An industrial water chiller is a device designed to remove heat from a process or equipment and transfer it to a separate water source. It is commonly used in various industrial applications, such as cooling machinery, lasers, plastic molding machines, and other processes that generate heat. The basic working principle involves the circulation of a coolant, typically water or a water-glycol mixture, through a closed loop.

Here is a general overview of how an industrial water chiller works:

Evaporator:
The process begins in the evaporator, where the chiller absorbs heat from the process or equipment that needs to be cooled.

The coolant (water or water-glycol mixture) flows through a coil or heat exchanger in the evaporator. As it circulates, it absorbs the heat from the process, causing the coolant to evaporate.

The vaporized coolant is then drawn into the compressor, which increases its pressure and temperature. This compression process is a key step in the refrigeration cycle.

The high-pressure, high-temperature vapor is then routed to the condenser.

In the condenser, the hot refrigerant vapor releases heat to a separate water circuit or air.

As the refrigerant gives up heat, it undergoes a phase change from vapor to liquid.

The high-pressure liquid refrigerant then passes through an expansion valve, where its pressure is rapidly reduced.

This reduction in pressure causes the refrigerant to expand, resulting in a decrease in temperature.

The now-cool refrigerant returns to the evaporator to absorb more heat from the process, and the cycle repeats.

Simultaneously, a separate water circuit, known as the cooling water circuit, is responsible for carrying away the heat absorbed by the chiller.

This cooling water is circulated through the condenser to remove the heat from the refrigerant.

A control system regulates the chiller's operation based on the temperature requirements of the process or equipment being cooled.
The system may include sensors, a thermostat, and a controller to maintain the desired temperature.

By continuously circulating the coolant through this refrigeration cycle, an industrial water chiller efficiently removes heat from the target process or equipment, ensuring that it operates within optimal temperature ranges.

OUMAL as a professional manufacturer and supplier of industrial chillers. Provides various types of cooling water chillers. Including air-cooled chillers and water-cooled chillers. Welcome to consult! oumal@oumal.com

In this era of advocating energy saving and environmental protection, it is very necessary to reduce the operating cost of the screw chiller. We can start from the product itself, and pay attention to various details in daily use, so as to reduce energy consumption and reduce the operating cost of the screw chiller. To reduce the operating cost of the screw chiller, we must start from its energy consumption. The energy consumption of the screw chiller mainly depends on whether the unit is faulty, and the other is the operating power of the unit. Next, let's talk about how to reduce the operating cost of the screw machine from several aspects.

1) Regular maintenance: Regular maintenance of the screw chiller is essential to ensure efficient operation. This includes cleaning the evaporator and condenser coils, checking and maintaining refrigerant levels, lubricating the compressor, and replacing worn out components.

2) Optimize water flows: Adjusting the flow rates of the chilled and condenser water can significantly impact the energy consumed. By minimizing the flow rates, the chiller consumes less energy.

3) Control temperature set points: Ensure optimal set points for both condensing and evaporator temperatures to prevent unnecessary operation of the chiller.

4) Use economizer mode: Many screw chillers have an economizer mode that utilizes free cooling when the outside temperature is cooler. This mode helps save energy and reduces running costs.

5) Upgrade to an energy-efficient system: Consider upgrading to a more efficient screw chiller model to reduce running costs. The initial investment may be higher, but it will pay off in terms of reduced energy consumption and lower operating costs.

6) Utilize VFDs: Variable Frequency Drives (VFDs) allow the chiller to operate at varying speeds, depending on the cooling requirement. This results in less energy consumed, along with reduced wear and tear on the equipment.

7) Use high-efficiency motors: The installation of high efficiency motors can significantly reduce energy consumption. These motors have high power factors, which means they consume less energy while operating at the same load.

8) Monitor energy usage: Regular energy monitoring helps identify inefficiencies and areas for improvement. By tracking energy usage, property owners can determine the best practices for reducing operating costs.

The selection of the water pump is a particularly critical step in the commissioning of the chiller. A suitable water pump can ensure the normal operation of the chiller, save energy and reduce maintenance costs.When choosing a pump for a chiller, there are several factors to consider:

Flow Rate: Determine the required flow rate based on the cooling capacity and specifications of the chiller. The pump should be capable of delivering the necessary flow rate to ensure efficient cooling. The flow rate is typically measured in gallons per minute (GPM) or liters per minute (LPM).

