X
(847) 734-1600

The Types of Industrial Chillers

Air chiller

Depending on your cooling needs, there are several types of industrial chillers on the market today. The basic types are air, water, and evaporative condensers with additional options for compressors that can customize your unit to fit your business needs. How to do know which type of OEM chiller system is right for you? Keep reading to learn more.

Air Chillers

As the name implies, air chillers use air and the movement of it to cool office buildings and freezer units. They range from small units used in some residential applications all the way up to units with 1,500 tons of cooling capacity for industrial applications in the food and medical industries. An air handler pulls air from outside of the unit, and a fan forces the air over coils filled with refrigerant. Cool air is then pumped into your facility through a network of ducts.

Water Chillers

While the air chiller uses air and induction to cool the air, water chillers use water as the condensing source. A water chiller system pulls heat from the environment using a heat pump. Heat is absorbed by the water in the system and circulated through a series of cooling towers where the heat is disbursed. Air chillers must be installed outside, but water chillers perform better indoors. They're also more efficient when compared to an air chiller because they don’t need electricity to operate a fan. Water chillers can help reduce energy consumption by an average of 15 percent. They're also quieter than other chillers on the market, which means you won’t have to soundproof your chiller storage room if you decide to install a water-based system inside.

Evaporative Condensed Chillers

Evaporative condenser chillers work similarly to water chillers, but they use mist instead of water to remove heat from the environment. These chillers use evaporating coils to move water through the system. Water is expelled as mist within the unit while air is forced over the coils. Temperatures are monitored constantly with a device called a wet bulb. The wet bulb controls how often mist is used, which helps reduce wear and tear on the unit. Evaporative condensed chillers aren't as energy efficient as water chillers.

Water chiller

The Right Compressor for Your Chiller

Industrial chillers, like residential HVAC units, use compressors to force air through the system. The type of condenser in your unit can affect its efficiency and energy usage. There are four types of compressors: reciprocating, centrifugal, screw driven, and absorption. A reciprocating compressor works like your car engine with pistons and a crankshaft. It works by compressing and delivering refrigerant in small amounts at very high speeds. Centrifugal compressors are very popular because they are easy to service with various parts that can be replaced as needed. Screw-driven compressors rotate inside the housing while gas is forced between them. They have the highest power range with up to 1,000 horsepower, a must for large industrial chillers. Absorption compressors use two liquids, one to cool the air and one to absorb heat simultaneously.

To determine which compressor or OEM chiller you need, consult the experts at KKT Chillers. Visit http://www.kkt-chillersusa.com to learn more.

What Makes Low-Temperature Chillers a Reliable Choice?

Industrial chiller

If you are in need of an ultra-low temperature solution, whether it is temporary or permanent, one possibility is to use a chiller specifically designed for achieving very low temperatures. All industrial chillers systems are designed to attain consistent cool temperatures, but some are specifically designed to provide extremely low temperatures in reaction to specific incidents or actions, as well as in a more stable scenario where a consistent low temperature is desired or needed. The following are several reasons why whether you need a short-term or more static solution, today’s low-temperature chillers can meet your demands.

Lower Temps with Less Equipment

Standard air cooled chiller systems can only provide cool temperatures to a certain level. They also have a number of equipment requirements to get the optimum cooling, which can be costly both in terms of space used and overall expense. Industrial chillers manufacturers can provide low-temperature chillers that can achieve extremely cold temperatures for the space you need cooled, in some cases down to -40 degrees Fahrenheit. They also can be designed to require less equipment to achieve your ideal cooling temperatures, particularly inside the cooling area.

Space Efficiency

An ultra-low temperature industrial chillers system is designed to achieve your desired temperatures while using a minimum of space. By using stacking technology, air handling units can be set up to be as effective as a traditional chiller system, but while having a very small footprint. Additionally, the external chillers and generators can be designed to save space and reduce the overall footprint of the system. That means more space inside and out of the area the system will cool.

Very cold

Fast Project Critical Paths

With very few exceptions, those needing exceptionally cold temperatures rarely have a lot of time to find a solution and implement it. A reliable chiller provider will send in engineers to work with your staff to help identify the best design that will meet your needs. Once that design is finalized, it is only a matter of matching required equipment with the chilling goals of your company. Installation, if there is not extensive preparation to get the space ready, can be done in a matter of days. That includes testing the configuration, troubleshooting it and modifying the design if it is necessary.

