Stationary Industrial Air Chiller Unit For Metal Finishing

Stationary Industrial Air Chiller Unit For Metal Finishing  

Stationary industrial air chiller unit is a type of cooling machine that works with a refrigeration system to release heat from circulating fluid to ambient air for cooling purposes. Air-cooled chiller units are types of chillers that rely on using fans to remove heat from outside the building rather than relying on a cooling tower.The main component is a stationary chiller that must be piped to a pump and a separate tank or pool to function.This chiller system typically has separate controls for the chiller and pump or pumps, with electrical connections for each component. Ideally, the controls should be wired together to prevent the chiller from cooling until the circulation pump is running.Stationary industrial air chiller unit is equipped with Panasonic/Danfoss scroll compressor for 1/2HP to 60HP cooling capacity , semi-hermetic hanbell /Bizter screw compressor for above 30HP cooling capacity usingR407c, R22, R134a, and R404a are all available depending on the chiller unit working condition, application requirements, and ambient temperature. The chiller temperature control range is from -30℃ to +25℃.

Stationary industrial air chiller unit for metal finishing is also called metal finishing chiller or metal finishing system ,which removes heat from metal finishing processing systems.As we know, most metal finishing processes, such as anodizing or electroplating, generate a lot of heat. In order to ensure the high quality of the final product, this heat must be dissipated, so the anodizing electroplating chiller can take advantage of metal finishing. The heat generated during the process maintains the optimal and suitable temperature required for anodizing and plating. The metal finishing chiller can use an air-to-water-cooled chiller or a water-to-water-cooled chiller. If the cooling capacity is large, we can also use a screw chiller.

Our stationary industrial air chiller units feature high-quality components and cutting-edge technology that adheres to industry standards. For the chillers offered by Tongwei, our clients can choose from many specifications and sizes. Furthermore, being one of the top water chiller manufacturers and suppliers, we offer these chillers to our customers at competitive prices,and has exported various stationary air cooled or water-cooled chillers cooling capacity from 10 Ton,20 Ton,40Ton,50Ton,80Ton 120 Ton and 200Ton to the USA, Canada, Philippines, Australia, Malaysia, Singapore, Indonesia, Chile, Mexico, ,Argentina, Colombia, South Africa, Kuwait, Egypt, Saudi Arabia etc. We not only provide high-quality chiller machines, but we prioritize excellent customer service. A major advantage of our Tongwei, is that our customers are our top priority, which sets us apart from our competitors. Our knowledgeable team is dedicated to providing excellent customer service and your satisfaction.Some of the key benefits our team provides for your chiller include:Thoroughly unpack, clean and test each chiller system before shipping; Conduct routine quality assurance checks on every unit; Only ship brand new machines and systems to our customers;Troubleshoot and resolve problems as promptly and efficiently as possible. Contact us today to get all of these great benefits with your stationary chiller. A member of our team will be happy to address any questions you may have and discuss complete technical specifications. We look forward to working with you.

Stationary Industrial Air Chiller Unit Technical Specification

How Does Stationary Industrial Air Chiller Unit Work?

Stationary Industrial Air Chiller Unit with Buffer Water Tank Outside Installation for Reference

Features of Stationary Industrial Air Chiller Unit

»Chiller cooling capacity from 1/2 ton to 200 Ton.

»High quality branded Panasonic/Danfsso scroll compressor or Hanbell/Bizter screw compressor for low noise ad running smoothly.

»Shell and tube /stainless steel plate type evaporator

»Use refrigerants such as R404A, R410a, R134a/R407C, etc. to meet the requirements of refrigeration temperature and environmental protection

»Temperature selection range: Process chilled water between 35°C and -30°C can be provided (users can choose different unit specifications according to different production needs)

»No need water cooling tower

»Easy installation&operation,low-maintenance cost

What Are The Main Components Of Stationary Industrial Air Chiller Unit For Metal Finishing?

4.1 Compressor

The compressor is the key mover in stationary industrial air Chiller unit because it produces pressure variations to stir the refrigerant around.

For stationary industrial air chiller unit For metal finishing , which is with Panasonic/Danfoss scroll compressor or Hanbell /Bizter brand Screw compressor for optional depends on the required refrigeration capacity, using R407C refrigerant,this brand compress is with high refrigeration efficiency,low noise ,energy saving,environmental protection and durability,safety and stability.

Each screw compressor with 4 steps of energy control 25%-50%-75%-100% to make sure the whole screw chiller is stable and guarantee high refrigeration performance.