Head Pressure: Consider the required head pressure or pressure drop for the chiller system. It depends on factors such as the length and diameter of the piping, the resistance of the heat exchangers, and any additional components in the system. The pump should be able to provide sufficient pressure to overcome the head loss and maintain the desired flow rate.

Pump Type: Select the appropriate pump type for your application. Common pump types used in chiller systems include centrifugal pumps and positive displacement pumps. Centrifugal pumps are generally more suitable for high flow rates, while positive displacement pumps are better for applications with variable or lower flow rates.

Steps for pump selection

1. Determine the working parameters of the chiller

Before selecting the type of water pump, it is first necessary to clarify the working parameters of the chiller, including cooling capacity, external ambient temperature, cooling water diameter, etc.

2. Choose the right pump type

When selecting models, it is necessary to choose popular pump types, such as centrifugal pumps, axial flow pumps, mixed flow pumps, etc. At the same time, full consideration should be given to indicators such as flow, lift, and efficiency, which can usually be calculated by professional selection software on the market or Refer to the selection manual of the large water pump manufacturer.

3. Determine the pump shaft power and motor power

After the selection, it is necessary to calculate the shaft power of the pump and the corresponding motor power based on the flow rate and head. In general, it is necessary to refer to the parameter manual of the pump manufacturer, or use professional software for calculation.

4. Check whether the matching of water pump and chiller is suitable

After determining the shaft power of the water pump and motor, it is necessary to check the data to ensure that the working range of the selected water pump can match the flow rate, head and other parameters required by the chiller, so as to ensure the normal operation of the chiller.

Industrial chillers can realize mutual switching, speed up production progress, reduce energy consumption, improve product molding efficiency, suppress product defects, and reduce the occurrence of defective products. Screw chillers are widely used in many fields such as electronics, rubber, plastics, papermaking, petroleum, chemical industry, food, machinery, brewing, vacuum coating, pharmaceuticals, etc., and are also widely used in places with centralized cooling to facilitate centralized management.

In industrial manufacturing, chillers are crucial to the transfer of heat. However, many chiller ma chines are prone to poor heat dissipation after a period of actual operation. At this time, product maintenance should be carried out in a timely manner.

First of all, let's clarify the signs of poor heat dissipation of the chiller. When the condenser of the chiller has poor heat dissipation, the efficiency of the compressor will decrease, and the operating current will increase, which will eventually lead to the air-cooled chiller high pressure. When the air-cooled high pressure rises to 24kg/cm2, the water-cooled chiller high pressure will rise to 20kg/cm2 is a sign of poor heat dissipation of the chiller. At this time, maintenance should be carried out in time.

Poor heat dissipation and treatment methods of water-cooled screw chiller:

When the heat dissipation of the condenser is poor, the efficiency of the compressor will be low, and the operating current will increase. The compressor will trip due to the protection of the high-voltage switch, causing the compressor to stop running. Whether the circulating water of the cooling tower is normal, whether the temperature of the cooling water is too high, whether the cooling tower fan pump is running, and whether the cooling water valve is open. After the above things are normal, you need to press the reset button again, or shut down and restart to operate normally. If high pressure overload occurs frequently, the condenser needs to be cleaned.

Treatment method for poor heat dissipation of air-cooled screw chiller:

1. Check whether thefin condenser of the chiller isdirty, if so, clean it with a small brush.

2. Check whether the fan of the chiller is working normally. If not, you can blow it with air or wipe it clean with a soft cloth dipped in some detergent.

3. Move the chiller to a well-ventilated place to avoid blocking the radiator.

4. If the heat dissipation performance of the chiller is still not good, you can consider upgrading the accessories of the chiller, such as fans, heat sinks or other components.

The above is Oumal's solution to the poor heat dissipation of the chiller. For more detailed information, please contact our Oumal manufacturer or Oumal sales: oumal@oumal.com.

