The global data center market is huge and is growing rapidly, with approximately data centers in the world today.  

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Data centers account for 1.3% of the world's electricity consumption, a relatively low percentage but grew by 70% between and . Although significant progress has been made in data center performance in recent years, further government and industry efforts are needed to improve energy efficiency to curb energy demand and rapidly reduce emissions over the next decade to achieve a net-zero emissions scenario by .

From this perspective, it is necessary to make the right choices in data center design, where energy efficiency is an important factor in minimising environmental impact. Reducing the environmental impacts of digital infrastructure is particularly related to cooling systems, whose consumption constitutes on average 30% of data center energy use. 

Overview of a data center cooling system 

The schematics above describe a typical HVAC plant for a data center, and introduce the main elements of Daikin’s solution, including several components: 

• Air-to-water chiller 
• Computer Room Air Handling (CRAH) unit 
• Control systems 
• After-sales services 

In this article, we will discuss the main challenges in the choice of chillers for data centers and how Daikin can support overcoming those challenges. 

Challenge #1: ambient temperature conditions 

As mentioned, we are experiencing increasingly rapid growth of data centers in all parts of the world. When designing the data center infrastructure, it is appropriate first to make some considerations regarding the external ambient operating temperatures in which the HVAC systems will perform. It is necessary to evaluate the system's equipment and its operating ranges to make sure that it will work properly at the required conditions.  

Given the strong growth of data centers also in parts of the world where temperature conditions are extreme, there is a need for cooling systems that can guarantee and ensure proper operation in both warm and cold regions, for example, the Middle East and Northern Europe, respectively.  

Reason #1: To overcome this challenge, Daikin can guarantee with its chillers an operating range from -30°C to +55°C ambient temperature, thereby enabling projects on a global scale.  

Challenge #2: Optimize the installation space 

The indoor design of the data center, the related IT power, and the capacity of the cooling system are strongly tied topics within a data center project. As for any other building, even in data centers the installation space for HVAC equipment is limited. 

Reason #2: Despite data centers may require hundreds of megawatts of cooling capacity, Daikin supplies extremely compact air-cooled chillers, allowing them to be fitted in restricted areas. This is specifically true for free cooling units, whose configuration does not exceed the unit footprint.  

This is a result of a re-design of the condensing section, which has been optimised resulting in a reduction of units’ length. This is particularly important because, given the limited space for installation, it saves space by allowing further redundancy of capacity (where needed) and easiness of maintenance activities. 

Challenge #3: how to cut operating costs and limit environmental impact 

Given the large size of the applications, the implementation of strategies to keep operating costs low represents a priority. Containing operating costs is directly related to the need to reduce the environmental impact of the various installations that are implemented. As for the cooling system, most of the energy consumption is due to the operation of the chiller units. Therefore, 6 strategies might be pursued to cut operating costs and reduce environmental footprint: 

• Select chillers ensuring optimal performance in part load conditions 
• Include free-cooling configuration in chillers’ selection 
• Adjust cooling system design allowing chillers to work with a high evaporator leaving water temperature 
• Implement control solutions to cut costs by enhancing system efficiency 
• Design the cooling system allowing to reuse of waste heat from the data center for district heating purposes 
• Add active harmonic filters to limit harmonic distortion related to chillers 

Optimize performance at part loads 

Part loads represent more than 95% of the operating time, due to varying ambient conditions (temperature, humidity) in the installation location. Being a critical aspect to consider, proper considerations must be made on the compressor technology mounted onto the chiller, and most importantly on the availability of a variable frequency drive (VFD) to modulate the compressor’s capacity.  

Reason #3: Daikin's in-house single-screw compressor is a very efficient component by design. It also integrates the Variable Volume Ratio (VVR) technology to adjust the compressor’s geometry according to the real operating conditions. That is, VVR consists of a sliding valve used to modulate the compression ratio enhancing the efficiency of the compressor with varying ambient conditions. Furthermore, Daikin single-screw compressor is also equipped with an integrated VFD, also designed, and manufactured by Daikin, mounted onto the compressor, and cooled down by refrigerant.  

Free cooling to further reduce energy consumption 

An additional help to further reduce electricity consumption is the use of Free Cooling technologies because when outdoor temperatures are favourable, chillers can turn off compressors and take advantage of the low outdoor temperature to chill water.  

Reason #4: Daikin offer different types of free-cooling configurations from 150 to kW of cooling capacity also including glycol-free systems allowing savings for the pumping system as well.  

Higher chiller leaving water temperature for further system optimization 

A further possible reduction in consumption is related to the design temperatures of the data center. Indeed, when cold and hot aisles are separated, the cooling system can operate at higher temperatures, even in the range of 25 to 30 °C. This leads to benefits in terms of chillers’ efficiency and thereby reduced running costs.  

