The Client –

Mobile MRI Scanner OEM


The Challenge –

Concerns over reliability & performance of legacy system and a lack of contingency provision 

The Solution –

Custom designed, modular cooling system

Mobile scanning trailers are used across the UK to bring essential scanning to patients that don’t have access to static facilities. Aqua were approached by an original equipment manufacturer, specialising in bespoke mobile spaces. They were keen to review the cooling used on their MRI lorry trailers. OEM Account Manager, Ben Newman, explains how Aqua designed and supplied a new, custom designed system with a host of benefits, including built-in redundancy.

Situation

The customer had concerns that their existing system was outdated, as well as taking up considerable space within the trailer framework. They also had no contingency provision,  should anything ever go wrong. Ideally, they were looking for an updated, more progressive design, with enhanced reliability and improved performance.

Reliability and redundancy are vital for any MRI cooling application, not only to ensure patient scanning appointments aren’t compromised, but also because cooling is critical to the way an MRI scanner operates.

Each scanner contains liquid helium, which cools down the MRI’s superconducting magnets to a temperature of below -269°C. These magnets generate the MRI images. If the scanner loses cooling, there is only a limited time before the liquid helium must be discharged. Liquid helium is the only non-renewable element and a finite resource. It can cost over £1,000/10kg, so any issues can have a heavy financial impact.

Solution

Aqua’s design team produced a completely bespoke, modular cooling system arrangement to provide chilled fluid at the optimum temperature to keep the MRI scanner cool.

Each module consists of a condenser, fan, evaporator, compressor, and process fluid pump. Three modules are fitted on each trailer, in a 2 run, 1 standby configuration, along with an internally mounted control panel. They’re mounted on a slider mechanism for easy access and fit on each side at the rear of the trailer, freeing up valuable space.

The 2 run, 1 standby configuration gives built in redundancy. If a module should fail for any reason, the system – and scanning – continues uninterrupted and the liquid helium is protected. In addition, each system is connected to the process via flexible hosing with quick release connections, meaning it can be inter-changed with a temporary hire solution if any repair work is ever required.

The system operates on R32 refrigerant which has a low Global Warming Potential (GWP). The legacy system had long lengths of pipework, filled with a high GWP refrigeration, meaning its green credentials were very low.

Results

With the new modular system already deployed in several of their trailers, our client is already planning to roll it out across their fleet.

“One of the things I believe we do really well here at Aqua is challenging the norm and believing that there’s often a better way of doing things” explains OEM Account Manager, Ben. “We are fortunate in having a fantastic in-house Design & Installation team and they really shone on this project. Our client has a system they can depend on, safeguarding their patients – and business – for now and the long term.”

For support with your next process cooling requirement talk to the team – 0333 004 4433.

 

Ben Newman - OEM Specialist - Aqua Temperature Control People

Our Original Equipment Manufacturer customers are in safe hands with Ben. He’s a qualified mechanical engineer with a background in creating & designing commodities, from electrical connectors through to military mobile phones and plastic furniture for domestic fridges.

Email: ben.newman@aquacooling.co.uk

Job Title: OEM Specialist

The Client –

Global chemical processor


The Challenge –

Production downtime due to variable temperature rise


The Solution –

Free cooling chiller based process cooling solution

Temperature control plays an important role when managing chemical reactions and the stability of chemical compounds. Aqua were approached by a global chemical processor to design & supply a cooling system for their product development division.

Situation

As a manufacturer of speciality chemicals, including silicone emulsions & compounds, our client was facing challenges with the development of a new product. The production process involved taking an aqueous emulsion and mixing it within a batch tank. The mixing and moving causes an exothermic reaction, which releases heat and increases the temperature of the solution.

This temperature rise was proving problematic, slowing production, and creating unwanted downtime. On occasion, production was having to be stopped mid batch cycle, resulting in product and hours of production time being wasted.

Solution

Aqua designed, supplied & installed 3 x Aqua EcoPro chillers, configured on a run/run/standby basis. All units were installed on the roof of the production facility, optimising available space.

The system is designed so that, in normal operation, the three units work on a cycle, so their running hours are similar. They run on a part load basis, dissipating the unwanted heat together. If the heat load exceeds the capacity of a single chiller, a second will start, with the third available if needed.

The run/run/standby configuration gives the system built in redundancy. In the very unlikely event that a unit should fail, the control system will ensure another unit takes over. This leaves production running as planned, with no risk of downtime.