If you have an existing system that has to be brought down, a temporary chilling system is also a possibility. That allows for the maintenance of the needed cold temperatures while the other system is being disassembled. This means relatively no downtime while your new low-temperature industrial laser chillers are installed and configured.

Constant Testing and Improvement

As with any system that has a lot of moving parts, no chiller system is every truly out of the development stage. Even routine maintenance can vastly alter how a chiller performs, which means your chiller vendor has to be committed to continuous testing and maintenance as well as introducing new technologies as they become available. Because the industry is constantly changing, a vendor that is not committed to this quickly becomes obsolete. That means by selecting a low-temperature chiller system, you ensure you will always have the latest, most efficient and most effective chiller system possible.

In some instance, a traditional air-cooled chiller system will give you the temperatures you need, but in some situations, an exceptionally low temperature is not only desired it is needed. In that case, a low-temperature chiller is the answer; check out the many options available with industrial cooling systems chillers at KKT Chillers.

Calculating Your Chiller Efficiency: Know the Importance

efficiency

Check the Efficiency

Once you start searching for OEM chiller manufacturers, you may also want to learn how to check the efficiency of any chiller you purchase. OEM chillers need to have energy to run. So, to figure out how much a chiller will add to your operational costs, you might want to calculate how much energy it will use. By calculating how much energy your chiller utilizes, you can also check to see if it's running optimally.

The Basics

Thankfully, calculating the efficiency your OEM chiller is an easy task. However, you should keep the phrase COP in mind. This acronym stands for coefficient of performance and will be what you're looking for. It shows you how well the chiller refrigerates when compared to how much electricity is used to refrigerate. For best results, measure all units in kilowatts.

A Mathematical Example

For one example, let's look at a hypothetical chiller. The chiller produces two-thousand and five-hundred kilowatts of cooling energy. While for the amount of electrical energy this chiller uses, it needs four-hundred and sixty kilowatts. In order to get the COP, you simply divide the amount of energy produced by the amount that's used. In this case, the COP would be about five kilowatts.

What the COP Means

Knowing a given chiller's COP will mean nothing if you cannot apply it. In our previous case, the COP was roughly five kilowatts. This means that for every one kilowatt of electricity you put into the chiller, about five kilowatts of cooling energy is produced. So, in order to find the most efficient chillers, you want to find ones that have a high COP. These will chill more with less electricity.

A Variable

Something that can affect the COP of any given chiller is its cooling load. And if your chiller is malfunctioning, the cooling load might be off. Moreover, if you check your chiller and compare it to the design data, you can see if your chiller is functioning properly. If it's not functioning properly, perhaps you will need to have someone fix it to get the cooling load under control.

What You Can Do

When you're looking to buy an OEM chiller, consider asking OEM chiller manufacturers about the design data. This will show you how the chiller should function. Then, once you're ready to make your purchase, keep a record of the design data to compare later on. If your chiller is functioning at less than ninety-eight percent when compared to the design data, you might need to get it fixed. Talk to the experts at KKT Chillers Inc. to learn more!

Tips for Maintaining Industrial Chillers during Winter

Industrial Chiller

It's not surprising to learn that MRI chillers need regular maintenance, but staying on top of upkeep does more than just avoid headaches. Fouled tubes, leaking refrigerant, and other problems can quickly lead to higher operational expenses. Winter months can be particularly harsh on machinery. Maintaining your industrial chillers during winter should be a top priority for every company.

Maintenance Log

This is one of the most obvious but also most important things to do. Keeping a log is essential for accurate and reliable maintenance. If your log isn't kept up-to-date, your crew has to guess as to what has or hasn't been done. This can lead to confusion and overlooked factors. Whether you conduct regularly scheduled maintenance or you've switched to a demand-based maintenance program, a well-kept log is essential. Train your staff to maintain it carefully, and you should be able to prevent any issues from becoming serious problems.