Reason #5: Daikin's new range of air-cooled chillers can supply an evaporator leaving water temperature of up to +30°C. This temperature choice also increases the relevance of free cooling operation as the ambient temperature changes, which is particularly relevant for countries with mild (e.g. Southern Europe, Australia) or even warmer climates. 

System control solutions to further raise efficiency 

As mentioned, data centers often require multiple chillers to reach the cooling capacity requirement. This implies that it is not sufficient to consider the efficiency of a single chiller to ensure the efficiency targets of the whole cooling system. Therefore, higher level control solutions should be considered to optimize performances of groups of units. 

Reason #6: In this sense, Daikin offers an Intelligent Data Center Manager (iDCM). It is an external panel that controls up to 20 chillers, including Primary pumps management and free cooling mode. iDCM is designed to ensure maximum reliability and leverages upon an advanced machine learning algorithm, working based on manufacturer data and live data recorded on site. iDCM can ensure an increase in system efficiency up to 10% for mechanical cooling system and up to 15% for free cooling integrated system compared to standard control solutions. As well, this control panel is fully suitable for TIER III DataCenter and as customised execution also for TIER IV. 

Recovery of waste heat for district heating 

Ideally, all the electricity consumed by IT is converted into heat, and the effective removal of which is one of the primary needs of data center facilities. Heat is a byproduct of data center operations, but it is available at relatively low temperature and for this reason do not find practical use so is wasted to the ambient. If that heat could be made available at higher temperature it could be reused instead of being wasted into the environment, however, becoming a valuable commodity for different purposes. As much as 90% of the energy used by data center IT equipment can be recovered as heat, providing thousands of megawatts of thermal power globally. 

Most data center heat recovery projects rely on district heating networks as heat off-takers. Reason #7: In this sense, Daikin can propose solutions to recover the heat produced by data center. The scheme below describes a possible scenario, where a water source heat pump extracts the heat from data center loop, raise the temperature to useful level to serve a heating purpose (for example a district heating loop). The air-cooled chiller will then see a lower cooling demand thanks to the operation of the water source heat pump which extracts the heat from the loop. Recovering the otherwise wated heat from the data center loop increase the whole system efficiency.    

Still on heat reuse, there is another solution that Daikin can provide. The scheme below describes the plant layout. In this case, heat is recovered directly from the air-cooled chiller, while working in mechanical cooling mode. This is ensured by means of an additional plate-to-plate heat exchanger placed in series to the condensing section. That heat is then supplied to the district heating system. Such solution can be integrated within free cooling chiller configuration as well, thereby offering facility managers a competitive alternative to satisfy heating needs and lower operating costs simultaneously. 

Reducing harmonic distortions 

Harmonic distortion is caused by nonlinear loads such as power electronic devices, variable frequency drives, and certain types of lighting, which inject harmonic currents into the power system. That said, harmonic distortion can happen in data centers. Harmonic distortion causes additional power consumption in electrical systems. It can lead to increased energy losses and reduced efficiency, resulting in higher energy costs. Low harmonic distortion helps minimize these losses, improving energy efficiency and reducing operational expenses. Many countries have established regulations and standards to limit the level of harmonic distortion produced by electrical equipment. By keeping harmonic distortion within the prescribed limits, manufacturers and data center operators can ensure compliance with these standards. 

Active harmonic filters (AHFs) are electronic devices used to reduce harmonic distortion in electrical systems. They are capable of dynamically compensating for harmonic currents in real time, thereby improving the power quality of the system. AHFs actively monitor the harmonic currents and generate compensating currents that cancel out the harmonics, resulting in a reduction in Total Harmonic Distortion (THD).  

Reason #8: As chillers may generate harmonic distortions, Daikin offers a unique solution for active harmonic filtration. Based on the same proprietary technology used for the compressor drive, the active harmonic filter by Daikin is fully integrated into the chiller. The device is installed inside the electrical panel, cooled by the refrigerant from the chiller circuit ensuring temperature control in all operating conditions regardless of environmental conditions. Being the AHF fully integrated, no additional space, installation, and maintenance are required. As well, Daikin AHF is fully assembled and tested directly in the factory.  