Refrigerant leakage is a common failure of air-cooled chillers. To deal with refrigerant leakage of chillers, we must first understand the cause of refrigerant leakage and find out the cause of the failure to reduce losses caused by refrigerant leakage. If you have a refrigerant leak in an air-cooled chiller, it is important to address it promptly to prevent further damage and ensure the efficient operation of the system. Here are some steps to deal with a refrigerant leak:

Identify the Leak: Use a refrigerant leak detector or bubble solution to locate the source of the leak. Common areas where leaks occur include connections, fittings, valves, and joints.

Ensure Safety: Make sure to follow proper safety procedures when dealing with refrigerants. Wear protective gear such as gloves and goggles, and work in a well-ventilated area.

Repair the Leak: Depending on the size and location of the leak, you may be able to repair it yourself or contact a professional HVAC technician. Common repair methods for air-cooled chillers include tightening fittings, replacing faulty valves or gaskets, or soldering joints.

Evacuate and Recharge Refrigerant: If the refrigerant has leaked significantly, it may be necessary to evacuate the remaining refrigerant from the system using a recovery machine. Once the leak is repaired, vacuum the system to remove any moisture or air, and recharge it with the appropriate amount of refrigerant as specified by the manufacturer.

Test for Leaks: After the repair and recharge, test the system for any remaining leaks. Use a refrigerant leak detector or soap bubbles to carefully check all connections and areas that were repaired.

Monitor and Maintain: Regularly monitor the chiller system for any signs of leakage, such as reduced cooling capacity or unusual noises. Perform routine maintenance, including checking and tightening fittings, cleaning coils, and replacing worn-out parts, to prevent future leaks.

Remember, handling refrigerants can be hazardous and may require proper certification or training. If you're unsure or uncomfortable with dealing with refrigerant leaks, it's best to engage a licensed professional HVAC technician to assess and repair the leak.

Industrial chillers consume a lot of energy, especially in hot weather, and they have to work harder to maintain the desired temperature. In order to achieve the purpose of energy saving, users of various industrial chillers in the enterprise can combine their own actual operating environment to choose a suitable energy-saving solution for industrial chillers to improve the overall operating efficiency. Help enterprises complete all production processes with higher capital. Here are some ways to reduce your industrial chiller’s energy consumption during hot weather:

Optimizing Chiller Operating Conditions: Make sure your chiller is running at peak performance by regularly checking set points, temperature differentials, and water flow. Also, make sure the chiller is serviced and maintained regularly to avoid any inefficiencies.

Install a Variable Speed Drive (VSD): A VSD can be installed on the chiller's compressor to ensure the chiller is only running at its required capacity. This helps to significantly reduce energy consumption, since the chiller does not have to work at full capacity all the time. Equipped with a frequency conversion processing device, the high-quality frequency conversion device can achieve the effect of adjusting the speed of the compressor. If the low-pressure refrigerant can increase the pressure when it passes through the compressor, the speed of the centrifuge will cause a large-scale increase. The higher the pressure, the greater the load capacity it can provide. Use the frequency conversion processing device to work at an appropriate frequency according to the specific use environment, which can reduce the energy consumption level.

Rationally increasing the temperature of the evaporator and effectively increasing the temperature of the evaporator can improve the overall working efficiency. It provides higher evaporation in a shorter time, ensures the rapid condensation effect of the condenser, and has a great effect on quickly reducing the ambient temperature.

Recirculate with an economizer: An economizer recycles outside air to cool the water in the chiller. This is a very effective way to reduce energy consumption in hot weather, especially if the outside air temperature is lower than the return water temperature.

Improve insulation: Make sure the chiller and its components are well insulated to prevent heat loss. This helps reduce energy consumption because the chiller doesn't have to work as hard to maintain the desired temperature. Reasonably reduce the temperature of the condenser and reduce the temperature range of the condenser to adjust the entire low temperature to a lower level. The lower the temperature of the condenser, the faster the ambient temperature will drop, thus increasing the working power of the whole device.

Implement a maintenance program: A regular maintenance program helps to spot any inefficiencies in the chiller system and resolve them in a timely manner. This helps reduce energy consumption and extend the life of the chiller. Of course, this kind of maintenance is purpose maintenance. For example, you can start with the system. Only by doing a good job of maintenance can the equipment be used better and the efficiency will be greatly improved.

