--------------------------------------------------------------------------------------------------------------------------------

Economic comparison between air cooled chiller and water-cooled chiller at

the same cooling capacity.
Introduction:
An industrial chiller is a refrigeration system used to lower the temperature
of machinery, industrial spaces, and process fluids by removing heat from
the system and transferring it somewhere else. Industrial chillers are
essential for temperature regulation in several industrial processes such as
injection molding, metal plating, oilfield production, and food processing.
Working principles:
Industrial chillers work based on the following principles of operation;
1. Phase Change
A liquid coolant undergoes a phase change into a gas when heated, and
when the gaseous coolant is supercooled, it condenses back into a liquid.
2. Heat Flow
Heat energy always flows from an area of high concentration to an area of
lower concentration.
3. Boiling Point
Reducing the pressure over a liquid decreases its boiling point and
increasing the pressure increases its boiling point.
Chillers consist of four basic components; an evaporator, a compressor, a
condenser, and an expansion unit. Every chiller system contains a
refrigerant.
The process starts with a low-pressure refrigerant entering the evaporator.
Inside the evaporator, the refrigerant is heated, causing it to undergo a phase
change into a gas. The gaseous refrigerant goes into the compressor which
increases its pressure.
The high-pressure refrigerant goes to the condenser which rejects the heat
using cooling water from a cooling tower or air from the surroundings,
condensing it into a high-pressure liquid. The condensed refrigerant then
goes to the expansion unit which has a valve that acts as a metering device
to limit the flow of refrigerant in the system.
Consequently, this lowers the pressure of the refrigerant and begins the
cooling process again. The entire process is known as the refrigeration cycle.

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Types of industrial chillers
The three main types of industrial chillers in use today are air-cooled
chillers, water-cooled chillers, and absorbtion chillers. We will also briefly
touch on cooling towers (an alternative or supplemental cooling system) and
special chillers like glycol and centrifugal chillers.
Selecting the right chiller for your application will help you to save costs,
reduce downtime, and improve operational efficiency.
Water-Cooled Chillers
Water-cooled chillers use water from an external cooling tower to reject heat
from a gaseous refrigerant in the condenser before it undergoes a phase
change into a liquid.
Air-Cooled Chillers
In place of the cooling water, air-cooled chillers use ambient air to reject
heat from the refrigerant in the condenser.
Vapor Compressor Chillers
This type of chiller uses refrigerants to cool process fluids and spaces. A
compressor is used as the driving force to pump refrigerant around the
system.
Vapor Absorption Chillers
Vapor absorption chillers have no compressor in the unit. Rather, they use a
heat source e.g., solar energy or waste heat to drive the coolant through the
system.
How Does an Absorption Chiller Work?
The process starts with liquid coolant in an evaporator which turns it into
gaseous form. The gaseous coolant is absorbed by a concentrated absorbent
such as Lithium Bromide or Ammonia, provided by a generator. The diluted
solution absorbs the coolant while the heat is being absorbed by the cooling
water.
The diluted solution of coolant and absorbent flows through a heat
exchanger to the generator where it is heated. The coolant vaporizes out of

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the solution, condenses, and is sent out for cooling again. The now-
concentrated absorbent is recycled as well.
Water-Cooled Chillers
Water-cooled chillers are typically installed indoors; air-cooled
What is a water-cooled chiller?

A water-cooled chiller is one of the types of chillers that removes heat from
it to cool the water used in projects or industrial or domestic structures and
re-enters the water into the operation cycle. In fact, chillers transfer heat
from a space that needs temperature control and transfer it to another space.
Therefore, the chiller is not a means of generating cold, but a means of
dissipating heat, and its task is to facilitate the transfer of unwanted and
undesirable heat caused by the activity to a place outside the system.

A cooling tower is specifically designed for the water-cooled chiller.

Because condensers of water-cooled chillers use water as their stimulant and
cooling material. Because wet surfaces are more successful at transferring
heat and also do compression work at wetter bubble temperatures, the
efficiency of water-cooled chillers increases.

How does a water-cooled chiller work?

