CHILLER

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Prepared By : Hassan Aslam

Chiller
A chiller is a machine that removes heat from a liquid
via a vapor-compression or absorption refrigeration
cycle. This liquid can then be circulated through a
heat exchanger to cool air or equipment as required.

Chiller is a compressor based equipment that cools

and controls the temperature of a liquid unlike the air
conditioners, which cools air.
Types of Chiller

On the basis of their functioning

1. Air-cooled Chiller
2. Water cooled Chiller

On the basis of driving force for refrigeration

1. Mechanical Compressor Chiller
2. Absorption Chiller
Air-cooled Chiller

Absorb heat from process water and is

transferred to the ambient air.
They are mostly used in applications where the
heat discharged is not a factor. They don't need
a cooling tower and condense water pump.
The maintenance of air cooled chillers are less
than water cooled units. However they
consume 10% more power.
Air-cooled Chiller

A fan forces air across small tubes containing

the hot refrigerant and discharges that heat into
the ambient air. Compared to water, air is a
poor conductor of heat and therefore air-cooled
chillers are larger and less efficient.
Air-cooled chillers also operate at higher
compressor ratios which means less cooling
per watt energy consumption.
Water Cooled Chiller
Heat is absorbed from process water and is
transferred to a separate water source like a river,
pond, cooling tower, etc.

Mainly used at the places where the heat generated by

air cooled chillers pose a problem.

Due to their less consumption of power they are

usually preferred by those seeking optimum
efficiency of power consumption.
Water Cooled Chiller
Water condensed units are more efficient than air
condensed, often operating in the range of 15 EER or
better (EER: energy efficiency ratio or BTU per hour
per Watt energy consumption).
Water cooled chillers require a source of cooling
water, such as cooling tower water, to extract heat
from the refrigerant at the condenser and reject it to
the ambient environment.
The typical condensing temperature in a water-
condensed chiller is 105F.
Mechanical Compressor Chiller

They are classified by the compressor type:

Reciprocating
rotary screw
Centrifugal
frictionless centrifugal.
At the heart of any chiller is the compressor.
Compressors are used to increase the pressure
of the refrigerant.
Reciprocating
Similar to a car engine with multiple
pistons, a crankshaft is turned by an
electric motor, the pistons compress the
gas, heating it in the process. The hot gas
is discharged to the condenser instead of
being exhausted out a tailpipe.
The pistons have intake and exhaust
valves that can be opened on demand to
allow the piston to idle, which reduces
the chiller capacity as the demand for
chilled water is reduced. This unloading
allows a single compressor to provide a
range of capacities to better match the
system load.
Capacities range from 20 to 125 tons.
Rotary Screw
The screw or helical compressor has
two mating helically grooved rotors
in a stationary housing. As the helical
rotors rotate, the gas is compressed
by direct volume reduction between
the two rotors. Capacity is controlled
by a sliding inlet valve or variable-
speed drive (VSD) on the motor.
Capacities range from 20 to 450 tons.
Centrifugal
The centrifugal compressor operates
much like a centrifugal water pump,
with an impeller compressing the
refrigerant. Centrifugal chillers
provide high cooling capacity with a
compact design. They can be
equipped with both inlet vanes and
variable-speed drives to regulate
control chilled water capacity
control.

Capacities are 150 tons and up.

Frictionless Centrifugal
This highly energy-efficient
design employs magnetic
bearing technology. The
compressor requires no
lubricant and has a variable-
speed DC motor with direct-
drive for the centrifugal
compressor.

Capacities range from 60 to

300 tons.
Absorption Chiller
The absorption cycle uses a heat-driven concentration
difference to move refrigerant vapors (usually water) from the
evaporator to the condenser.
The high concentration side of the cycle absorbs refrigerant
vapors (which, of course, dilutes that material). Heat is then
used to drive off these refrigerant vapors thereby increasing
the concentration again.
Lithium bromide is the most common absorbent used in
commercial cooling equipment, with water used as the
refrigerant.
Smaller absorption chillers sometimes use water as the
absorbent and ammonia as the refrigerant.
Absorption Chiller
The absorbent is the material that is used to maintain
the concentration difference in the machine. Most
commercial absorption chillers use lithium bromide.
Lithium bromide has a very high affinity for water, is
relatively inexpensive and non-toxic.
.
Absorption Chiller

Absorption chillers are available in two types:

Single Effect (Stage) Units : using low pressure
(20 psig or less) as the driving force

Double Effect (2-Stage) Units :

available as gas-fired (either direct gas firing,
or hot exhaust gas from a gas-turbine or engine)
or steam-driven with high pressure steam
(40 to 140 psig).
Types of Refrigeration Cycles

There are 2 types of Refrigeration cycles :

1. Vapor Compression Cycle
2. Absorption Cycle
Vapor Compression Cycle
During the compression cycle, the refrigerant passes
through four major components within the chiller:
The evaporator, the compressor, the condenser, and a
flow-metering device such as an expansion valve.
The evaporator is the low-temperature (cooling) side
of the system and the condenser is the high
temperature (heat-rejection) side of the system.
Key Components of Mechanical Compression
Chillers
Evaporator:
Chillers produce chilled water in the evaporator where cold
refrigerant flows over the evaporator tube bundle. The
refrigerant evaporates (changes into vapor) as the heat is
transferred from the water to the refrigerant. The chilled water
is then pumped, via the chilled-water distribution system to the
buildings air handling units.
The chilled water passes through coils in the air-handler to
remove heat from the air used to condition spaces throughout
the building. The warm water (warmed by the heat transferred
from the building ventilation air) returns to the evaporator and
the cycle starts over.
Contd

