Process chillers help optimize production in a wide variety of industrial operations. The refrigerant system quickly removes heat and can handle large loads during manufacturing. The working principles of industrial process chillers include vapor-compression or absorption of heat. They provide reliable and efficient cooling, ensuring optimal performance and quality of products in industries such as plastics, food and beverage, pharmaceuticals, and more.
Since 1963, Compressed Air Systems, Inc. has provided air compressor solutions to companies around the world. We specialize in air compressors, blowers, vacuum systems, industrial process water chillers, and other equipment and accessories. Our 60+ years of experience allow us to offer exceptional 24/7 customer assistance, installation, rentals, quick diagnosis, and repair services.
What Are Process Chillers?
Process chillers use water or air condensers combined with ammonia or halocarbon refrigerants to achieve an efficient cooling process for a wide variety of industries and applications. The thermal device removes heat by repeatedly conducting chilled water through a closed-loop system that creates a drop in the rising process temperatures.
The heated water then gets circulated through a chiller unit, undergoing a continuous cycle of absorption/refrigeration to remove heat from the correlated process. During this cycle, compressing a liquid from its vaporized state intensifies the cooling effect.
Most industrial process chillers rely on the physical properties of their fluid components for effective cooling. The working principles of process chillers include the following methods:
Heat Absorption Chillers
These energy-efficient cooling units utilize a single cooling cycle by circulating a coolant through the heated process. Lithium bromide is the most common refrigerant used in heat absorption process chillers.
Vapor Compression Chillers
Vapor compression chillers are comprised of several key components, with the compressor unit being a crucial element of the system. The compressor is responsible for generating the cooling effect by converting the heated refrigerant vapor into a cooler liquid form. Additionally, vapor-compression chillers often come equipped with evaporative or air/water-cooled condensers, depending on the manufacturer. These components work together seamlessly to create an efficient and effective cooling solution for a wide range of industrial processes.
Process Chillers Applications
A broad range of industries benefits from industrial process chillers in many different applications, some of which include:
- Cover Area Cooling: In manufacturing facilities, equipment often generates excessive heat that can create hazardous working conditions for employees. To mitigate this issue, companies can install a cover area cooling unit to provide a safer and more comfortable work environment. These units cool the air inside factories, offices, or other working spaces, without requiring a full-sized HVAC system, making them a cost-effective solution for temperature control in industrial settings.
- Process Cooling: Process chillers can increase equipment longevity and keep operations running efficiently. A liquid such as propylene, water, or ethylene glycol circulates throughout the area that requires cooling to maintain a safe operating temperature during manufacturing.
- Plastic Manufacturing: When molding plastics, industrial process chillers can increase the efficiency of the injection phase by lowering cycle times.
- Metal Plating and Anodizing: Electroplating and anodizing are important processes that require high temperatures to achieve an electric bond for finishing metal. However, these high temperatures also create a significant amount of heat that can be challenging to manage. Heavy-duty industrial process chillers are designed to effectively remove heat from the solution and cool the fluid in the tank, ensuring that the electroplating or anodizing process can be completed safely and efficiently.
- Food Processing: Food products such as confectionery and chocolate require regulated temperatures during the manufacturing process. The baking industry requires the use of process chillers to assist with mixing and maximize the capacity for large loads to improve product quality.
Benefits of Industrial Process Chillers
The benefits of using industrial process chillers in industries such as food production, pharmaceuticals, plastic production, petrochemicals, agriculture, and metal plating include:
- Improved Productivity
- Protection of Machines
- Saves Water Costs
- Flexible Scalability Option
- Optimized Production Limits
Process Chillers from Compressed Air Systems
Our advanced nano C¹ industrial process chillers benefit from a design repeatedly proven through tens of thousands of units in worldwide operation and perfected over 50 years of industry utilization. Our process chillers have withstood the test of time in virtually every application and industry and provide a broad range of benefits.