Clean Tubes

Heat transfer efficiency is the single most important element to consider when it comes to your chiller's performance. As a result, clean tubes are a must-have. Any contaminants, such as minerals, algae, mud, or other impurities can lead to an increase in thermal resistance. That quickly becomes evident by reduced performance. Pay attention to approach temperatures to help you identify heat transfer efficiency. It's a great indicator. At a bare minimum, your condenser tubes need to be brush cleaned once a year. Keeping them clear of contaminants should be a priority.

Maintain Refrigerant

Cooling is directly dependent upon refrigerant. Your chiller's total cooling is largely determined by how much coolant is moved through its compressor. Obviously, this means you need to maintain an appropriate level of refrigerant. Too much refrigerant, and you'll be lowering temperatures more than desired. Too little, and you won't be keeping the temperature low enough. Not enough refrigerant also causes your compressor to overwork. You should periodically check for refrigerant leaks and prevent any moisture or air from being allowed into the system.

An MRI chiller is a fantastic piece of machinery, but it needs to be maintained for optimum performance. Winter isn't particularly forgiving when it comes to any equipment. Contact the experts at KKT chillers, Inc., to learn more about what you can do to keep your industrial chiller running at its best all year long.

Latest Trends in Refrigerant Chillers

oem chillers

OEM chillers have a variety of practical uses, from serious to recreational. On the serious end of the scale, manufacturers use them when making a variety of beverages such as milk, and they can be used to keep delicate equipment cool, especially medical equipment. They aren’t just useful in industry, though. Anyone who enjoys ice skating, hockey, or other ice-based activities have probably benefited from the chillers in ice skating rinks. Most shoppers have also felt the effect of chillers in mall air conditioning units. Essentially, chillers pull heat away from something, and the main trend at the moment is for scientists to make them as environmentally friendly as possible.

World Trends

Recent legislation in the European Union means that while most common OEM chillers are still allowed, they are trying to phase out GWP (Global Warming Potential) refrigerants, so some models with a GWP higher than 2,500 will still be leaving the market. There will also be regular leak checking, also in the interest of helping the environment. In Japan, the rules are a little stricter, and they are getting their GWP limit down to 750, and Canada is getting it down to 700. This means that on a world scale, ammonia, hydrocarbons, and other specific types of refrigerants will be dominating the market by 2020 or 2025, and OEM chiller manufacturers are adjusting their stock accordingly.

United States Trends

US trends are mainly influenced by the Environmental Protections Agency’s Significant New Alternatives Policy (SNAP) program. In this program, the EPA evaluates potential substitutes for substances that are harmful to the environment and come up with lists of these alternatives. When it comes to OEM chillers, the types of chillers aloud depend on the compressor type and use. For example, chillers except those with scroll compressors may use R-410A, R-404A, R-407C or R-134a although they have a high GWP and they aren’t heavily in use. Any chiller can use R-513A, R-450A, R-1336mzz(Z) or ammonia. Chillers with centrifugal compressors can use R-1234ze(E) unless it’s for industrial purposes.

A Guide to Choosing the Best Industrial Chiller

Industrial Chiller

If you work with equipment that puts out massive amounts of heat, you know how important industrial chiller systems are to basic functioning. More importantly, you probably know how important getting the right chiller system in place is in order to avoid having to upgrade in the future or even replace a functioning unit with something larger. Choosing the right chiller, however, can be difficult. Here's a simple guide for making sure your first choice is the one you need.

Heat Load

Industrial cooling systems chillers come in an array of cooling options, ranging from those that can handle a very basic heat load to those that can process and cool massive heat output. There are multiple formulas that can help you determine your heat load, ranging from BTU requirements to processing requirements to input and output capacity. Understanding your heat load needs will help you pick the right chiller from all the industrial chillers manufacturers out there.

Coolant Type

Determining the coolant is driven in large part by the heat load, the target temperature of the equipment, and the flow rate that the chiller has to maintain. To attain the best outcome for any particular piece of machinery, the method chosen is vital and that, combined with the above data, will help you choose the proper coolant. For example, coolant oil will cool differently than just water.

Installation

Where your chiller will be located is the very important next deciding factor. Indoor chillers can experience very high temperatures and environments that collect dirt, dust and debris, all of which can affect chiller performance. External chillers tend to be subjected to extremes in ambient temperatures, which also can affect chiller performance. Where the chiller is placed will also help determine extra equipment you will need such as air filters, HVAC modifications, sump heaters, etc.