Challenge #4: ensure reliability of equipment 

The management of a data center is particularly challenging and complex, as the main objective is to ensure continuous operation all day, every day. This places high demands on the reliability and quality of components, including the HVAC system. Concerning the causes of system failures, the Uptime Institute reports in a survey that 14% of downtime episodes are caused by cooling system issues, negatively impacting the business. In addition to that, it is reported that the causes of downtime are predictable in most cases (76%), as they are often related to human error. In this area, problems due to inadequate equipment management and maintenance are significant (36%). For this reason, the reliability of HVAC systems implemented for data centers is crucial and strongly depends on chillers. In this sense, 6 considerations should be made:  

• The different compressor technologies available on the market  
• The kind of variable frequency drive to be employed  
• The kind of protections against power failures  
• The potential impact of corrosive environments on the chiller’s condensing section  
• How to limit the effects of potential refrigerant leakages  
• If the chiller is covered by a certification programme and can be tested before delivery   

The importance of the compressor design 

Reason #9: From a product standpoint, Daikin offers technology that is designed to be extremely reliable and durable, even in harsh environments. That is the case of the inverter single-screw inverter compressor by Daikin. Differently from a standard screw compressor, the Daikin screw compressor uses one main screw mashing with star rotors to produce a volume-matching compression cycle. Due to the main rotor, being balanced in both radial and axial direction, the compressor bearing has extremely high reliability.  

Refrigerant-cooled variable frequency drive for every operating condition 

Reason #10: As far as the integrated VFD is concerned, then, it is specifically designed to withstand the most difficult ambient conditions. The VFD integrated in the Daikin screw inverter compressor differentiates from other inverter types for being refrigerant-cooled, and then for not being affected by environmental conditions such as ambient temperature, altitude, or air quality (presence of pollutants, dust, or sand).  

Electro-mechanical components limiting the impact of power failures  

The proper functioning of the cooling system is critical to ensure the uptime of the data center. Therefore, it is suggested to consider the adoption of automatic transfer switches (ATS) to limit the impact of power failures on proper chillers’ operation.  

Reason #11: Upon demand, Daikin can include automatic transfer switches in its solution. Together with ATS, it would be suggested to include additional components to make sure the chiller would reach its full capacity in a very short time, thereby limiting the impact of power failures on the data center's proper operation. This is the case of Daikin Rapid Restart. It consists of a UPS to keep the unit controller ON for 180 seconds during a power failure. When rapid restart is active, the compressor is activated within 30 seconds after power restoration (thanks to ATS). The time to restore full capacity can be lower than 3 minutes. 

Protection of the condensing sections with anti-corrosion treatments 

As air-cooled chillers are used to cool data centers, it is recommended to assess the corrosive potential of the environment in which they will be installed. Indeed, corrosion reduces the cooling capacity with consequent risks to data center operations.  

Reason #12: Daikin offers several types of condensing section treatments to prevent corrosion in environments with mild to elevated risk of corrosion. 

Monitoring of refrigerant leakages 

The correct operation of the chiller is related to the appropriate amount of refrigerant for the operation of the unit. Therefore, it is worth considering the use of refrigerant leakage monitoring systems through which the chiller can communicate any anomalies to the data center’s building management system. 

Reason #13: Daikin provides a full monitoring of units’ working status via its Daikin on Site (DoS) remote monitoring platform. Thanks to this service, facility managers can intervene promptly, and also plan maintenance activities in advance based on the trend of units’ working parameters. 

Product certifications and factory acceptance testing  

Another crucial factor in guaranteeing our reliability is that we are committed to ensuring that our products are certified.  

Reason #14: When choosing the components that will be part of the HVAC system, Daikin exclusively provides units under Eurovent or AHRI certification programmes. Within these certification programmes, standards are set for manufacturers to be satisfied. These relate to the declaration of performance data, and to the software applications used by manufacturers and their customers to simulate the performance of units under specific design conditions. The software is certified and subsequently submitted to regular testing, both for full load and part load performances. In addition, every product declared for certification can be subject to testing to validate performance data. All Daikin units sold in Europe are Eurovent certified. As well, many Daikin units are AHRI-certified, including free-cooling configurations of the latest product releases with inverter screw compressors and with scroll compressors. 

Furthermore, in critical applications like data centers, additional tests are normally requested on the chillers before their delivery.  

Reason #15: In this regard, Daikin can offer factory acceptance testing to certify that the units that will be installed can satisfy project requirements at specific ambient temperatures.  

Daikin Applied Europe’s chiller factory disposes of certified testing facilities, including a climatic chamber to test units up to kW cooling capacity. This facility tests chillers across a wide range of operational modes in all climate conditions, from extremely low ambient conditions (-18 °C) to extremely high temperatures (+52 °C). The climatic chamber is operated following a rigorous set of procedures to ensure compliance with international standards set by certification bodies such as AHRI and Eurovent.   

Challenge #5: consider the noise related to HVAC equipment  

Cooling systems, involving the use of chillers, pumps, compressors, etc., emit noise into the surrounding environment. Since data centers are in different environments, in some cases even close to residential areas, it is highly recommended to employ noise-reducing solutions for the equipment used.  