The cycle of water-cooled chillers, like any other chiller, consists of four
main members: evaporator, compressor, condenser and expansion valve, in
each of which a thermodynamic process takes place. The way the chiller
works is that the refrigerant is delivered to different phases of the material at
different pressures and temperatures to cool the water instead and pump it
out of the chiller. In fact, the main work of chillers is based on the phase
change or physical state of the refrigerant or refrigerant. In the meantime,
the work of water-cooled chillers is based on the condensation of steam or
gas.
The first step in chiller operation:

The starting point of this cycle is where the water in the production process
enters the evaporator to enter the chiller cycle.

In this part of the cycle, the heat absorbed by the refrigerant first shows itself
in the form of a liquid-to-gas phase change. As the refrigerant absorbs the

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heat of the water, the environment in contact with this part drops in
temperature, so the water leaves at a lower temperature. This water enters
the fan coils and brings cold air to the desired spaces.

In fact, an evaporator is a place that, in addition to the current cycle,

participates in another cycle, and that cycle is between the evaporator and
the water outlet to the cooling devices. In fact, hot water enters the chiller
evaporator and then cools it out to be pumped throughout the building to the
desired location.
second stage:

The gas refrigerant, which had reached the gas phase in the pre-liquid state,
then enters the compressor. In the compressor, the gas condenses and the
temperature and pressure increase so that it can enter the next stage with
high pressure. This increase in pressure and temperature as it exits the
compressor is important because the refrigerant needs to release heat from
inside the condenser, so it must carry enough heat to the condenser.

Another key function of the compressor is to draw refrigerant into the

evaporator at the appropriate time so that the pressure inside the evaporator
remains high enough to absorb heat again.
third level:

The third step takes place inside the condenser. High-temperature gas enters
the condenser. In the condenser, the gas refrigerant is converted to a high-
pressure liquid that is saturated. This is a constant pressure process.

On the other hand, since the condenser is present in another cycle between
the cooling towers, water enters the cooling tower after the temperature rises
for the water. Because cooling towers in water-cooled chillers have the main
task of cooling the consumed water and the condenser uses this water as its
driving material.

This is where the unwanted heat of the water disappears and the water
temperature is brought back to the desired low temperature. The heating
process that we mentioned earlier takes place in the condenser to release the
gas refrigerant from the heat itself, the heat source that is now being talked
about and needs to be eliminated by the cooling tower. In this way, the water
coming from the condenser to the chiller cooling tower is in contact with the

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airflow and transfers its heat to the air, then goes back to the condenser.
The fourth and final step:

The expansion valve is the last stage that the refrigerant goes through. This
milk, as its name implies, expands and reduces the refrigerant. These
processes that take place on the refrigerant in the expansion valve cause the
refrigerant to become a mixture of liquid and gas. Eventually, the same
compound re-enters the evaporator to resume the cycle with hot water re-
entering the evaporator from another direction.

Applications and limitations

As mentioned earlier, water-cooled chillers are used for domestic and non-
domestic purposes. Cooling water chillers can be found in large and
medium-sized structures and buildings, such as hospitals, airports,
manufacturing plants, industrial workshops, shopping malls and even
residential buildings, but all of this is provided that there is sufficient water
to meet the water-cooled chiller needs. Finally, it can be concluded that
water-cooled chillers are suitable for high or medium capacity installations
that have sufficient access to water and do not face the problem of water
shortage. Also, the use of these chillers is not recommended in wet cities.

In fact, one of the limitations of using water-cooled chillers is that they use
very high amounts of water. As such, the water-cooled chiller is not suitable
for areas struggling with water shortages and may not be responsive. Also,
water supply has its own costs.

