Water-Cooled vs. Air-Cooled Chillers

The decision to choose between a water-cooled and an air-cooled chiller is an important one for various industrial applications. Both options have their advantages and disadvantages, and the choice to use one over the other will depend on several factors such as available space at site, the size of the system, the environment, and the water quality and availibility.

This case study will compare the differences between water-cooled and air-cooled chiller in the context of industrial applications in general.

Background:

Many industrial processes generate heat during operation, and it is essential to keep them cool to prevent damage and ensure optimal performance. Therefore, cooling systems are a critical component of many industrial applications.

There are two primary types of cooling systems used in industrial applications: water-cooled chiller and air-cooled chiller.

Water-Cooled Chiller :

Water-cooled chillers use water cooled condensers. The system typically consists of a chiller, cooling tower, condenser pump, primary pump.The chiller is having shell and tube type condenser. The conderser is cooled down by water from cooling tower through condenser pump. The heated water is then returned to the cooling tower, where it is cooled and circulated back to the chiller condenser.The process water is being cooled by evaporator shell , by circulating through primary pump.

Advantages:

Water-cooled chiller are more efficient than air-cooled chiller.
Water-cooled chiller are less noisy than air-cooled as condenser fan is not being used.
Water-cooled chiller are more effective in hotter climates as the cooling tower can use evaporative cooling
Water cooled chillers consume less power than air cooled chillers as condenser fan is not used.
Water cooled chillers occupy less space, as cooling tower can be placed outdoor in open area saving the main factory workspace.
No ducting is required to vent out hot air from condenser.

Precautions to take when using water-cooled system

Water-cooled chiller require specific precautions to ensure their proper operation and prevent damage. Here are some of the essential precautions you should take:

Use the correct water: Use only high-quality water that is suitable for cooling purposes. Avoid using hard water or water containing contaminants, which can cause scaling and corrosion in chiller condenser.
Maintain water quality: Regularly monitor and treat the water to maintain its quality. You may need to add chemicals in cooling tower to prevent scaling and corrosion or use a water treatment system.
Check water flow: Ensure that the water flow rate is sufficient to condenser maintain the desired operating temperature. Insufficient flow can cause overheating, while excessive flow can be a problem in chiller operation.
Inspect the cooling tower: If the system includes a cooling tower, inspect it regularly for algae growth, scaling, and corrosion. Clean the tower as needed to maintain optimal performance.
Use a filtration system: Use a filtration system to remove debris and other contaminants from the water, which can cause clogs and damage to the condenser.Regular cleaning of condenser pump filter required.

Air-Cooled Chiller :

Air-cooled chiller use fin and tube type condenser, which is being cooled down by condenser fan.

Advantages:

Air-cooled chillers are simpler and less expensive to install and maintain than water-cooled systems.
Air-cooled chiller do not require a dedicated water supply to cooling tower,which makes them more flexible and easier to install in existing buildings.
At project site where either water is not available or water quality is not good, air cooled chillers are always recomended.

Precautions to take when using air-cooled chiller

1. Keep the air cooled condenser always clean: Regularly cleaning of aircooled condender needed to ensure that the system is getting adequate airflow. Dirty condenser can cause the system to overheat and reduce its efficiency.
2. Proper ventilation system:If the hot air from condenser is not being removed through proper ventilation system, overheating problem will arise, causing high discharge temperature and pressure.
3. Air cooled Chiller dimemsion is higher than the same capacity water cooled chiller.
4. More power consumption than a same capacity water cooled chiller.
5. Vibration in condenser fan may cause leak in chiller

Conclusion:

The water-cooled and air-cooled chillers having their own advantage and disadvantage.Proper site inspection, load calculation, and environmental conditions mapping is required through experts. At Tempcon we help our clients to choose a proper cooling system so that they can get proper service year after year.

Tempcon is much more than a manufacturer of cooling and temperature control systems. We are technical advisors with the expertise to recognize the best solution- in terms of productivity, efficiency, environmental impact. Innovation creates new opportunity & being able to customise our cooling solutions is what makes us unique!