Reason #16: Daikin can include these configurations ensuring up to 7 dB(A) of noise reduction using compressor enclosures and insulation material on the pipework. As well, Daikin ensures further noise reduction by means of modulating fans’ speed with variable frequency drives.  

Challenge #6: Refer to manufacturers capable of handling project requirements  

Data center projects are particularly complex, frequently involving a series of requirements specifically for chiller units regarding product features, delivery times, and maintenance services. This service can be satisfied only by specialised manufacturers, capable of handling the requirements and performing with the due capacity that this type of project requires. 

Reason #17:   Daikin is the world’s leading company in the air-conditioning sector, present worldwide with sales offices and centers specialising in the design and production of HVAC equipment. Development and production of chillers is one of the main competences of Daikin. Daikin has already been able to manage complex supplies, even supplying 105 MW of cooling capacity for a single data center project in Northern Europe. Through its global presence, Daikin has an extensive service network, capable of providing adequate maintenance in critical installations such as data centers. 

Air Cooled Chillers: Types, Applications and Principles

Chapter 1: Understanding the Functionality of Air-Cooled Chillers

This chapter provides an introduction to the fundamentals of air-cooled chillers, discussing their essential components and functional mechanisms.

What Exactly Are Air-Cooled Chillers?

Air-cooled chillers are a type of refrigeration system used to lower the temperature of fluids, working alongside a building’s air handling system. Unlike the conventional industrial chillers that require cooling towers, these chillers expel heat outside by utilizing fans. By using air to cool water and other fluids, they effectively reduce the temperatures of equipment, processes, and spaces by absorbing heat and dissipating it efficiently.

Comprising a compressor, evaporator, condenser, and expansion valve, air-cooled industrial chillers are employed in diverse environments including large industrial operations, shopping malls, industrial complexes, hotels, and medical facilities. These chillers are also ideal for locations with several buildings such as amusement parks and outdoor shopping centers, delivering reliable cooling solutions for both substantial and smaller operations.

Their compact build renders them portable, cost-effective for maintenance, and easy to install. Versatile portable air-cooled chillers are practical for large-scale events or urgent situations, resembling the simpler structure of water-cooled chillers. Most air-cooled chillers feature either screw compressors or scroll compressors.

Often known as modular chillers, air-cooled chiller units can be stacked horizontally to boost cooling capabilities, ranging from approximately 10 refrigeration tons (RT) to 550 RT. A single air-cooled chiller with scroll compressors can reach a maximum capacity of about 200 RT, while those equipped with screw compressors can hit up to 550 RT.

These units typically incorporate at least two compressors for added reliability. Should one compressor experience a malfunction, the other maintains operation, although cooling strength is lowered to 50%. Air-cooled chillers offer lower efficiency levels than their water-cooled counterparts, with an energy efficiency ratio near 1.00 kW/ton, as opposed to the enhanced efficiency observed in water-cooled chillers.

Key Components of an Air-Cooled Industrial Chiller

The key elements of an air-cooled chiller include:

Compressor of an Air-Cooled Industrial Chiller

The compressor drives the refrigerant flow within the chiller. Compressor types include screw, reciprocating, scroll, rotary, and centrifugal. Centrifugal compressors are particularly dynamic, operating differently by using an impeller to accelerate and then slowly reduce the speed of the gas to compress it, contrasting with positive displacement compressors that condense gas using mechanisms such as screws, pistons, or rotors to elevate vapor pressure.

Are you interested in learning more about Air Cooled Integrated Refrigeration Chillers? Contact us today to secure an expert consultation!

Ideal for high-capacity uses, compressors come in three forms: hermetic, semi-hermetic, and open. In hermetic compressors, both the compressor and electric motor are encased in a hermetically sealed enclosure, typically serving low-capacity needs. Semi-hermetic compressors feature a two-part casing, allowing mid-range capacitancy, with the electric motor and compressor sharing an enclosure. Open compressors, with separated but coupled motor and compressor units, suit high-capacity applications.

Condenser of Air-Cooled Industrial Chillers

This component functions as a heat exchanger, transferring heat from refrigerant to air, utilizing copper tubes with liquid refrigerant and aluminum fins to promote heat exchange. Hid efficient air-cooled chillers usually employ air-cooled condensers, while others can be evaporative or water-cooled.

In water-cooled versions, water facilitates refrigerant cooling, unlike evaporative condensers that blend both air and water to raise air temperature through water evaporation. Air aids this process by facilitating vapor removal.

Fans of the Air-Cooled Industrial Chiller Condenser

The defining feature of air-cooled chillers, these fans circulate air across the condenser, extracting heat and allowing the system to restart the cooling cycle effectively.