Primary System Components

Chilled-water systems consist of these functional parts:
 Chillers that cool the water or fluid.
 Loads, often satisfied by coils, that transfer heat from air to water.
 Chilled-water distribution pumps and pipes that send chilled water to
the loads.
 Condenser-water pumps, pipes, and cooling towers or condenser fans
that reject heat from the chiller to ambient air
 Controls that coordinate the operation of the mechanical components
together as a system

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In most cases, the chiller’s purpose is to make water colder. Some chillers
cool a mixture of water and other chemicals, most commonly added to
prevent freezing in low-temperature applications. Other additives may be
used to modify the properties of the fluid, thereby making it more suitable
for its intended application. For the purposes of this manual, the term water
can be understood to be any such acceptable fluid, with recognition of the
diverse applications in which chillers are used.
The chiller rejects the heat extracted from the chilled water, plus the heat of
compression (in the vapor-compression cycle), or the heat of absorption (in
the case of an absorption chiller) to either the ambient air (air-cooled) or to
another circuit of water (water-cooled). If the compressor-motor is
refrigerant cooled, the chiller also rejects heat generated by motor
inefficiency. Air-cooled condensers use fans to facilitate cooling by the
ambient air. Water-cooled condensers typically use an evaporative cooling
tower.
After the water has been chilled, it is distributed via pumps, pipes, and
valves (the distribution system) to the loads, where a heat exchanger.
For example, a cooling coil in an air-handler transfers heat from the air to
the chilled water, which is returned to the chiller. Each component of the
chilled-water system is explained in more detail in the following sections.
Chiller
There are a variety of water chiller types. Most commonly, they are
absorption, centrifugal, helical rotary, and scroll. Some reciprocating chillers
are also available. Chillers can be either air- or water-cooled. Major vapor
compression chiller components include an evaporator, compressor(s),
condenser, and expansion device(s) (Figure 1). This manual discusses the
chiller’s evaporator and condenser and their relationship to the chilled-water
system.
Water-
cooled
chillers
are

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typically installed indoors; air-cooled chillers are typically installed outdoors
—either on the roof or next to the building. In cold climates, air-cooled
chillers may have a remote evaporator inside the building for freeze
protection.
Chiller evaporator
The evaporator section of a water chiller is a shell-and-tube, refrigerant-to
water heat exchanger. Depending on the chiller’s design, either the
refrigerant or the water is contained within the tubes.
• In a flooded shell-and-tube evaporator (Figure 2), cool, liquid refrigerant at
low pressure enters the distribution system inside the shell and moves
uniformly over the tubes, absorbing heat from warmer water that flows
through the tubes.

Figure 2 Flooded evaporator cut-away

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In a direct-expansion (DX) shell-and-tube evaporator warmer water fills the
shell while the cool, lower-pressure liquid refrigerant flows through the
tubes.
In either design, there is an approach temperature, which is the temperature
difference between the refrigerant and exit water stream temperatures. The
approach temperature is a measure of the heat transfer efficiency of the
evaporator.
Effect of chilled-water temperature
For a given chiller, as the leaving chilled-water temperature drops, the
refrigerant temperature and pressure must also drop. Conversely, as the
leaving chilled-water temperature rises, so do the refrigerant temperature
and pressure. When the leaving chilled-water temperature changes, the work
a compressor must do also changes. The effect of leaving chilled-water

temperature change on power consumption can be 1.0 to 2.2 percent per

degree Fahrenheit [1.8 to 4.0 percent per degree Celsius]. Always consider
the energy consumption of the entire system—not only the chiller. It is
important to remember that although reducing leaving chilled-water
temperature penalizes the chiller, it may reduce the overall system energy
because less water is pumped through the system. System interactions are
covered in more detail in “System Design Options”.
Effect of chilled-water flow rate and variation
The evaporator is sensitive to the water flow rate. Excessive flow may result
in high water velocity, erosion, vibration, or noise. Insufficient flow reduces
heat-transfer efficiency and causes poor chiller performance, which might
cause the chiller controls to invoke safeties. Some designers have concerns
over low flow rates causing fouling. Generally, as Webb and Li1 noted,