Compressor
Vaporized refrigerant leaves the evaporator and
travels to the compressor where it is mechanically
compressed, and changed into a high-pressure, high-
temperature vapor. Upon leaving the compressor, the
refrigerant enters the condenser side of the chiller.
Contd

Condenser
Inside the water-cooled condenser, hot
refrigerant flows around the tubes containing the
condenser-loop water. The heat transfers to the water,
causing the refrigerant to condense into liquid form.
The condenser water is pumped from the condenser
bundle to the cooling tower where heat is transferred
from the water to the atmosphere. The liquid
refrigerant then travels to the expansion valve.
Contd

Expansion valve:
The refrigerant flows into the evaporator
through the expansion valve or metering device.
This valve controls the rate of cooling. Once
through the valve, the refrigerant expands to a
lower pressure and a much lower temperature. It
flows around the evaporator tubes, absorbing the
heat of the chilled water thats been returned from
the air handlers, completing the refrigeration cycle.
Vapor Compression Refrigeration

Refrigeration Cycle

3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor

1 2 Low
Pressure
Evaporator Side
 Explanation
Low pressure liquid
refrigerant in evaporator
absorbs heat and changes
to a gas

3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor

1 2 Low
Pressure
Evaporator Side
 Explanation
The superheated vapour
enters the compressor
where its pressure is
raised

3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor

1 2 Low
Pressure
Evaporator Side
 Explanation
The high pressure
superheated gas is cooled
in several stages in the
condenser

3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor

1 2 Low
Pressure
Evaporator Side
 Explanation
Liquid passes through expansion
device, which reduces its pressure
and controls the flow into the
evaporator

3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor

1 2 Low
Pressure
Evaporator Side
Type of Refrigerant
Refrigerant determined by the required cooling
temperature
Chlorinated fluorocarbons (CFCs) or Freon's: R-11,
R-12, R-21, R-22 and R-502
To select the appropriate refrigerant, their ODP
(Ozone Depletion Potential) and GWP ( Global
Warming Potential) need to be considered.
Selection
Choice of compressor, design of condenser,
evaporator determined by
Refrigerant
Required cooling
Load
Ease of maintenance
Physical space requirements
Availability of utilities (water, power)
Absorption Cycle

Main components in absorption cycle are:

Solution Pump
Condenser
Evaporator
Generator
Absorber
Absorption Cycle
Components
Solution Pump A dilute lithium bromide solution is collected
in the bottom of the absorber shell. From here, a hermetic
solution pump moves the solution through a shell and tube
heat exchanger for preheating.

Generator After exiting the heat exchanger, the dilute

solution moves into the upper shell. The solution surrounds a
bundle of tubes which carries either steam or hot water. The
steam or hot water transfers heat into the pool of dilute lithium
bromide solution. The solution boils, sending refrigerant vapor
upward into the condenser and leaving behind concentrated
lithium bromide. The concentrated lithium bromide solution
moves down to the heat exchanger, where it is cooled by the
weak solution being pumped up to the generator.
Components
Condenser The refrigerant vapor migrates through mist
eliminators to the condenser tube bundle. The refrigerant vapor
condenses on the tubes. The heat is removed by the cooling
water which moves through the inside of the tubes. As the
refrigerant condenses, it collects in a trough at the bottom of
the condenser.
Evaporator The refrigerant liquid moves from the condenser
in the upper shell down to the evaporator in the lower shell and
is sprayed over the evaporator tube bundle. Due to the extreme
vacuum of the lower shell [6 mm Hg (0.8 kPa) absolute
pressure], the refrigerant liquid boils at approximately 39F
(3.9C), creating the refrigerant effect. (This vacuum is created
by hygroscopic action - the strong affinity lithium bromide has
for water - in the Absorber directly below.)
Components
Absorber As the refrigerant vapor migrates to the absorber
from the evaporator, the strong lithium bromide solution from
the generator is sprayed over the top of the absorber tube
bundle. The strong lithium bromide solution actually pulls the
refrigerant vapor into solution, creating the extreme vacuum in
the evaporator. The absorption of the refrigerant vapor into the
lithium bromide solution also generates heat which is removed
by the cooling water. The now dilute lithium bromide solution
collects in the bottom of the lower shell, where it flows down
to the solution pump. The chilling cycle is now completed and
the process begins once again.
Absorption Cycle

Condenser Generator

Hot
Side

Evaporator

Cold Absorber
Side
 Explanation

Evaporator:
 Explanation

Absorber
 Explanation

High pressure generator

 Explanation
Condenser
Application of Chillers
Chillers are used to cool the hot plastic in the plastic industry.
It cools the plastic that is injected, blown extruded or stamped.
They are also used to cool down the equipment used in the
manufacturing process.
In the printing industry, chillers are used to remove the heat
generated by the printing rollers. They also help cooling the
paper when it comes out of the ink drying ovens.
Sophisticated chiller are used in the high powered electronics
inside the machines like MRI and PET, used in the latest
diagnostic tools.
Chillers cool down the lasers and the source of power supply
used to power them
Any Question ?