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Chiller Sizing
Chiller Sizing
Introduction
After a technical review, a company has decided that a chiller is required for the molding operations. The next, more difficult, step is how much chiller is needed for my operations. If they select too small a chiller, the undersized unit will never cool the processing equipment creating bad parts. They can choose too large a chiller, allowing for future expansion. However, the company could be paying for capacity that will never be used. Because of these issues, sizing a chiller to slightly exceed the capacity requirements is the most cost effective option. To facilitate this choice, we recommend the following calculations for providing data to the decision-making process. In addition, utilizing more than one formula to cross-check operations is recommended.
J. DeRosnay (July 3, 1998): "Entropy and the Laws of Thermodynamics", in: F. Heylighen, C. Joslyn and V. Turchin (editors): Principia Cybernetica Web (Principia Cybernetica, Brussels), URL: http://pcp.lanl.gov/ENTRTHER.html .
January, 2007
CHILLER SIZING
The HEAT OUT part of the equation is primarily a chiller. Some heat is lost by natural conditions such as being emitted into the ambient air. Systems where it is not desirable to lose heat (energy) to the surrounding air use some form of insulation. For the purposes of this training, the universe can be defined simply as a Plastic Processing Apparatus that has some form of heat source and is being cooled by an IMS Chiller. Here is a simple schematic:
The arrow shows flow of the heat transfer fluid which is typically a mixture of ethylene glycol and water. Optimum heat transfer is commonly 25% glycol by volume. Propylene glycol can also be used. The Plastic Processing Apparatus can be any number of physical items. Some of the most common are: an injection mold an extrusion die an extrusion cooling tank To accurately size the chiller using the above definitions and principles, you can see that it is necessary to define (and ideally measure) all sources of heat going IN or OUT of the process. With this understanding, we can now discuss some common ways to approach chiller sizing.
January, 2007
CHILLER SIZING
Chiller Sizing Method #1
Based on Resin usage.
The IMS Company Catalog contains a formula that can be used to size a chiller on an injection molding process. The formula and description are as follows: Tonnage = A x ( B C ) Removal Capacity where: A=Material Use in lbs./hr B=Temperature of Melt C=Temperature of part when it comes out of mold Removal Capacity=12,000 BTU/hr./ton removal capacity of chiller system set at 50F, which includes estimated radiation losses, etc. At 40F, use 8,000. At 30F, use 6,100. At 20F, use 5,800. Always round up. Example: 100 lbs./hr processes (not the machine rating) 450F melt temperature 150F part temperature when mold opens Tonnage = 100 x ( 450 150) = 12,000 100 x 300 12,000
= 30,000 / 12,000 = 2.5 Round up to the next size: 3 Ton Here is the process model that forms the basis of this sizing formula:
Heat is transferred from the melt to the mold as it flows into and resides in the mold cavity. The formula assumes that this is the only transfer of heat out of the plastic and is the sole reason that the temperature of the part is less than the temperature of the melt. Heat is transferred from the mold to the cooling water that circulates from the chiller. The formula assumes that this is the only transfer of heat out of the mold. The calculated cooling capacity (chiller size in Tons) is the measure of the amount of heat given off to the mold by the plastic that must be carried away by the cooling water. Once back in the chiller, this heat is removed from the water, via a heat exchanger, and can re-circulate as chilled water. The large
G.Hise, author J. Cavanaugh, editor January, 2007
CHILLER SIZING
tank in the chiller acts as a reservoir to spread out the load on the refrigeration system (meaning the heat exchange in the chiller does not have to match the rate of heat exchange at the mold). For best results with this formula, these considerations must be evaluated: The process must be similar to the drawing above. Likely, this will be an injection molding process. You must know intended chilled water temperature set point that the molder will use because it greatly affects the formula (the Removal Capacity). The colder the water temperature that will be maintained, the larger the calculated chiller size will be. The temperature of the plastic part should be taken immediately when it falls from the mold. A delay allows the part to cool. This can actually cause the chiller sizing to be too high (the B-C number will be larger than actual).
