What Are the Advantages of Small Air Cooled Chiller？

Many regions in the world are facing significant water scarcity. The numerous efforts in desalination and international water trade underscore the severity of this issue. According to the World Bank, 2 billion people live under conditions of absolute water scarcity—a figure that could reach 4.6 billion within the next 65 years. This water-energy nexus has been a continually discussed topic over recent years. Power plants, essential to many nations, consume large amounts of water, directly or indirectly. When conducting a feasibility study for a cooling plant, the decision of whether to use water becomes crucial. Based on these studies, the choice between water-cooled and air-cooled chillers is made.

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What is a chiller?

This device removes heat from a load and transfers it to the environment using a refrigeration system. This heat transfer device is the preferable cooling machine in power plants and other large-scale facilities. It is simply a system consisting of ethylene + water or water reservoir and circulation components. The cooling fluid is circulated from the reservoir to the equipment undercooling. There are also air-cooled chillers, which disperse heat using fans. These are more recent and common in power plants. In this post, we will compare the two technologies, helping you to make an informed decision. ARANER would be happy to assist you in the decision-making process.

Water-Cooled Chiller

Water-cooled chiller systems come equipped with a cooling tower, making them more efficient than air-cooled chillers. Water-cooled chillers are more efficient because they condense based on the ambient wet-bulb temperature, which is generally lower than the ambient dry-bulb temperature. The lower a chiller condenses, the more efficient it is. This system consists of several components including:

• Cooling towers
• Condenser water pumps
• Make-up water pumps
• Chillers
• TES reservoirs

What are the benefits of a water-cooled chiller? Users may prefer these chillers for their smaller size compared to air-cooled chillers, higher efficiency, and longer lifespan. They are also ideal for indoor placement.

In The Evaporator

The role of the evaporator is to produce chilled water. The device releases the water at about 6°C (42.8°F) and pushes it throughout the facility with the help of a pump. A network of pipes passes the chilled water through every necessary section of the building. After exchanging coldness with room air, which blows across the Air Handling Units (AHUs) and fan coil units (FCUs), the water is now warmer at about 12°C (53.6°F). It returns to the evaporator where the refrigerant absorbs the unwanted heat and directs it to the condenser. The chilled water is cool once again and it can now continue to cool the facility. Note how this is called "chilled water" throughout no matter the temperature.

In The Condenser

A refrigerant brings unwanted heat from the evaporator and passes through the condenser. There is another loop connected to the condenser—the condenser water loop, which is between the cooling tower and the condenser. After entering the condenser at about 27°C (80.6°F), the water leaves at 32°C (89.6°F) and heads to the cooling tower. Note that at no time do the refrigerant and the condenser contact directly. Heat exchange is only through a pipe wall. The condenser water, carrying the unwanted heat, goes to the cooling tower for further heat rejection.

In The Cooling Towers

This is where the unwanted heat in a facility ends up. A large fan feeds the unit with air. The air meets with the incoming condenser water. From the direct contact, the condenser water loses heat to the air. The condenser water goes back to the condenser and the cycle continues. These open-topped devices come in many designs depending on various factors. Examples are cross-flow, counter-flow, natural draft, and mechanical draft. Stay with us for coverage of these designs in upcoming posts. This is a good way of resolving the cooling tower vs. chiller confusion. However, if you need more details about the water-cooled chiller components and operation, reach out to our team for assistance. Now, let's compare it to the air-cooled chiller discussed below.

Air-Cooled Chiller

Where aesthetics, environmental conditions, or water access restrictions exist, the air-cooled chiller may be applied. Both air-cooled and water-cooled chillers rely on an air stream for heat transfer. The difference is that water-cooled chillers or cooling towers use a humid air stream (ambient air + water spray), whereas air-cooled chillers use a current of ambient air. Generally, water-cooled chillers are cheaper and more efficient but have the disadvantage of high water consumption. ARANER has managed to combine modern manufacturing methods and advanced technology to achieve highly effective and efficient air-cooled chillers. As a result, the company's chiller plants are highly competitive with water chillers in various aspects. For example, these plants are impressive in terms of footprint, efficiency, and noise. Unfortunately, some people still believe that air-cooled chillers cannot offer good efficiencies. However, a closer look at the progressive increase in NPLV rating of air-cooled chillers over the years shows significant improvements. Many chiller plants in the Middle East and elsewhere have adopted ARANER's air-cooled designs and have expressed satisfaction. When used in part-load applications, these chillers are very reliable. In summary, here are the benefits of using air-cooled chillers:

• No cooling towers
• Better environmental stability—no water wastage
• Low maintenance costs
• Easier to operate and control—no tower freezing or tower bypass issues
• Avoidance of chemical costs
• Avoidance of water costs, especially in urban areas
• No water problems in case of disasters

Fig 1: Air-Cooled Chill Alongside Water Cooled (Traditional) Chiller

How do I choose between the two?

The cooling capacity is the main guideline for chiller selection. Equally important is balancing operating costs with capital costs. Some clients base their buying decision on initial costs. However, a value-based option considers both operational costs and initial costs. To determine the initial cost of each option, include costs for contractors and equipment. For a water-cooled chiller, remember to add the cost of the cooling tower. When it comes to life cycle costs, consider both purchase and operating costs. Evaluating each chiller this way helps determine its total cost. Water-cooled chillers may appear more valuable if one overlooks initial and water costs. However, a broader cost evaluation reveals a clearer picture.

Other alternatives: hybrid chillers

Hybrid chillers can operate as air-cooled chillers under certain conditions and as water-cooled chillers under others. They are an interesting alternative for areas with predominantly dry climates and low water availability or where water availability is inconsistent or unreliable.

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It might interest you: Environmental Consideration of Chillers for District Cooling Plants

Water-cooled chiller and air-cooled chiller, the main advantages!

Energy cost remains a major consideration in any powered equipment. Energy-saving measures are being implemented everywhere. While the chiller has a direct impact on energy usage, there are other factors to consider. While the water-cooled chiller may be more energy-efficient, it faces stiff competition from air-cooled chillers in terms of installation cost, maintenance cost, number of equipment, and several other aspects. Most importantly, air-cooled chillers avoid water consumption, making them ideal in areas with water scarcity or where energy is cheap but water is costly. Have you made your choice already? Give us a call today for specialized and customized attention. If you enjoyed this post, you may want to learn about different heat rejection condensing technologies.

Air vs. Water Cooled Chillers