Panasonic Compressor

Danfoss Compressor

Hanbell Screw Compressor

Bizter Screw Compressor

4.2 Evaporator

The evaporator is a crucial component of stationary chiller as it is responsible for extracting heat from the liquid being cooled,it is located between the compressor and the expansion valve. There are three types of evaporators : Stainless steel coil in water tank evaporator , stainless steel plate type evaporator ,shell and tube evaporator.

SS Coil in SS Water Tank Evaporator

Shell and Tube Evaporator

3.3 Water Pump

The water pump is designed to increase the pressure and the flow of the chilled water in a closed space.

the water pressure water pump for chiller is about 2 bar , but if you need more higher water pressure , pls tell us when you inquiry .For example ,when you use chillers for cooling bottle blowing machine ,the water pressure for water pump need about 4 bar .

Water Pump

High Pressure Water Pump

3.4 Condenser

The condenser for stationary industrial air-cooled chiller unit is equipped with efficient cross-seam fins and female threaded copper tubes for high heat exchange efficiency and good stability.Its function is to cool down the refrigerant steam released from the compressor into a liquid or gas-liquid mixture.

Aluminum fin+fan Condenser

4.5 Controller Panel

Tongwei chillers use precision digital temperature controller, it RS485 communication port，which can do remote monitoring and control. Simple operation, low failure rate, high safety factor, easy installation.

Controller Panel

Stationary Air Cooled Chillers Vs Stationary Water Cooled Chillers

▪ Air cooled chillers require less maintenance than water-cooled units.

▪ Air cooled chillers do not require a water cooling tower or a condenser water cooling pump.

▪ Consume approximately 10% more power than a water-cooled unit due to wet surfaces transferring heat better than dry surfaces.

▪ Air-cooled chillers require less water.

Air-cooled chiller systems are widely used in places where water resources are not sufficient or water quality is not very good. The most convenient part is that air-cooled chiller systems do not require cooling towers, so they are easy to install. (If an air-cooled chiller isn’t what you need, please refer to water-cooled chiller.)

120 Ton Stationary Air-Cooled Chiller                        

120 Ton Staitionary Water-Cooled Chiller

What are Differences Between Stationary Chiller and Portable Chiller ?

The main difference between stationary chiller and portable chiller is that :

Stationary chiller does not include a pump or tank inside , which need buffer water tank and water pump outside;

Portable chiller combines all necessary components including – the refrigeration circuit, full diagnostic touch screen controllers and electrics, process pump ,a reservoir tank,which is easily to install.

Stationary Air-Cooled Chiller                              

Portable Air-Cooled Chiller

How I can Choose the Right Stationary Air Chiller System?

There are FIVE important chiller specifications you need consider when you choose a chiller for your application :the cooling capacity for chiller ,the voltage required for operation, the associated pump horsepower and flow rate (contact us for custom selection), refrigerant, and the evaporator type.

7.1 Calculate Right Cooling Capacity For Chiller

One of the most frequently ask about how we can know the cooling capacity for chillers.  We use KW ,Ton, But/h,Kcal/h to choose chiller cooling capacity :1 KW=860 kcal/h ;  1 TON=3.517 KW;

1 KW=3412 Btu/h;

There is also a formula to calculate the cooling capacity for chiller:.

Cooling Capacity(kw)= Flow Rate(m3/h)*Temp Change(T1-T2)/0.86

Heat Load= C(specific heat)* M(quality output per hour )*Temp Change(T1-T2)

Oversize the chiller by 20% Ideal Size in KW = KW x 1.2

Noted : T1:Incoming Water Temperature (℃)      T2:Required Chilled Water Temperature(℃)    

For example, what size of chiller is required to cool 10m³ water from 35°c to 15 °c in 1 hour?

Temperature Differential = 35℃-15℃=20℃

Water Flow Rate = 10 m³/hour

Cooling Capacity in KW = 10 x 20 ÷ 0.86 = 232 KW

Oversize the chiller = 232 x 1.2 = 278.4KW

278.4 kw cooling capacity for chiller is required.

7.2 Power

Different countries and regions have different standards for industrial electricity, the common power supplies are 208-230V, 380-420V,440-480V,50Hz or 60Hz, 3phase.

Such in Philippines ,the power supply is 220V 60HZ 3PH , 380V 60HZ 3PH ,460V 60HZ 3PH;

in Singapore and Malaysia ,the power supply is 415V 50HZ 3PH;

in Mexico ,the power supply is 220V 60HZ 3PH;

In USA ,the power supply is 208V 60HZ 3PH;575V 60HZ 3PH;480V 60HZ 3PH and so on

7.3 Refrigerant

R22, R407C, R404A, R134A are optional choices.

R22: good cooling effect, but R22 is considered a powerful greenhouse gas, so it’s forbidden in most countries.