By installing Aqua EcoPro units, the system also benefits from fully integrated free cooling. Not only does free cooling dramatically cut energy consumption, it also substantially reduces operating costs and extends equipment lifetime.

Free cooling uses the natural air to cool, rather than the need for mechanical refrigeration. The outside ambient temperature dictates whether partial or full cooling is possible, but both have a significant impact on carbon footprint and energy usage. The Aqua EcoPro units also operate on R454B, which has a low global warming potential (GWP) value and is a much more sustainable refrigerant than commonly used options like R410A.

Results

“My client has gone from having no process cooling, to having a state of the art, reliable system with built in redundancy. This gives them complete peace of mind, safeguarding their production strategy against delays and downtime” explains Will Coles, Aqua Area Sales Manager.

“In addition, for 72% of the year, they’ll benefit from a level of free cooling. The new system will really make a difference day to day, and they’ll also make some impressive savings along the way!”

If you’d like support with your next temperature control conundrum and to find out how free cooling chillers can help your business, call the team on 0333 004 4433.

 

Free Cooling Chiller for chemical company

The Client –

CNC machinery OEM


The Challenge –

Under performing chiller solution


The Solution –

Correctly sized chiller, reducing outlay whilst improving performance

OEM clients are always on the look-out for ways they can help their clients achieve improvements, in both business productivity and profitability. For a CNC machinery specialist, based in the South-East, they were actually able to decrease their initial outlay cost whilst achieving a better performance.  Ben Newman, our OEM specialist, explains how: 

Situation

Computerised Numerical Control (CNC) is effectively a computerised manufacturing process whereby the machining tools are directly controlled by a computer.  The process follows coded programmed instructions rather than relying on a manual operator.  CNC machines are used in several different ways, often to produce customised parts, where accuracy and precise detailed design are needed. They’re used across most industries, commonly in sectors like automotive, aerospace, healthcare, marine, military and defence.

Our client produces spindle CNC cutting machines. When they operate, the spindles and motors get hot, so need cooling.  Each time a machine is supplied to an end user, the client also supplies a stand-alone chiller. The chiller sits behind the machine, supplying chilled water.  This chilled water is recirculated to the component parts to keep them cool.

After having a long-term relationship with a chiller supplier, they asked Aqua to review their cooling to see if any improvements could be made. 

Early in the review process, it transpired that the chiller they used wasn’t always performing as well as it could be.  When supplying cooling to their larger CNC machines, the chiller often appeared to temporarily ‘stop’ cooling the fluid.

Solution

Aqua analysed the flow rate requirements and temperatures involved, which indicated that the existing chiller model being supplied was oversized.

Chillers have a fail-safe program, which only allows the compressor to start ten times per hour.  If a chiller is too large for its application, the compressor will switch on, the fluid will reach the top of its range and the compressor will turn off again.  Once this happens ten times an hour, the fail-safe will stop the compressor activating until a full 60 minutes has passed. Even though the chiller pump continued to circulate fluid, it was the compressor switching off that was causing the temporary pause in cooling.

The solution? Very simple to be honest.  Aqua now supply a correctly sized chiller, from our Aqua Pro range.  When the compressor is called for, it operates for longer each time, so the number of compressor stops and starts is now easily within the 10 time per hour limit.

Results

Essentially, a smaller capacity chiller costs less money, so our client’s outlay automatically decreases!  They also have reassurance that the performance of their CNC machines will be the same – if not better.  Overall, this example proves that over engineering isn’t always the answer!

If you’re an original equipment manufacturer, looking for support with your temperature control, give Ben a call on 0333 004 4433 or email sales@aquacooling.co.uk

 

Ben Newman - OEM Specialist - Aqua Temperature Control People

Our Original Equipment Manufacturer customers are in safe hands with Ben. He’s a qualified mechanical engineer with a background in creating & designing commodities, from electrical connectors through to military mobile phones and plastic furniture for domestic fridges.

Email: ben.newman@aquacooling.co.uk

Job Title: OEM Specialist

The Client –

Petrochemical manufacturer


The Challenge –

Seasonal temperature increases affecting production


The Solution –

Temporary cooling solution, incorporating Aqua Pro hire chillers

Hiring, rather than purchasing temperature control equipment, is perfect for businesses affected by seasonal temperature changes. There’s no need for capital investment and you only pay for the period you need the equipment for. Many of our clients rent from us annually, to cover the summer months when their existing cooling system is impacted by the higher ambient temperatures. That was exactly the case for a blue-chip petrochemical manufacturer looking for help with cooling their furnace facility.