Expansion Valves of Air-Cooled Industrial Chillers

The expansion valve finely controls refrigerant flow based on cooling load variations. By receiving and depressurizing liquid refrigerant before it enters the evaporator, it creates a backflow and transforms refrigerant into a low-pressure liquid and vapor mixture, eventually turning it into hot then cold gas as pressure rises.

Seven expansion valve types exist—thermal, low-pressure, high-pressure, electronic, and automatic, among others—each regulating refrigerant flow and helping maintain the pressure difference between condenser and evaporator while enabling refrigerant transformation inside.

Evaporator or Heat Exchanger of an Air-Cooled Chiller

The evaporator extracts heat from the refrigerant before it goes back to the condenser. It's a heat exchanger moving heat from refrigerant to water or coolant. Evaporator types include coil, shell and tube, and plate, defined by efficiency in heat transfer.

By cooling the refrigerant to gas, the evaporator allows it to absorb heat from water or air handling units. Evaporator modifications, like shell and tube, finned, and plate, aid distinct cooling applications by fostering greater contact area for efficient heat transfer.

Notably, evaporators vary in design—

1. Shell and Tube: Typically comprising copper or steel tubes, ideal for liquid cooling.
   
2. Finned Evaporators: Feature secondary fins enhancing heat exchange, improving air cooling efficiency through increased surface exposure.
3. Plate Evaporators: Utilize grooved metal plates for refrigerant distribution. Variations include welded metal plates encasing a tube, utilizing eutectic solutions for enhanced contact.

Filter Drier of Air-Cooled Industrial Chillers

This part protects the system by removing impurities and moisture. Due to clogging from extended use, replacing the filter drier periodically is necessary to ensure system longevity and efficiency.

Chapter 2: How Air Cooled Industrial Chillers Work?

The operational concept of air-cooled industrial chillers revolves around extracting heat from processed water within a closed-loop chilling system. These refrigeration units are essential in process cooling applications for manufacturing, plastics, food and beverage, and HVAC systems. After the chilled water circulates through the facility's air handler or process equipment, it absorbs heat and returns to the chiller. Inside the chiller’s evaporator, efficient heat exchange occurs as the liquid refrigerant absorbs the unwanted thermal energy from the water. The refrigerant evaporates over the evaporator tube bundle, turning into a low-pressure vapor.

This low-pressure refrigerant gas then travels to the compressor, where it is compressed into a high-pressure, high-temperature vapor. Next, the refrigerant moves into the air-cooled condenser coils. Here, condenser fans force ambient air across the coils, rapidly dissipating heat and condensing the refrigerant gas back into a high-pressure liquid. Installing air-cooled chillers outdoors or in a well-ventilated indoor area helps eliminate excess heat buildup, making them ideal for environments where water use is limited or not feasible.

Once heat is released from the chiller by the condenser fans, the now high-pressure liquid refrigerant is directed through an expansion valve. This valve regulates flow and reduces the refrigerant’s pressure and temperature, transforming it into a low-pressure liquid. As a continuous cycle chilling process, this cooled refrigerant returns to the evaporator, where it begins absorbing heat again. This ongoing cycle provides reliable cooling for critical equipment, industrial processes, and climate control solutions.

Modern air-cooled chiller systems offer features such as microprocessor controls, variable speed compressors, energy-efficient EC fans, and environmentally friendly refrigerants for optimized performance, energy savings, and compliance with current industrial refrigerant regulations.

Air Cooled Industrial Chillers vs. Water Cooled Industrial Chillers

Air-cooled chillers and water-cooled industrial chillers are both types of vapor compression systems commonly used to provide process cooling and commercial air conditioning. Both utilize mechanical compressors (such as scroll, screw, or centrifugal compressors) to circulate refrigerant throughout the chiller system, but the primary difference lies in how each rejects heat from the refrigeration cycle.

In water-cooled chiller systems, water is circulated through a sealed condenser and then flows to a cooling tower, where the process water is cooled via evaporation. This requires additional infrastructure, including cooling towers, condenser water pumps, and treatment systems. In contrast, air-cooled chillers use powerful condenser fans to force outdoor (or facility) air over the condenser coils, eliminating the need for a cooling tower. Because air-cooled models do not require extra water system components, they offer a more compact design, easier installation, lower upfront investment, and reduced long-term maintenance costs—making them a popular choice for many industrial, institutional, and commercial cooling applications.

While water-cooled chillers may offer higher efficiency in extremely large or hot applications, they incur extra maintenance costs and require regular water treatment. Air-cooled chillers are valued for their lower operating costs, ease of maintenance, and reliable operation in fluctuating climates. When comparing chiller technologies, consider total cost of ownership, installation requirements, energy efficiency ratios (EER), seasonal performance, and local water resource availability.