9
these concerns are unwarranted since the chilled-water loop is a closed
system, thus reducing the chances of materials entering the system and
causing fouling. Chilled-water flow through the evaporator must be kept
within specific minimum and maximum limits. Contact the manufacturer for
these limits.
Some chiller controls can accommodate very little flow variation during
machine operation.2 Other, more sophisticated, chiller controls allow some
flow variation. Some chillers can tolerate flow-rate variations—as much as
50 percent per minute or greater—while others can only tolerate up to 2
percent per minute. It is important that chiller capabilities are matched to
system requirements. Contact the chiller manufacturer to determine the
allowable rate of flow variation before varying the flow through the
evaporator in a chiller. Flow variation is discussed in detail in the section
“Variable-Primary- Flow Systems”.
Water-cooled condenser
To cool a building or process, the transferred heat must ultimately be
rejected outdoors or to another system (heat recovery). The total amount of
heat rejected includes the sum of the evaporator load, the compressor work,
and the motor inefficiency. In a hermetic chiller, where the motor and
compressor are in the same housing, these loads are all rejected through the
condenser. In an open chiller, where the motor is separate from the
compressor and connected by a shaft, the motor heat is rejected directly to
the surrounding air. The evaporator load and the compressor work are
rejected through the condenser, and the motor heat must be taken care of by
the equipment room’s air-conditioning system.
Effect of condenser-water temperature
For a given chiller, as the leaving condenser-water temperature rises,
refrigerant temperature and pressure also rise. Conversely, as the leaving
condenser-water temperature drops, so do refrigerant temperature and
pressure. As the refrigerant pressure and temperature changes, the work a
compressor must do also changes. The effect of leaving-condenser-water
temperature change on power consumption can be 1.0 to 2.2 percent per
degree Fahrenheit [1.8 to 4.0 percent per degree Celsius]. Always consider
the energy consumption of the entire system—not just the chiller. It is

10
important to remember that although raising the leaving condenser-water
temperature penalizes the chiller energy, it may reduce the energy used by
the condenser pumps and cooling tower through the use of reduced flow
rates and higher thermal driving-forces on the tower.
Effect of condenser-water flow rate
The condenser is sensitive to the water flow rate. Excessive flow may result
in high water velocity, erosion, vibration, or noise, while insufficient flow
reduces heat transfer efficiency and causes poor chiller performance.
Therefore, condenser-water flow through the chiller should be kept within a
specific range of limits, except during transient startup conditions. Contact
the manufacturer for these limits. Some chillers may allow extended
operation below the selected flow rates. If water velocity through the
condenser tubes is too low for significant periods of time and the water is
extremely hard, long-term fouling of the tubes may also occur. Webb and
Li1 tested a number of internally-enhanced condenser tubes at low velocity
(3.51 ft/s [1.07 m/s]) and high-water hardness.
While they found that some of the internally-enhanced tubes fouled in the
long term, they concluded: Because of the high hardness and low water
velocity used in these tests, we do not believe that the fouling experienced is
typical of that expected in commercial installations. With use of good
maintenance practices and water quality control, all of the tubes tested are
probably suitable for long-term-fouling applications. It is important to
remember that a chiller selected for low flow does not necessarily have low
velocity through its tubes, as discussed in the chapter “System Design
Options” on page 27. If tube fouling is a major concern, consider the use of
smooth, rather than internally-enhanced, tubes in the condenser for ease of
cleaning.
SENHO water cooled chillers feature compact design and high efficiency.
With generously sized shell and tube condenser and for heat removal, they
perform reliably & powerfully. Top components and fine processing skills
ensure high quality and reliability of SENHO water cooled chillers.
Small footprint make SENHO water cooled chillers very suitable for limited
space installation. With no heat discharged to the surrounding air, water
cooled chillers can be installed in a room with poor ventilation conditions.

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9.2KW to 2590KW cooling capacity is within the standard range of our
water cold industrial chillers. Modular type design makes it easy to expand
the capacity for larger scale cooling process.
Advantages and disadvantages of water-cooled chiller

One of the advantages of water-cooled chillers over cold air chillers is that
they take up less space and can be installed indoors. This can reduce the
maintenance and repair costs of the chiller to some extent and increase its
useful life. The next item goes back to the longer useful life of the water-
cooled chiller. Water-cooled chillers are known for their high stability and
useful life compared to other types of chillers.

One of the reasons why it is said that water-cooled chillers have better
performance and higher efficiency than other types of chillers is their higher
bubble temperature. Since the temperature of a wet bubble is always lower
than that of a dry bubble, there is a large difference between the activity of a
water-cooled chiller at a certain temperature and pressure and the activity of
a cold air chiller at the same temperature and pressure; Therefore, the
refrigerant is active with significant pressure and temperature difference, and
this gives the chiller a more useful performance. Of course, it should not be
forgotten that the positive performance of the chiller goes back to other
criteria.

