Six Methods for Calculating

Application Thermal/Heat Load

Mitchell Howard, Technical Manager.

June 2018
© Applied Thermal Control 2018
 What is this guide for?
To ensure chiller cooling capacity matches or exceeds heat load.
• Excess heat build-up can;
• Shorten component/product lifespans.
• Distort experiment results.
• Affect nearby equipment.
• Cause safety hazards.
• A carefully sized chiller can last upwards of
15 years with proper care and maintenance.
© Applied Thermal Control 2018
 Method 1
For when you have no data at all!
• Consult manufacturer documentation.
• Normally, figures for thermal load are described
to help source 3rd party chillers.
• These documents may also describe pressure
and flow requirements.
• Contact ATC – we may have sized for similar
applications in our 20 year history!
© Applied Thermal Control 2018
 Method 2
For when you can view a product rating label.
Example;
Q=P*SF
Q=Heat load in Watts (W) Q=P*SF
P=Rating plate Power in Watts (W)
SF=Safety Factor Q=1000*1.2
Q=1200W
• Assumes ALL energy used by the application is
converted to heat
• This method is likely to result in an overestimate

© Applied Thermal Control 2018

 Method 3
For when you can measure AC power supply output.
Example;
Q=P=(V*I*PF)*SF
Q=Heat load in Watts (W) Q=P=(V*I*PF)*SF
P=Application Power Consumption in Watts (W)
V=Voltage of AC supply in Volts (V) Q=P=(240*3*0.85)*1.2
I=Current absorbed in Amps (A)
PF=Power Factor
SF=Safety Factor
Q=P=612*1.2
Q=P=734.4W
• This method looks at the amount of energy
released into an AC circuit, versus the amount Q=734.4W
provided at source.
• Still assumes ALL energy used is converted to
heat, apart from power supply.

© Applied Thermal Control 2018

 Method 4
If application output power and estimated efficiency are known.
Example;
Q=P=(W/η)*SF
Q=Heat load in Watts (W) Q=P=(W/η)*SF
P=Absorbed Power in Watts (W)
W=Output Power in Watts (W) Q=P=(370/0.7)*1.2
η=Efficiency (0-1, i.e. 70% efficient=0.7)
SF=Safety Factor Q=P=529*1.2
• This method takes rated output power from a
datasheet or rating label and asks the user to
Q=P=635W
assess efficiency (always <100%). Absorbed power
will therefore be higher. Q=635W
• This is a strong method, especially if prior
knowledge of equipment efficiency is known. For
example, electrical motors can be anywhere
between 40-70% efficient.
© Applied Thermal Control 2018
 Method 5
If pump flow rate, inlet and outlet temperatures are known.
Example;
Q=((ρ*Qv*Cp*ΔT)/60)*SF Q=((ρ*Qv*Cp*ΔT)/60)*SF
Q=Heat load in Watts (W)
ρ=Density of circulated fluid (kg/m3) Q=((998*9.7*4.19*5)/60)*1.2
Qv=Volumetric flow rate of circulated fluid (L/min) Q=(202809/60)*1.2
Cp=Specific heat capacity of circulated fluid (kJ/kg.°C)
ΔT=Temperature difference between inlet and outlet (°C) Q=3380*1.2
SF=Safety Factor
Q=4056W
• Useful if an incumbent chiller or thermal • Chiller ‘actual’ temperature is the outlet value. For
management device is already in place. inlet, a measurement is needed.
• Pump flow rate can be seen on rating label if type is • If an existing process is using running tap water, ΔT
positive displacement, or from pump flow curve if is the difference between tap water temperature,
pressure is measurable. An inline flow meter is most and application outlet. Often a bucket and
accurate. stopwatch are used to measure flowrate!

© Applied Thermal Control 2018

 Method 6
If fluid volume, desired temperature change and duration are known.
Example;
m=(ρ*V)/1000 m=(ρ*V)/1000
Q=((m*Cp*ΔT)/t)*SF m=(998*65)/1000
Q=Heat load in Watts (kW) m=64.87kg
m=Mass of circulated fluid (kg)
ρ=Density of circulated fluid (kg/m3) Q=((m*Cp*ΔT)/t)*SF
V=Total circuit volume of circulated fluid in litres (L) Q=((64.87*4.19*15)/1800)*1.2
Cp=Specific heat capacity of circulated fluid (kJ/kg.°C)
ΔT=Difference between starting temp and target (°C) Q=(4077/1800)*1.2
t=Timeframe to achieve temp change, in seconds (s) Q=2.718kW
SF=Safety Factor

• This method sizes a ‘pull-down’ cooling capacity, • It assumes no additional heat is being put into the
i.e. capacity required to do a cooling job within a circulated volume.
constrained period of time.
© Applied Thermal Control 2018
 Need further assistance?
Visit our website at www.app-therm.com
Email sales@app-therm.com
Call +44 (0) 1530 839 998
Visit us at Gee Road, Coalville, LE67 4NB, United Kingdom

© Applied Thermal Control 2018