Choosing the Right Cooling System for your Process
How do you determine the correct equipment to provide cooling for your process? At Thermal Products Inc., we specialize in and represent and distribute for manufacturers of Heat Exchangers, Cooling Towers, and Process Chillers. Below, we provide general guidelines to help you select the best system for your requirements.
Selecting the Right System
Start by determining the target temperature for your fluid to be cooled to. Your geographic location plays a role, but here are some general recommendations:
- If temperatures of 95°F or higher are acceptable, an Air-Cooled Heat Exchanger is a cost-effective, low-maintenance option with zero water usage.
- For mid-range temperature requirements (typically 85°F – 95°F), an Evaporative Cooling Tower is often a practical and efficient solution, depending on your climate.
- If you need a consistent temperature of 85°F or lower, a Chiller System is likely the best choice.
A comparison of these cooling technologies:
An Air-Cooled Heat Exchanger transfers heat from the process fluid by blowing ambient air via fans across bar and plate core.
- Heat Exchangers can efficiently cool the process fluid to within 15°F of the ambient temperature.
- If lower than 15°F from ambient is required, the Heat Exchanger size can increase to achieve a smaller approach temperature.
- No water loss using this technology.
- Power is only additional utility required.
- Best for applications if your process can handle 110°F+ temperatures during the peak temperatures of the year.
- Low initial equipment cost compared to a Chiller and a Cooling Tower system.
An Evaporative Cooling Tower can cool process fluids to below ambient temperature depending on the humidity level.
- Water falls and counter airflow through the tower causing the water to cool and a portion of the water to evaporate.
- Under design conditions, 1% of the water evaporates and needs to be replenished during operation.
- When contaminants must be kept out of process water, a closed loop system utilizing a plate and frame heat exchanger can isolate the process water and the tower water.
- Most effective in dry climates, although they can function under all conditions.
- Best suited for process temperatures of 85°F to 95°F.
- Low initial equipment cost compared to Chiller system.
- Operating Expenses are lower than Chillers and slightly higher than Air-Cooled Heat Exchanger systems.
Process Chillers compress refrigerant to allow for process fluid cooling greatly below the ambient temperature.
- Units cool the refrigerant loop via air-cooled or water condensers.
- Suitable for almost any climate
- Cools process fluids as low as 15°F
- Initial equipment costs and operating expenses are higher in comparison to Cooling Towers and Air-Cooled Heat Exchangers
The Thermal Products sales team is available to discuss your application and help select the correct equipment needed for your process. Please contact us for an on-site or virtual consultation.