In terms of the mere use of water-cooled chillers, if we ignore the costs of

water supply and the initial installation costs of water-cooled chillers, this
chiller

They seem to be more economical, otherwise, it is better to use cool air

chillers if the initial costs are important for the consumer and are limited for
them.

One of the main disadvantages of water-cooled chillers is the need for a

large amount of water. Also, despite the maintenance of water-cooled
chillers in closed environments, these chillers still have many different parts
in them, which increases the total cost of maintaining the chiller.

Application of Water Chiller System

We offer water cooled chiller solution for varies of applications and working
conditions including:
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  Scroll type, screw type or reciprocating type compressor.
 Complete stainless steel heat exchangers for deionized water, food
process or medical use cooling.
 Acid corrosion resistance heat exchangers for processes like surface
treatment.
 Sea water condenser for marine use.
SENHO provides not only a comprehensive range of water cooled chillers,
but also professional customized cooling solutions for various industries and
applications.
A properly selected water-cooled chiller will have a longer service life and
better performance. Please let us know more details about your applications.
Air cooled chiller:
Introduction:
Air-cooled chillers utilize the mechanical refrigeration cycle to produce
chilled water or a chilled water and antifreeze mixture. They reject the
building heat to the ambient with an air- cooled condensing coil. Chillers are
the heart of the chilled-water air-conditioning system since they serve the
pivotal function of creating the cooling effect required to maintain comfort
conditions.
Chillers are used in a variety of comfort air- conditioning and process
cooling applications. The chilled liquid is transported by pumps and pipes
that can be connected to literally hundreds of room fan coils and terminals.
This allows chillers to be applied on applications requiring many zones of
control
Air-Cooled Chiller Package
Air-cooled chillers do not use condenser-water, since they reject their heat
by passing ambient air across refrigerant-to-air heat exchangers. In packaged
air-cooled chillers, the manufacturers improve performance by staging fans
in response to chiller load and ambient, dry-bulb temperature. Air-cooled
chillers can also be split apart. One technique is to use an indoor remote
evaporator with a packaged air-cooled condensing unit outdoors. Another
technique is to locate the compressor(s) and the evaporator indoors (also

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known as a condenserless chiller) with an air-cooled condenser outdoors. It
is also possible to have an indoor air-cooled condenser.
Air-cooled chillers are common in modern systems and have been growing
in popularity since the 1980s, nearly doubling in the last ten years. Today,
air-cooled chillers are applied on small to large commercial jobs and can be
used in multiples to form systems reaching several thousand tons of installed
capacity.
The popularity is primarily due to the all-inclusive nature of air-cooled
chillers and the reduction of costs associated with eliminating cooling tower.
On some models, even the hydronic accessories, such as the pump and
expansion tank, may be included, assembled, and tested from the factory
ready to begin operation.
Typical air-cooled chiller applications include schools, hospitals, retail
environment, and offices. Additionally, air-cooled chillers are popular for
cooling process or manufacturing operations.
Basic Refrigeration Cycle for Air-Cooled Chillers The refrigeration cycle of
an air-cooled chiller includes two important processes:
1. The evaporation of the liquid refrigerant in the evaporator, which absorbs
heat and lowers the temperature of the chilled-water system
2. The condensation of the refrigerant vapor in the air-cooled condenser and
rejection of heat to the atmosphere in the air-cooled chiller refrigeration
cycle, water enters the evaporator (also known as the cooler) and is cooled
by the colder refrigerant flowing through the other circuit inside the
evaporator. The chilled water is pumped from the chiller to the building coils
to provide cooling. In the evaporator, the chilled water cools the building or
process load and the cycle is completed when warmer water flows back to
the evaporator. A mixture of cold liquid refrigerant and flash gas passes
through the evaporator circuit opposite the water to be chilled.
The refrigerant in the evaporator absorbs heat from the warmer return water,
evaporates to a vapor, and finally exits the evaporator as a superheated
vapor. The superheated refrigerant vapor then enters the suction inlet of the
compressor.