Consider Alternative Cooling Solutions: Depending on the application, alternative cooling solutions such as evaporative cooling or geothermal cooling may be used. In some applications, they are more energy efficient than traditional chillers.

Overall, reducing energy consumption of industrial chillers during hot weather requires a combination of regular maintenance, optimizing operating conditions and considering alternative cooling solutions.

Industrial chillers

can produce vibrations and noise during operation, so it’s important to take measures to reduce them. Here are some steps you can take to reduce vibration and noise in industrial chillers:



Choose an appropriate chiller model with high-quality components and sound insulation technology that help minimize vibration and noise.



Install the chiller on a solid and flat surface, and use rubber or vibration-damping pads under the chiller to help reduce vibration and noise.



Make sure there is enough space around the chiller, and avoid placing other equipment or items near the chiller to prevent interference that could cause vibration and noise.



Install sound-absorbing materials, such as acoustic foam or soundproof panels, on the sides of the chiller to reduce the reflection and propagation of sound.



Ensure that the chiller is properly maintained and cleaned on a regular basis, including replacing old vibration-damping pads or filters, to keep it running smoothly and reduce vibration and noise.



By following these steps, you can effectively reduce vibration and noise in industrial chillers and improve their efficiency and comfort in usage.

Air-Cooled scroll chiller VS Air-Cooled Screw Chiller

Functionally: The air-cooled screw chiller and the air-cooled scroll chiller have the same cooling function. The cooling, heating and energy are all electric energy.

Application industry: are mainly used in industry, medicine, plastic, food, coal, shopping malls and other industries.

It can be installed on the roof or outdoor courtyard, without the need for a dedicated machine room and cooling tower.

The smallest air-cooled screw chillers are 30HP/30Ton, while air-cooled scroll chillers range from 1HP/1Ton to 60HP/60Ton. The two categories differ on the basis of capacity range. Another difference is that screw chillers do not have a built-in water tank and water pump, while air-cooled scroll chillers have a water tank and water pump. Furthermore, it has a compact design, so it is easy to integrate. Unlike screw chillers with touch screens, air-cooled scroll chillers are equipped with an easy-to-use PID controller. The Oumal air-cooled screw chiller control system uses Siemens PLC + WeiView HDMI Touch Screen.

Unit characteristics comparison:

Features of air-cooled screw chiller:

Semi-hermetic screw type high-efficiency compressor, and there are single-machine system and double-machine system options. The unit has a compact structure and is easy to maintain. Adopting a new 5:6 multi-national patent asymmetric rotor tooth profile, the occlusion is tight, and the operation is stable; the use of high-efficiency motors is energy-saving and economical; the advanced intelligent defrosting method, the microcomputer analyzes the temperature of each point at any time, optimizes the defrosting cycle time, and ensures the removal of The frost is timely without affecting the heating operation, and the defrosting and heating are carried out at the same time, and the operation is more reliable and stable. Professional motor cooling device to meet harsh operating conditions. The unique design of the condensate pan eliminates the need for additional electric heating equipment, which completely eliminates the problem of freezing at the bottom of the coil during heating. A new generation of high-efficiency heat exchange tubes, the heat exchange coefficient is increased by 5%; the double-slot tube sheet hole design and advanced tube expansion technology make the structure more sealed and reliable, completely avoiding the possibility of mutual penetration. Economizer mode operation improves the cooling capacity and COP of the unit more effectively.

Features of air-cooled scroll chillers:

The use of fully enclosed scroll compressors, high-efficiency and high-quality components, and optimized system design. The scroll refrigeration system is also a simple system process in the industry. The heat pump unit cancels the one-way valve and adopts the unique bidirectional expansion valve throttling technology, which makes the system process greatly simplify. That is, the system resistance is reduced, the performance is improved, and the hidden danger of leakage is reduced, and the unit runs stably and reliably. The evaporator adopts internal thread type high-efficiency heat exchange copper tube or coil evaporator. The outer surface of the copper tube is spirally smooth and the baffle plate on the water side adopts a non-short circuit design, which improves the heat exchange efficiency of chilled water mixing. The main control equipment of the unit adopts a special microcomputer controller. Parameter setting, query is convenient, and operation is simple. Unit operation, energy regulation and self-protection. Automatic monitoring, after receiving the goods, only need to connect the water system and power supply and can be used.