Situation         

For several months of the year, our client’s furnace is successfully cooled by their existing dry air cooler system. However, as the weather warms up, the coolers start to struggle which affects production. The furnace generates a huge amount of heat during operation and if it isn’t cooled sufficiently components can get damaged and safety can become compromised.

Solution

Aqua supplied a hire package of 3 x 160kW Aqua Pro chillers and 3 x plate heat exchangers. The kit was supplied on a 5-month rental agreement to cover the warmer months. The chillers provide water at a specific temperature – in this case 15°C – to the plate heat exchangers. The process fluid passes from the furnace through the heat exchangers and, as a result, is cooled to the required temperature, before being recirculated back into the furnace.

The Aqua Pro chiller range has been specifically designed for industrial cooling applications, making it ideal for a furnace cooling application. They have an innovative coaxial evaporator, which is manufactured in 0.7mm thick copper and has up to 8mm water ways. The chillers are highly efficient and operate on low GWP R454B refrigerant. Robustly built, with a power coated galvanised steel frame, the Aqua Pro range stands up to the most aggressive environments.

Result

The client has peace of mind that their facility will operate efficiently and safely over the summer months.

“This is the second year running we’ve supported this particular client” explains Aqua’s Jack Crawford. “Summer in the UK is, at best, a little unpredictable, which makes hire a great option. I work with so many clients who just can’t afford to have any production downtime, so when they need help, they need it fast. Contingency planning can also be beneficial for clients in this scenario as we can ensure we have exactly what you need, available when you need it.”

For help with your next hire chiller requirement call the team on 0333 004 4433.

The Client –

Oxfordshire based OEM


The Challenge –

Designing flexible cooling solution for OEM product offering


The Solution –

An air-cooled Aqua Pro water chiller

A long-standing water treatment customer asked us to design a cooling solution for their range of reverse osmosis (RO) water purification plants. 

Situation            

Based in Oxfordshire, our client manufactures RO plants, supplying them to their own customer based. Reverse osmosis is used for purifying water and is popular in the metal finishing and pharmaceutical sectors, amongst others. 

A semipermeable membrane cleans the water as it pumps through.  The RO process can remove 99% of organic and inorganic contamination.

Purifying water this way can replace the need for chemical deionisers and omits the need to hold and handle aggressive chemicals on site.  An additional advantage is that no chemical effluent is discharged.

The systems have a UV light and a pump that get warm during operation, so require cooling. Without cooling, the water will overheat, rendering the RO equipment ineffective and potentially causing it to stop operating completely. 

Solution

Aqua specified a single phase, air-cooled water chiller from the Aqua Pro range. The chiller will circulate chilled water through the plant’s plate heat exchanger, keeping the deionised water at optimum temperature. The size of the chiller supplied can be easily varied, depending on the reverse osmosis plant being supplied.

Result

“For an OEM peace of mind is really important” explains Ben Newman, Aqua’s OEM specialist.  “They need to be confident that their product will work exactly as it should for their customers.  In addition, when choosing Aqua as your temperature control partner, you can rest assured that we’ll be on hand for any technical support that may be needed along the way.”

If you’re an OEM looking for help with your temperature control requirements, call 0333 004 4433.

Ben Newman - OEM Specialist - Aqua Temperature Control People

Our Original Equipment Manufacturer customers are in safe hands with Ben. He’s a qualified mechanical engineer with a background in creating & designing commodities, from electrical connectors through to military mobile phones and plastic furniture for domestic fridges.

Email: ben.newman@aquacooling.co.uk

Job Title: OEM Specialist

The Client –

Suffolk based biogas facility


The Challenge –

Emergency breakdown putting plant operation at risk


The Solution –

Temporary heating hire solution incorporating air handling units

Equipment hire comes into its own when faced with a breakdown scenario.  When a Suffolk based biogas plant’s existing heating system malfunctioned, they turned to Aqua for a rental solution.

Situation            

A biogas plant, also known as an anaerobic digestion (AD) plant, is a facility that converts organic waste materials into biogas through the natural process of anaerobic digestion.  Effectively, organic materials like food waste and animal manure, are turned into a sustainable energy source which can be used for heating and electricity generation.

Part of the process of converting the waste involves drying it out which is referred to as digestate drying.  Hot air is blown through the waste, to remove the moisture, and as it biodegrades natural gases are given off.  These natural gases can then be captured for use as natural energy. 