R407C: a good replacement for R22, good cooling effect.

R404A: suitable for application that requires low temperature(below -10°c).

R134A: a non-flammable gas used primarily as a “high-temperature” refrigerant, suitable for air-cooled chiller working at a high ambient temperature above 50℃.

7.4 Evaporator Choose

Air cooled screw chiller generally uses one evaporators: just is shell and tube heat exchanger.Shell and tube type evaporator, which requires an additional water buffer tank to connect.

7.5 Buffer Water Tank Capacity Choose

Buffer tank’s capacity can be customized according to specific needs. It can buffer a larger heat load, store more chilled water .

304 Stainless Steel Water Tank

Industrial Applications of Stationary Industrial Air Chiller Unit

Stationary chiller are very popular refrigeration system that can provide steady and reliable water cooling sources for both industrial and commercial usage.

Air chiller units are not only used for metal finishing process ,but also are also widely used in plastic industry,food industry ,chemical industry and Cement/ Concrete Cooling.

Anodizing cooling system

Anodizing of metal parts refers to the process of applying a metal film to their surface. The metal parts to be treated are designated as the anodes of an electrolytic cell, which also contains a cathode made of another element, and these parts are immersed in a chemical bath.

When electric current passes through the device, metal ions are ejected from the cathode and deposited in a thin film on the anode. The thickness of the deposited layer depends on the exposure time of the anode in the charged bath.

As mentioned previously, the anodizing process will generate a large amount of heat that needs to be removed from the process to ensure efficient and uniform metal oxide deposition.

Tongwei Stationary air chiller unit  can be effectively employed to maintain anodizing temperatures at optimal levels. The use of air-cooled chillers or water-cooled chillers alongside the electrochemical vats to achieve this result.

Spot Welder Cooling System

When resistance electrodes are used to weld joints, the heated electrodes are subjected to very high temperatures in a short period of time. Using a water cooling system prevents premature electrode burnout.

Usually, a water pipe is placed inside each electrode to keep the welding temperature in a stable state and prevent electrode breakdown and poor welding strength.

Quench Tank Cooling System

This metal cooling technique involves completely immersing the material in a container surrounded by a heat exchanger. The heat transferred from the metal parts to the cooling tank is dissipated by a heat exchanger through which coolant (usually a mixture of glycol and water) from the chiller is circulated.

Die Casting Cooling System

Forging metals of various shapes and designs is a process that requires close thermal regulation to ensure optimal results. A typical setup for a die casting cooling system consists of a cooling basin/mold into which molten metal is poured. Attached to this vessel is a heat exchanger that circulates cooling fluid to remove heat from the process.

Induction Furnace Cooling System

Various methods are currently being used to achieve induction cooling. Most industrial induction cooling equipment uses a closed-loop unit that passes air or water in a heat exchanger surrounding the manufacturing process.

Shipping Way of Stationary Industrial Air Chiller Unit

As a professional water chiller supplier &exporter,we have our own shipment forwarder to arrange the shipment .Our chiller machine is with plywood packing,which prevent damage during transportation and meet export standards.There are three ways can delivery your chiller unit :

1. Ship by Air: As the chiller is with compressor ,water pump and fans ,the compressed refrigerant and oil inside the compressor is a dangerous item with the possibility of explosion , so it needs to release the compressed refrigerant before transportation. (It means that water chiller without refrigerant when choosing this shipping way. After the machine arrives at your destination, you need to add refrigerant by local professionals. The airline company also request us to provide many documents to prove that the chiller not a dangerous product. The freight cost by air is very high may be higher than the cost of chiller , So By air for delivery is not the mode of transport recommended to our customer.

2. Ship by Sea: The transportation time is longer than by air , but the freight cost is cheap ,and there is no need to add refrigerant after the equipment arrives at the destination.This shipping way is the most suitable mode of transportation for you to delivery your local port.

3.If you have your own shipment container in your other supplier in China, we can help you delivery the chiller machine to your supplier in any city of China .

Why should you choose Tongwei for your stationary industrial air chiller unit supplier?

▪ Experience you can trust

We have been designing and building water chiller for over 15 years. From air cooled chiller to water cooled chillers and everything in between, we have built chillers for nearly every industry and every application.

▪ Fast Quote

Get a quote for your project today! We typically provide a custom quote within 2 hours.

▪ 24/7 customer service

Believe that we will always be by your side. Whether you have a question or need a quote, there‘s always someone answering the phone 24 hours a day.

▪ Durable and reliable machine

Our products are manufactured from high quality materials and we offer a competitive warranty on all  industrial chillers.