Process Water Cooling – Applications and Challenges

A chiller unit is used in process water cooling to remove heat from manufacturing machinery. For temperature increases, the chiller uses a refrigerant that expands and stretches rather than water. It is more efficient to transfer heat away from the machines. Lower operating temperatures extend the life of process equipment and make it cleaner for workers.

Process cooling chillers build a circuit that transfers heat by passing liquids through the device. The heat from the machines is carried into the process cooling system by a stream. It integrates heat with the refrigerant system to cool the working fluid, decreasing equipment temperatures.

What Applications Require Process Cooling?

Process cooling is used for a wide range of industries. In fact, the configurations are as varied as the custom-designed chiller options. Irrespective of their different applications, they each have one common factor: they all need to remove heat from a method.

1. Plating and Anodizing

Both electrolysis plating and aluminum anodizing necessitate exceptionally high temperatures. Process cooling is being used by manufacturers to remove unnecessary heat from equipment and staff. The final result struggles if the plating bath is not at the optimum temperature. Specifically with zinc and chrome plating. To build the perfect product, machine cooling chillers optimize the bath temperature for the plating process.

2. Plastics Industry

The plastics industry needs process cooling for thermoforming, extrusion, and shaping. The extrusion process heats a wide sheet of plastic to a precise temperature in order to turn it into the desired shape. Extrusion is the process of feeding molten plastic through a die into a machine that produces long pieces of plastic. Molding is the process of keeping molten metal in a set of mold cavities. Plastic in the right form. All of these processes include temperature regulation. Phase cooling falls into play in this situation. In certain cases, such as extrusion, the process cooler will need to be supplemented by external equipment such as a cooling liquid filter or a secondary heat exchanger.

3. Food Processing

Both food production and storage necessarily require strict temperature control. Process coolers will maintain the low temperatures needed for chilling ingredients or building cool storage environments.

4. Pharmaceutical Industry

To get the formulas correct, drug manufacturing often requires temperature control during the process. In addition, after processing, certain medications must be stored at low temperatures. In the pharmaceutical industry, process coolers may help with these and other roles.
Process chillers may be used for a variety of uses, including those mentioned above. A process cooler, on the other side, will help any business that requires lower temperatures to make the machinery run more effectively.

What Are Some of the Main Challenges of Process Cooling?

Process cooling is not without drawbacks. There are several issues regarding new processes. However, advances in the chiller industry are anticipated to overcome some of the existing issues in the future, allowing process cooling more efficient and effective.

1. Climate and Cooling Towers

When the outside temperature drops, the need for a process chiller does not go anywhere. If you don’t take care, the water in cooling towers will freeze. In cold weather, still provide a heat load for the water tower, and never leaves the water tower unsupervised when temperatures drop below freezing. Hold temperature at 45 degrees F or above and use the maximum possible water flow rate to minimize the risk of freezing while retaining the most cost-effective model. Still, water has a lower chance of freezing than moving water. Turn off the cooling fans to avoid circulating cold air over the water and further chilling it.

2. Water Use for Water-Cooled Process Chillers

Water restrictions are common in drought-prone areas. These restrictions also relate to industrial water use, making it difficult to use water-cooled process coolers. In Texas, a glass manufacturer uses 107 million gallons of water annually. However, by reusing wastewater for cooling towers and other non-potable applications, the facility was able to save 27.5 million gallons of water. Reclaimed wastewater in water-cooled chillers, then using freshwater, could help reduce the environmental impact of these units.

3. Bacteria in Water Towers

The life of a chiller can be extended by testing and removing bacteria from the cooling tower’s water. If the machine isn’t inspected, bacteria will create a slime that clogs the workings, causing more frequent repairs. Legionella bacteria, which may kill individuals who inhale the bacteria, is another point of concern.

Despite these difficulties, process cooling continues to be a safe way to remove heat from equipment during processing and storage. Many businesses have adopted new process cooling trends in order to meet these obstacles.

ABOUT US

DANA water heaters & coolers factory LLC (www.danawatercoolers.com) established in 2001 is an ISO 9001:2015 certified company. Our company manufactures our products and we are stainless steel water cooler supplier in UAE. And we present our gratitude to you with immense pride and honor to associate ourselves among the leading producers of water chillers with other cooling and refrigerant solutions, being able to provide our services in almost all Gulf countries and also some African countries including Oman, Bahrain, Kuwait, Saudi Arabia, Jordan and some other GCC nations alongside Arab countries.

We at DANA group have always kept in mind, restrictions, and problems our consumers face and tend to work with utter determination so that we can eliminate these boundaries and bring the best to you at affordable prices. We bring about the product for use in a variety of sectors. Our domestic overhead coolers are an example of our dedication to bringing the best for the complete spectrum of consumers.

Feel free to contact me in case of any inquiry. Listed below are the mediums through which you can reach us out!

For Within UAE we have our Expert Mobile Team, which handles all the installations and after-sales support. We provide service across Dubai, Ajman, Sharjah, and Abu Dhabi, Al Ain, RAK, UAQ, and surrounding areas.

For Outside UAE, we are having our agent network, or we also able to send our technicians overseas to handle complete turnkey installations.

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