Solution

The facility’s existing system had malfunctioned, due to a split coil.  Aqua’s Hire team attended site, identified the problem, and ordered up a temporary heating solution from our warehouse to keep the plant operational.  At the same time, our Service team were introduced so that replacement parts and a repair could be arranged.

Aqua connected 2 x 150kW temporary air handling units (AHU) to the site’s hot water system, along with 25 metres of flow & return pipework.  Ductwork was also run to provide a supply of warm air back to the digestate process.   Once the temporary units were plumbed into the existing hot water system and commissioned, the new air handlers could take over the waste drying process.

Result

The Hire solution stayed in place until replacement parts were delivered and installed.  Aqua have subsequently serviced the entire heating system and carried out a full system flush.

“Our client’s number one concern was, understandably, keeping their plant running” explains Hire Sales Engineer, Ben Hughes. “With our Hire & Service teams working together, just one phone call from the client to our rental desk, was all it took.  Hire started the ball rolling with an initial site visit, but the client was so impressed with our response and technical expertise that they’ve now asked us to look after their cooling & heating requirements in the long term.

For support with your next temporary heating – or cooling – requirement call the team on 0333 004 4433. 

 

 

The Client –

Online Retailer


The Challenge –

Warehouse and offices too warm due to seasonal temperature rise


The Solution –

Air conditioning rental package with evaporative coolers and portable air conditioners

Distribution centres play a crucial role within the supply chain network.  The emergence of e-commerce and the rise in online shopping has led to huge demand for fulfilment facilities and warehousing to store, organise and manage goods prior to despatch. 

When a well-known online retailer realised a potential issue at their distribution centre, they turned to Aqua for support.

Situation

The warehouse building had large sky lights across the roof area.  Whilst this made for a bright, well- lit space, it could also get quite warm from the heat of the sun shining through.  Our client was, understandably, concerned that during the warmer months this solar energy gain would be result in an uncomfortable working environment for their employees. 

Solution

A same day site evaluation quickly established that the warehouse space had a good level of air circulation but single – rather than three phase – power supply.  Whilst on site, our Hire Engineer identified that the adjoining office area was also experiencing temperature control problems on warmer days.  The office however had opening windows, which widened the choice of viable options.

After calculating size  of space, number of people, the amount of heat sources (for example IT equipment), power supply and availability of doors/windows, Aqua specified 25 x large capacity evaporative coolers and 10 x 4kW portable air conditioners.  All equipment was quickly despatched from our rental fleet, delivered, and installed the same afternoon.

Evaporative coolers are very effective in large areas so ideally suited to the warehouse cooling requirement.  They are simple to install, easy to operate and running costs are low.  Another plus with evaporative coolers is that they give a cooling effect pretty much immediately.

The portable air conditioners will keep the office space at a consistent, comfortable 20°C, regardless of the ambient temperature.  The units have casters so are very easy to position and move around.  They are highly effective and low noise but do need an openable window to operate.   Our units come supplied with a convenient window adaptor on the heat rejection hose, minimising the amount of heat returning through the opening back into the offices. 

Results

“With temperature control addressed in both the warehouse space and office area, our client – and their people – are assured of a comfortable working environment for the months ahead” explains Aqua Hire Director, Ben Davies.

“They also have zero worries when it comes to service & maintenance as all our rental equipment is covered by 24/7 support.  The stand-out for me with this project was our speed of response.  The customer made one phone call and by the end of the day their issues had been resolved, leaving them to focus on their business.”

For help with your next air conditioning rental requirement, call our Hire desk today on 0333 004 4433.  

 

Are you looking to hire portable air conditioning to help your business or facility over the summer months? If you are, it might be that you’re finding it’s a bit of a minefield. There’s lots of options and it can be tricky navigating through all the different terminology used. So, we’ve put together this guide to give you a quick overview of the main types of portable air conditioning units available. We’ve listed them in order of cost, starting with the most budget friendly.

Fan Units

A fan unit is effectively your no frills, entry model. Very simple in design, the fan moves the air, creating a breeze and increasing evaporation. Using a fan won’t lower the air temperature in a room, but the combination of air movement and increased evaporation achieves the feeling of cooling. Their effectiveness can be improved by simply opening a window.

Evaporative Coolers

This type of air conditioning uses the principle of natural evaporation, with water being used to cool the air.