Many companies use chillers, but they don't know how to choose them. When you chose a industrial chiller, we need to consider the working conditions, the installation, and the cost. Now we are talking about the cost for the air cooled chiller and water cooled chiller system.

The total cost for an air-cooled chiller system and a water-cooled chiller system can vary depending on several factors, including the capacity of the chiller, the complexity of the installation, and the specific requirements of the site. Here are some cost considerations for each type of chiller system:

Air-Cooled Chiller System:

Chiller Unit: The cost of the air-cooled chiller unit itself can vary based on the cooling capacity and efficiency rating. Higher-capacity or more energy-efficient units tend to have higher costs.

Installation: The cost of installing an air-cooled chiller system is often lower compared to water-cooled systems because there is no need for a cooling tower, water pumps, or associated water piping.

Electrical Requirements: Consider the electrical infrastructure needed to support the chiller unit, including electrical panels, wiring, and any necessary upgrades. This cost will depend on the site's existing electrical capacity.

Maintenance: Factor in ongoing maintenance costs for the chiller, such as regular inspections, filter replacement, and cleaning of the unit's condenser coils.

Water-Cooled Chiller System:

Chiller Unit: Water-cooled chiller units typically have a higher initial cost compared to air-cooled units, primarily due to the additional components required, like a cooling tower, water pumps, and water piping.

Cooling Tower: Consider the cost of the cooling tower, which is used to dissipate heat from the chiller system. The size and complexity of the cooling tower will impact the cost.

Water Pumps and Piping: Factor in the cost of water pumps and associated piping to circulate water between the chiller, cooling tower, and other components.

Chilled Water System: If the site doesn't have an existing chilled water system, additional costs may be incurred to install distribution piping and terminal units (such as air handling units or fan coil units) for delivering chilled water to the desired areas.

Water Treatment: Water-cooled systems typically require water treatment to prevent scale, corrosion, and biological growth. Consider the cost of water treatment equipment and ongoing maintenance.

In short, when choosing an air-cooled chiller and a water-cooled chiller, we need to consider comprehensively. We can contact the chiller manufacturer. They have professional refrigeration engineers who can provide professional advice for our industrial cooling water system. We choose the right chiller system.

Water Chillers have various applications in the production of the plastic industry. Some of the key applications include:

Cooling injection molding machines: In the injection molding process, high-temperature plastic materials need to be cooled and solidified to obtain the desired shape and properties. Industrial chillers can control the temperature of the injection molding machine by circulating cooling water, ensuring rapid cooling of the plastic and improving production efficiency and product quality. How to equip an injection molding machine with a chiller, please contact our sales to get a solution.oumal@oumal.com

Cooling extrusion machines: In plastic extrusion processes, high-temperature plastic pellets are extruded through an extrusion head to form shapes. During extrusion, the plastic needs to be cooled to maintain product appearance and dimensional stability. Industrial chillers provide cooling water to lower the temperature of the plastic, meeting the requirements of the extrusion process.

Cooling molds: In plastic injection molding, molds need to be cooled to facilitate demolding and rapid solidification of the plastic. Chillers can circulate cooling water into the mold to reduce mold temperature, ensuring quick solidification of the plastic, thus improving production efficiency and product quality.

Cooling plastic processing equipment: During plastic processing, equipment such as extruders, blow molding machines, and vacuum forming machines generate a significant amount of heat. Industrial chillers can use cooling water to lower the temperature, preventing equipment overheating, and improving equipment stability and lifespan.

Controlling plastic forming temperature: Different plastic materials require specific temperature ranges for molding to ensure product quality. Industrial chillers can control the molding temperature by providing cooling circulation, catering to the requirements of different plastic materials.

In summary, the applications of chillers in plastic industry production primarily revolve around temperature control and regulation during the plastic processing stage, aiming to enhance production efficiency, product quality, and equipment stability. The Air cooled chiller is widely used in the plastic industry. Also if the cooling water flow is big, we can use an air cooled screw chiller or water cooled screw chiller. When many machines need to be cool, but we use one central chiller to supply cooling water, the screw chiller is a good choice. We will help to make the best solution for your cooling water system. Contact us to chose your right chiller. WhatsApp: +86 15112554736.