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 In the compressor, the refrigerant is compressed, raising its pressure and
temperature. High pressure and temperature refrigerant gas exits the
compressor, passes through the discharge line and enters the condenser.
While in the air-cooled condenser coil, the hot gas condenses to liquid inside
the tubes as it gives up heat to the cooler outside air being drawn across the
condenser coil by the condenser fans.
The condensed liquid refrigerant then leaves the condenser and enters the
expansion device. As the refrigerant passes through the expansion device, its
pressure and temperature are decreased to the point that some of the liquid
flashes to vapor. The expansion device controls the amount of flashing in
order to maintain a certain superheat to ensure
no liquid droplets enter into the compressor suction. After leaving the
expansion device, the refrigerant enters the evaporator and the cycle is
repeated.
Refrigeration Cycle Components of an Air-Cooled Chiller
Air cooled chillers components
All air-cooled chillers are comprised of the following components:
 Evaporator (cooler)
 Condenser
 Compressor
 Expansion Device
Let’s examine these components individually and the role of each in the air-
cooled chiller.
Evaporator
The most common choice of evaporator design for larger screw and
reciprocating chillers has been the shell-and tube types while smaller chillers
utilize brazed-plate. Shell- and-tube evaporators are widely used and they
are larger and heavier than brazed-plate heat exchangers. The tubes for some
evaporator types may utilize internal and/or external enhancements to
promote turbulence and create increased heat transfer between the fluid and
the refrigerant.

15
 Turbulence actually increases the heat transfer process by keeping more of
the fluid in contact with the heat exchanger surface area. On the refrigerant
side and water side, more contact means greater heat transfer and a higher
efficiency rating. Enhancement of tubes typically is achieved through a
rifling or finning process during manufacturing.
 Condenser
The condenser in an air-cooled chiller is a heat exchanger that condenses
the hot refrigerant gas by using cooler outside air passing over a coil. In a
typical air-cooled chiller, propeller-type fans are used to draw the outdoor
air over the coil. The hot, high-pressure refrigerant vapor flows through the
coil tubes and is condensed to a liquid. In the last portion of condenser
tubing, the condensed liquid refrigerant is then subcooled. A final portion of
the condenser is used to lower the refrigerant temperature below the
saturated condensing temperature. This is called subcooling. This increases
the refrigeration effect and increases system capacity by about 1 percent for
each degree of subcooling provided.
Condenser Design of an Air-Cooled Chiller
Compressor
There are three types of compressors utilized for air-cooled chillers. They
are reciprocating, scroll, and screw.
Reciprocating
Reciprocating compressors, like a reciprocating engine, have pistons, rods,
and discharge and intake valves. The valves operate on suction and
discharge pressure. Compression is achieved by trapping a fixed amount of
refrigerant gas into a chamber. For this reason, reciprocating compressors
are positive displacement type com- pressors as are scrolls and screws.
Reciprocating compressors were the workhorse of the small chiller market
for decades and are still used in many designs. Multiple reciprocating com-
pressors were often installed in a single chiller to provide chiller capacities
of up to 400 tons. The reciprocating compressor is available open, semi-
hermetic, or hermetic. Open compressors extend the shaft through a seal in
the crankcase for use with an external driver. Hermetic compressors have the
motor and compressor contained in the same housing, typically welded and

16
sealed. Semi-hermetic compressors utilize a bolted housing, instead of a
welded one, to facilitate repair in the field.
References
API Heat Transfer, Buffalo, NY. http://www.apiheattransfer.com/
ARI Standard 550/590, “Water Chilling Packages Using the Vapor
Compression Guide.” http://www.ari.org/std
ASHRAE Standard 15, “Safety Standard for Refrigeration Systems.”
ASHRAE Standard 90.1, “Energy Efficient Design of New Buildings Except
Low-Rise Residential Buildings

Carrier Corporation, Syracuse, NY. Packaged Chiller Selection Program,

Version 2.8. http://www.carrier.com/

Honeywell International, LLC, Morristown, NJ. http://www.honeywell.com/

Standard Refrigeration, Melrose Park, IL, http://www.stanref.com

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