Notice this is the same basic drawing used to define our terms earlier in the article. This should give you a sense that this formula is much more general and universally applied than the previous published formulas. One fact should stand out and it is the primary reason why this formula cannot be used exclusively, that is, this formula depends upon the process already having circulating cooling water that can be measured. This may be a portable chiller, a central chiller, water from a well, water from a cooling tower, or any other source of cool water. If the process is new or for some other reason does not already have cooling going on, then some other formula must be used.
January, 2007
CHILLER SIZING
If the cooling that you measured is adequate and represents the same job (heat removal) that you wish the new chiller (that you are sizing) to do, then you are done. Your answer is the required chiller size. Suppose a circulating cooling line is in place, but it is not adequate. For example, suppose you need the process cooled to 200F. Water from a cooling tower is flowing through the process and keeping it at 250F. Suppose that without the water from the cooling tower, the process is at 400F. Clearly, the existing cooling is providing some heat removal, however if you size the chiller to match that capacity, the chiller will be undersized. If this is an injection molding process, then the IMS formula may work, otherwise it is necessary to take a step back, define the process and take a more general approach explained below.
CHILLER SIZING
Following are three examples showing a variety of approaches: Example A is injection molding of coat hangers. The chiller cools the injection mold each cycle. Example B is an extrusion line. A spray tank is used to cool extruded pipe. The chiller supplies the spray tank with cool water. Example C is vertical molding using a tank of chilled water to keep the mold cool. The chiller keeps the cooling tank at a constant temperature.
January, 2007
CHILLER SIZING
EXAMPLE B: Chiller Sizing General Approach
PROCESS INFORMATION ON THE SIZER incoming water temp: 65F water temp upon exit: 70.5F spray nozzles in use: 140 max water flow each nozzle: 1.35 gal/min incoming water pipe: qty.2 1.5 inch lines length of cooling chamber: 240 inches schedule 40 PVC pipe, 4.25OD, 4.00 ID (also run schedule 80) processing speed: 2000 pounds/hr melt temp: 320F die temp: 380F pipe temp upon exiting the die: 360F pipe temp upon exiting the cooling chamber: 113F specific heat of plasticized PVC: 0.30 density: 87.4 pounds/foot3 thermal conductivity: 1.11 BTU-in/hr-ft2-F CHILLER REQUIREMENTS 45-50F water out 50-60F tower water coming in 480VAC incoming power air-cooled optional filter on incoming water CHILLER SIZING CALCULATION kW = [WT X CP X T] / [3412 X H] where WT = weight of material to be cooled (lbs.) CP = specific heat T = temperature decrease (F) H = cooling time (hours) Using one cooling chamber length of material: WT = 240 in X X [(4.25in)2 (4in)2] X 87.4 lbs/ft3 X 1ft3/1728 in3 = 78.65 lbs (78.65 lbs) / (240 in) = 0.3277 lb/in (2000 lb/hr) X (1in / 0.3277 lb) = 6102.65 in/hr H=(240 in) / (6102.65 in/hr) = 0.0393 hr T = 360F - 113F = 247F CP = 0.30 So, kW = (78.65 x 0.30 x 247) / (3412 x 0.0393) = 43.46 kW 43.46kW x 3414.99 BTU/hr-kW = 148,415 BTU/hr (148,415 BTU/hr) / (12,000 BTU/hr/ton) = 12.4 Ton closest size is 15 ton. Recommend 15 Ton Chiller.
G.Hise, author J. Cavanaugh, editor January, 2007
CHILLER SIZING
Suppose you cannot afford a 15 Ton chiller. To get the chilling requirements down to 10 Ton, the next smaller size and price point, you could slow down the processing speed, hurting production and cutting profits, or not cool the pipe down as much provided you can still hold the dimensional tolerances and handle it. Better yet, you can use the full 15 Ton chiller, speed up the line, thereby increasing production and profits and making the chiller a great return on investment.
kW = (20 x 50) / (325 x 1) = 3.08 kW Converting kW to BTU/hr: 3080 W x 3.4129 = 10,512 BTU/hr 10,512 BTU/hr / 12,000 BTU/hr/ton = 0.876 Ton Closest Chiller Size is 1-Ton Chiller
CHILLER SIZING
Tonnage = 40 x (400 80) = 1.07 Ton 12,000 Closest Chiller Size is 1-Ton Chiller
January, 2007