Factors to Consider When Choosing an Air Cooled Chiller

When selecting an air-cooled chiller or industrial cooling system for your facility, several key factors can impact operational efficiency, energy consumption, and system longevity:

Minimum Industrial Chiller Capacity

Evaluate your process’s peak thermal load and consider environmental conditions when sizing an air-cooled industrial chiller. Air-cooled chillers are well-suited for cooler climates with significant day-night or seasonal temperature swings. Ensure the unit’s cooling capacity (measured in tons or kilowatts) meets your specific process or HVAC demands. For equipment or applications with moderate cooling loads, air-cooled chillers offer a flexible and energy-efficient solution.

Effect of Industrial Chiller Height

Altitude plays a critical role in an air-cooled chiller’s cooling capacity. At higher elevations, thinner air means reduced heat rejection efficiency, which can decrease overall system performance. Manufacturers provide derating guidelines to adjust for high-altitude applications in industrial and commercial environments.

Industrial Chiller Control Type

The choice of control system can dramatically influence energy efficiency and remote monitoring capabilities. Advanced chillers are equipped with digital or microprocessor-based controls for enhanced precision, alarm notifications, and integration into building management systems (BMS).

Industrial Chiller and Refrigerant Pressure

Industrial chillers are engineered to safely manage high refrigerant pressures. Select units with proven safety mechanisms and high-quality heat exchangers. Employing lower-pressure, environmentally friendly refrigerants (such as R410a, R134a, or next-generation HFO blends) can improve performance and reduce compliance costs with environmental regulations.

Resistance to Air Temperature

Ambient temperature significantly affects chiller efficiency and compressor energy use. For every 1°C rise in ambient temperature, air-cooled chiller capacity can decline by approximately 1%. Consider units with oversized condensers, variable-speed fans, and hot weather optimization if your operation is in a warm climate or exposed installation.

Evaporator Pressure Drop Value

Minimize evaporator pressure drop to maximize system efficiency and reduce energy costs. Specify chillers with large-diameter or enhanced-surface evaporator designs for lower fluid friction losses, ensuring a stable and efficient cooling process.

Physical Size of an Industrial Chiller

Compact footprint is a major advantage of air-cooled chillers, which facilitates installation in dense or space-limited facilities. Make sure to confirm clearance for air flow and maintenance access during system design.

The Amount of Noise Produced by the Device

Operating noise is a significant factor for many industrial settings. Look for air-cooled chiller models engineered with low-noise fans, sound attenuating enclosures, and vibration isolation. For noise-sensitive environments, select models with guaranteed sound pressure levels below 75 dBA at 16.4 feet (5 meters).

Number of Compressors

Multiple compressor configurations provide redundancy and staged capacity control, optimizing performance under variable load conditions. Review the technical specifications to match the number of compressors to your reliability and energy efficiency goals.

Additional Considerations:

• Energy Efficiency Ratio (EER) and Coefficient of Performance (COP): Prioritize air-cooled chillers with high EER or COP ratings to minimize electricity consumption and operational expenses.
• Industry Certifications and Compliance: Ensure your chiller meets relevant standards such as AHRI, CE, UL, or ISO certifications for industrial refrigeration systems.
• Maintenance Requirements: Evaluate the ease of service, accessibility of key components, and availability of after-sale support from the manufacturer or distributor.
• Warranty and Service Agreements: Thoroughly review warranty terms and consider extended service agreements for critical installations.

Leading Manufacturers and Suppliers

Chapter 3: What are the types of air-cooled industrial chillers?

Air-cooled industrial chillers are essential components in process cooling and HVAC systems across a range of industries. These chiller systems are categorized by the type of compressor utilized, which include screw, reciprocating, scroll, rotary, and centrifugal compressors. Understanding the various types of air-cooled chillers ensures optimal selection for specific industrial cooling applications, maximizing energy efficiency, cooling performance, and system reliability.

Portable Air Cooled Industrial Chiller

The term "portable air cooled industrial chiller" refers to the system's standard configuration, rather than the ability to move the unit. In reality, once installed, most portable air cooled industrial chiller units are stationary and not intended for frequent relocation. This designation describes any packaged chiller system that integrates all necessary components—including the refrigeration circuit, circulating pump(s), and water reservoir—within a compact cabinet.

These air-cooled chillers are designed for plug-and-play installation, enabling fast setup for industrial process cooling, manufacturing, laboratory, or medical applications. The built-in chiller controls typically feature motor starters with a single-point electrical connection for streamlined installation. Advanced controllers on modern air cooled chillers provide automated maintenance reminders, diagnostic fault codes, technical alarms, and system alerts to minimize unplanned downtime and extend operation life. Portable chillers are available in a variety of cooling capacities, ranging from 2 to 100 tons, meeting the needs of both small and large-scale facilities.