Performance Curves

Every chiller has a performance curve for all its parts that affect how it will perform and how it will perform against desired outcomes. Make sure you heat load matches with your chiller’s performance curve and that no parts thresholds will be exceeded during the duration you need the chiller to function. The determining factor in an upgrade or replacement is usually the performance curve.

Selecting industrial chillers systems can be a challenging task if you walk into it blindly. Follow these guidelines and you will have the vast majority of your needs covered.

How Cooling MRI Machines Result in Patient Satisfaction

MRI

Doctors rely heavily on imaging and laboratory results to come up with accurate diagnoses. Hospital equipment like magnetic resonance imaging or MRI continually needs to perform in top condition to ensure its reliability. For this reason, it is crucial for any medical facility to invest in a good MRI chiller. Here are two reasons why it's essential to cool down the MRI in hospitals.

Patients Have the Right to a Correct Diagnosis

Doctors and medical professionals must uphold a patient’s rights, and one of these is to come up with the right diagnosis. When a hospital’s MRI overheats and becomes unreliable, it will delay the many patients' diagnoses—and subsequent interventions. Also, some patients don’t have the luxury of time like trauma and stroke patients. They need instant imaging to know the extent of the injuries.

MRI Scans Can Be Expensive

MRI scans can be costly. Clients need to come up with the funds so that they can undergo imaging procedures accurately and on time, the least that a medical facility can do is to ensure that the machine works correctly and that it does not suffer overheating.

MRI chillers can also benefit the hospital because these machines are top income generators for any medical facility. If the MRI overheats or gets damaged, it could set back the hospital millions in lost revenues and repairs. It can also greatly inconvenience clients who have scheduled imaging scans.

How to Cool Down MRIs

MRI machines need low temperatures to ensure accuracy and reliability. Helium cools down the magnet in the center of the equipment through a compressor called cryocooler. Layers of heat exchangers and coils further cool the cryocooler. Without these, the liquid helium will leak out and cause the machine to overheat. Without the cooling capability, the magnet and the device can suffer significant damage and render the hospital unable to provide imaging procedures. Furthermore, damage to the machine will cost millions, which can convert to hospital losses.

Building a dedicated MRI chilling system that uses cold water to cool down the cryocooler will help prevent costly damage to the machine by acting as a buffer if the liquid helium suddenly overheats, vaporizes, or leaks out. Furthermore, it can protect your patients’ interests and provide them with a continuous and reliable basis for diagnosis.

Things to Consider When Choosing an OEM Chiller Manufacturer

Factory

Regardless of what you use it for, your OEM chiller is one of the most important pieces of equipment your business can own. That makes selecting the right manufacturer imperative. As you look at OEM chiller manufacturers, here are a few characteristics you should insist upon.

State of the Art Production

Chiller technology has been pretty steady throughout the years, but production processes have been constantly improving. Because of that, you need to insist that your OEM chiller be made by a manufacturer who employs the latest in production equipment, processes and protocols. They need to be highly automated and that automation must be able to produce quality checks on a regular and on a scheduled basis. It also helps if manufacturing chillers is a major part of their business, if not the only product they produce.

Load Run Testing, QA, and QC

It is mentioned above but it cannot be understated. Quality assurance and quality control are key components to be sure OEM chillers will withstand rigorous use. Additionally, the manufacturer you choose has to be able to perform under load. That means they must have production machines that are continuously tested while performing under load. They also need to have continuous improvement processes that enhance the production of chillers. Finally, they need to be able to perform quality control and catch any errors before the product is shipped to you.

While a physical tour may not be possible, each of the above has to be documented. You should ask to see not just the processes to go into their quality testing, but also results from several production runs. You should also insist on random quality assurance testing. If they do random testing at the quality assurance or control level, you should ask to see the results.

Technology Capabilities

You also need your OEM chiller manufacturer to utilize the latest in production technology. Part of this should include being able to show you in 3D what any design concept would look like when carried to fruition. The production processes should also include quality check capabilities, scheduling, and monitoring of any particular piece of equipment and where it is in the production process.

