling Products feature water cooled scroll chillers from 1 to 60 tons, water cooled chillers with semi-hermetic reciprocating compressors from 10 tons to 100 tons, and water cooled screw chillers from 30 to 350 tons.
Evaporative Condensed chiller
The Evaporative condensed chiller is the most energy efficient alternative available. It does have a higher initial cost, however the payback on that difference is typically just a few years. What makes an evaporative condensed chiller unique is that it relies on an integral evaporative condenser to remove the sensible and latent heat from the system.
To better explain how evaporative condensed chillers work, let us first discuss what “wet bulb” is and how it is tied this chillers performance. Wet bulb temperature is based on the amount of moisture in the air and is measured by a sling pyschrometer. The psychrometer is made of two glass thermometers. One thermometer is used to measure the ambient air temperature. The second thermometer has a wick attached to its bulb. The wick is dipped in distilled water and then spun around. As the thermometer is spun, the water evaporates. After a few minutes the temperature will reach its lowest temperature and hence, the correct wet bulb temperature for the location. Now, keep in mind, the lower the wet bulb temperature, the drier the air. The drier the air, the more moisture that air will accept.
The refrigerant in the chiller system travels through a coil bundle inside the evaporative condenser. Within the condenser, water is either drawn or blown across the coil and evaporated. Remembering that the drier the air, the more evaporation that can take place; the lower the wet bulb, the more efficient our system will be. Where most air cooled chillers use a condensing temperature of 120-125ï
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January 25, 2012 9:03 pm 3 Comments
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