Portable Air Cooled Industrial Chiller Standard Flow

The standard flow chiller system comes equipped with an integrated water tank. It operates within a closed-loop process cooling arrangement, where chilled water is pumped from the chiller, circulates through the equipment or heat exchanger, and returns to the unit under pump pressure, ensuring consistent coolant temperature and stable chilled water supply.

Portable Air Cooled Industrial Chiller Reversal Flow

The reverse flow air-cooled industrial chiller lacks an on-board tank, instead utilizing an open-loop cooling design. With this configuration, the chiller relies on an externally situated tank or trough. Water gravity-feeds from the external reservoir to the chiller's pump, passes through the evaporator and filtration system, and is redirected back to the reservoir, making it ideal for process cooling where direct fluid recirculation is required.

Portable Air Cooled Industrial Chiller Continuous Flow

Continuous flow portable industrial chiller units are engineered for high-throughput operations that require fluid temperature control in a single pass. These systems incorporate a dedicated pump, integrated tank, and secondary heat exchanger, followed by an inline filter, ensuring precise temperature management and contamination control even under demanding industrial load profiles.

Industrial Stationary Air Cooled Chillers

Industrial stationary air cooled chillers, also called modular chiller systems, are designed for permanent installation and large commercial or industrial environments. A "stationary air cooled industrial chiller" typically does not include an integrated pump or water tank. Instead, these chillers operate as central cooling modules, connected to external pumps and reservoirs via engineered piping networks.

Each major component—chiller, pump, and reservoir—requires dedicated electrical connections and precise controls. Correct sequencing and wiring of electrical controls are critical, ensuring the chiller does not initiate the refrigerant cycle until pumped circulation is established. Stationary air cooled chillers are available in cooling capacities from 2 tons up to 200 tons, making them suitable for large-scale process cooling, industrial HVAC, plastics manufacturing, chemical processing, and other demanding chilled water applications.

Reciprocating Industrial Chiller

Reciprocating industrial chillers utilize piston compressor technology to compress refrigerant gas. The reciprocating piston design applies incremental pressure to the gas, raising its temperature for heat exchange. Adjustable intake and exhaust valves orchestrate piston cycles, and advanced systems disengage pistons in response to part-load cooling requirements, delivering high adaptability to fluctuating heat loads. For precise temperature control, some reciprocating industrial chiller systems use a combination of hot-gas bypass and digital capacity control to match refrigeration output with user demand, though hot-gas bypass can reduce energy efficiency compared to more modern control strategies.

Reliable operation depends on correct electrical setup of each component. Reciprocating chillers are commonly used in smaller industrial facilities and laboratories, with models available from 2 to 200 tons cooling capacity. These chillers excel in process cooling where intermittent or variable workloads are present.

Rotary Screw Industrial Chillers

Rotary screw industrial chillers employ helical (screw-type) compressor technology for continuous, energy-efficient operation. The compressor features interlocking rotors inside a precision housing, reducing refrigerant volume through direct mechanical action as the helical rotors spin. This design minimizes vibration and maintenance requirements, resulting in reliable industrial refrigeration for large-scale operations.

Screw compressor chillers are favored for their robust performance and low noise characteristics. The cooling capacity of a rotary screw compressor ranges from 20 tons up to 450 tons, serving extensive industrial, commercial, and institutional applications. Capacity control is achieved using a sliding inlet valve or variable speed drive (VSD/VFD), enabling precise modulation according to real-time process or building cooling demands—an important factor for energy savings and sustainability goals.

Centrifugal Compression Industrial Chillers

Centrifugal compression industrial chillers leverage high-speed impellers—much like those in a centrifugal pump—to compress refrigerant efficiently. This design translates to a compact physical footprint and exceptional cooling capacities, making centrifugal chillers popular in large commercial buildings, district cooling plants, and heavy-industrial environments that require bulk chilled water supply.

Modern centrifugal industrial chillers incorporate energy-saving technologies such as variable speed drives (VSDs) and adjustable inlet guide vanes to optimize cooling performance under part-load conditions, reduce energy costs, and minimize system wear. With capacities often starting at 150 tons and scaling much higher, these chillers deliver high-efficiency cooling for a wide variety of mission-critical environments.