As you review OEM chiller manufacturers, it is important that you insist upon certain qualities. The above guidelines can help make sure that you get the chiller you want and that it will be able to serve you for years to come.

Commonly Overlooked Maintenance Areas of Chillers

Laser chillers

Maintenance, preventative and needed, is a key aspect to any precision machinery’s lifecycle. Production schedules, client demands, and time constraints can often lead to overlooking aspects of maintenance routines and that can lead to breakdowns in the overall performance of the equipment as well as a shortening of its life. Following all the maintenance recommendations of laser chillers manufacturers, for example, is extremely time-consuming, if important. The following are areas of chiller maintenance that are often skipped or overlooked.

Optic Recalibration

Every time an industrial laser chiller has maintenance done on it, the optics should be reset to OEM specifications. This is because out of compliance optics can affect the quality of beam and mode, cutting performance and even the lifespan of the optics. To recalibrate the optics in a chiller, follow the manufacturer’s guidance and any guides that are included on the equipment.

Air Flow

Just about every laser uses an assist gas, which exits via the cutting nozzle and helps the laser achieve a cleaner cut. The most common gasses used are oxygen, nitrogen and shop air. For these gases to work effectively, the lines have to be clean in order for the system to maintain proper air pressure and filtration. All lines should be checked and the compressed air source should be tested regularly.

Chiller Temperature

The chillers for lasers have a temperature gauge that has to be monitored whenever the machine is in use. Variable temperatures could affect the machine’s performance or reflect a larger issue like refrigerant leaks or similar problems. In the most extreme case, temperature variations can cause resonator damage. Sensors will detect most temperature variations, but it needs to be continually monitored.

Cleanliness Equals Functionality

Keeping the chiller and associated equipment clear of dust, dirt and debris is key to it operating efficiently and effectively. A dirty machine can cause material shifts, which result in handling problems. In extreme cases, buildup can cause scrap drawers and slugs to become jammed. A neglected machine also poses a danger for thermite buildup, which can ignite and cause extensive damage to the equipment as well as pose a threat to the employee.

The maintenance guidelines for laser chillers manufacturers are pretty specific, but the key to all of this is diligence on the part of the employee. If the machine is kept in good order, it will provide accurate cutting for its lifespan.

Why Are Medical Chillers Important for Patient Care?

MRI

Medical equipment and supplies are highly sensitive to temperature changes, which is why hospitals and other medical facilities must have dedicated areas to store them. Hospital apparatuses such as those used in laboratories, blood cooling systems, MRI and CT scanners, and cancer treatment and applications all need the right temperature to be effective. Without medical process chillers, they will be prone to damage and the cost of maintaining equipment will go up significantly.

Hospital Equipment Is Vital

Hospital equipment is vital for operations and patient diagnosis. When a machine is out of order, it increases the risk of misdiagnosis and patient care. For example, MRI is an essential piece of equipment for imaging for all types of patients. Doctors can see things internally without the need for surgery.

When an MRI scanner is unavailable, it puts patients’ safety in peril, especially those who need stat imaging procedures like critical vehicular accident patients, and more. Time is essential when providing proper treatment and care. Otherwise, patients may need to go elsewhere for diagnosis and treatment. For this reason, hospitals must invest in medical chillers for MRI to maintain their equipment and to serve their clients well.

Medical Chillers Increase the Longevity of Hospital Equipment

A working cooling system will ensure that professionals can use different expensive equipment to provide an appropriate procedure and care for a long time. Health care workers use different modalities to help map out every patient’s disease process. With the help of specialized equipment, they can learn about a client’s condition, and come up with the most suitable care for the patient.  Besides, the longer these apparatuses work optimally, the more profitable a hospital becomes.

Providing care is not limited to bedside procedures. Medical equipment also plays a role in making sure that patients get the best possible care in a hospital. Doctors and nurses also base their patient care interventions on measurable data from the use of medical equipment.

Many air-cooled chiller application systems also come with backup systems that fulfill the standards for medical cooling. Moreover, highly-specialized systems and equipment must employ specifically-trained staff that can troubleshoot the equipment anytime. If you're a hospital or a laboratory owner, make sure to invest in a good cooling system to protect your equipment and maintain the integrity of your work.