Frictionless Centrifugal Industrial Chillers

Frictionless centrifugal industrial chillers represent the state-of-the-art in oil-free chiller design. Similar in operation to standard centrifugal chillers, they are distinguished by the use of magnetic bearings, which eliminate mechanical friction and the need for lubrication. This results in ultra-quiet operation, reduced maintenance, and enhanced energy efficiency—key advantages in data centers, hospitals, and manufacturing facilities with sensitive environmental controls.

These chillers incorporate high-efficiency, variable-speed direct drive (DC) motors for precise energy management. Frictionless centrifugal chiller systems are available in capacities from 60 tons to 300 tons, catering to end-users requiring superior reliability, quiet operation, and maximum energy savings.

Absorption Industrial Chillers

Unlike mechanical compressor-based chillers, absorption industrial chillers deliver cooling using a thermally driven refrigeration process powered by waste heat, steam, or natural gas. This technology is preferred in facilities where reducing electrical demand is a priority, or where waste heat is readily available, such as combined heat and power (CHP) plants and large manufacturing complexes. Two working fluids, most commonly lithium bromide as the absorbent and water as the refrigerant, interact through carefully controlled cycles to provide chilled water for air conditioning or process cooling needs.

The absorption refrigeration cycle starts by using thermal energy to drive off water vapor from the absorbent solution. The refrigerant vapor is then condensed to release heat before being routed to the low-pressure evaporator, where rapid vaporization absorbs heat from the chilled water circuit. The process results in efficient cooling with minimal electrical input, making absorption chillers environmentally friendly options with low greenhouse gas emissions. These systems are especially attractive for sites seeking sustainability certifications or for applications with variable energy sources.

When evaluating which air-cooled industrial chiller is best for your facility, consider critical factors such as cooling load requirements, available energy sources, installation space, maintenance preferences, and integration with existing cooling or process infrastructure. Industrial chiller manufacturers and suppliers can help with system sizing, application engineering, and life-cycle cost analysis to ensure you select the optimal chiller technology for your specific needs.

Chapter 4: AWhat are the applications and benefits associated with air-cooled industrial chillers?

This chapter will explore the applications and advantages of air-cooled chillers.

Applications of Air Cooled Industrial Chillers

For industrial operations, air cooled chillers are used to create heat through the use of friction, high-powered equipment, and furnaces or ovens. They are able to increase the lifespan of heavy-duty equipment by circulating cooled liquid through equipment to maintain their efficiency and productivity. Due to the fact that the food industry has strict regulations regarding the storage temperatures of ingredients and products, air cooled industrial chillers are used as a traditional cooling system for food. In the pharmaceutical field, medicines require using chilled water in the manufacturing process and precise temperature control. Industrial chiller systems have the accuracy and precision for the chilling process and can be central process chillers or compact process chillers.

Common types of pharmaceutical chillers include reciprocating, centrifugal, and absorption units. In power generation, power plants generate significant heat during electrical power production. Chillers are employed to cool components and processes by absorbing the generated heat. Medical instruments, such as CT scanners, MRI scanners, and LINAC machines, require precise temperature control to manage the heat they produce. Air-cooled chillers are utilized to maintain consistently cool temperatures, ensuring the efficient operation of critical equipment.

Benefits of Air Cooled Industrial Chillers

Air cooled chillers can be quickly integrated into existing systems, saving both time and money during installation. Their simpler setup compared to water cooled systems means installation teams require less time, resulting in significant upfront cost savings. Another advantage of air cooled chillers is their reduced number of components to maintain compared to water cooled systems. They do not require a condenser pump, cooling tower, or other complex parts, thereby lowering maintenance needs. Air cooled chillers are particularly beneficial in areas prone to drought or with limited water supply, offering a water-saving alternative to traditional systems. By using ambient air instead of water for cooling, air cooled chillers eliminate the need for water, optimizing performance. Additionally, air cooling systems do not alter ambient humidity or temperature as significantly as other chiller systems.

Drawbacks of Air Cooled Industrial Chillers

Air cooled chillers may have a shortened lifespan due to their outdoor location, exposing them to environmental elements such as ice, rain, snow, wind, and hail. Additionally, air cooled chillers tend to produce higher levels of noise because of the cooling fans.

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Conclusion

• Air cooled industrial chillers are refrigeration systems that cool fluids and work in tandem with the air handler system of a facility.
• Air cooled industrial chillers are types of industrial chillers that rely on the use of fans to reject heat outside the building rather than relying on cooling towers and have four major parts, which are a compressor, an evaporator, a condenser, and an expansion valve.
• Air cooled industrial chillers can be found in various types, which include portable air cooled chillers and industrial stationary air cooled chillers.
• The working principle of air cooled industrial chillers is based on the absorption of heat from processed water. Once the air handler system uses up the water, it becomes warm and is returned to the chiller. The chiller’s evaporator is utilized to transfer heat away from the water.