Water is pumped over pads, keeping them wet and saturated. As warm air enters the unit, it passes through the wet cooling pads. The air takes the moisture from the pads and the moisture is evaporated into the air. This results in a cooling effect.

Because the water in the unit’s tank evaporates during the cooling process, you do need to have the ability to top the water level up. It doesn’t need to be a permanent water supply, although our units can work with one. They can also accommodate bags of ice, which improves the air temperature even further. It is important to note that evaporative cooling works best when humidity is on the lower side, so having a window or a door open, or increasing fresh air delivery from your existing AHU will help with performance.

Evaporative coolers are quick & easy to install, with low running costs. Several of the other types of air conditioners require a heat rejection duct to be installed through a window. These don’t so are a good alternative if you don’t have openable windows and they’re effective at cooling large areas. Common applications include cooling warehouses and retail spaces.

Portable air conditioners

Portable air conditioners are powerful, easy to move around your space and very quiet when running. This makes them an ideal choice for offices and marquees as they’re less intrusive for smaller, heavily populated areas.

To use portable air con units, you do need an openable window or door so that the heat exhaust can be directed out of it. Without this, you won’t be able to successfully remove the heat from the area you’re trying to cool.

Spot coolers

Spot coolers give you the ability to cool a specific area – or “spot” – without having to cool the entire room or building. They’re on casters, so still portable and are designed to move large volumes of air in a space. Each unit has several cooling ducts on the front, which can be angled to get the air distribution exactly where you need it. With Aqua’s units you have the option to extend these cooling ducts.

Spot coolers are more industrial in appearance, which may affect your choice dependent on your working environment. You also need a window, door, or adjacent area to put the heat rejection hose through.

Split air conditioners

Split air conditioners come in two parts, so they are literally “split.”  One part houses the compressor and evaporator and must be situated internally within your building. The second holds the condenser and fan and needs to be positioned outside. The two sections are joined together by a flow & return line.

Split air conditioners are very powerful and use a highly efficient heat rejection technique. Water removes the heat – not air – which maximises efficiency. Because the fan is situated externally, split units can move a large volume of air across the fan, which is  great for cooling large areas. They’re often used in warehouses, event spaces, larger offices, leisure facilities and data centres.

With split air conditioners there is a small element of installation work in connecting the two separate parts together. You also need to have somewhere suitable to site the external unit. It isn’t large – normally the size of a laptop bag – but it isn’t something you would want to have exposed in a busy commercial area. If this proves prohibitive then you’d be better with a style of air conditioning unit that has the heat ducted going through an open window.

What type of portable air conditioning is best for me?

To decide the most suitable solution for your specific circumstances you need to consider a few factors, including:

  • Size of the space that needs cooling.
  • Average occupancy levels.
  • Options for venting heat, for example are there windows that can be opened and external doors.
  • Equipment within the space that generates heat, things like computers, servers, and other IT kit.

But you don’t really need to worry about which equipment is best because that’s our job! We’ll also happily come to site and carry out an evaluation to make sure you get exactly the right type of air conditioning equipment to keep your business on track however warm it gets.

For your next portable air conditioning requirement just give our Hire Desk a call on 0333 004 4433!

The Client –

Metal finishing OEM


The Challenge –

Achieving reliable temperature control


The Solution –

Fully customisable temperature control system 

Dependable temperature control is key to the success of metal finishing processes. It ensures the manufacturing process stays operational and on schedule, as well as maintaining consistency and quality of the final product. Ben Newman, our OEM Specialist, worked with Aqua’s internal design team to devise a customisable temperature control system for a new OEM customer operating within this sector.

Situation

Metal, or surface finishing, refers to a range of industrial processes which alter the surface of metal. It covers techniques such as powder coating, galvanising, and anodising, to name but a few. Ben’s OEM client supplies plant equipment and ancillaries to end clients within this industry.

From time to time, these end clients expand their businesses, acquiring new or larger plant or replacing their existing process equipment. If the equipment does not work correctly, downtime, reduction in production and quality issues can result, all of which they’re obviously keen to eliminate.

A typical plant system consists of several baths that products are dipped into, either cleaning up, degreasing, or giving different finishes to the surface of the product. These baths need to be kept at a pre-set temperature for optimum results, otherwise the fluid within them could overheat and evaporate, which puts the process – and the finished product – in jeopardy.

Solution

Ben and the team proposed a solution which would be easily customisable depending on the specific equipment and operating conditions that the OEM client was supplying.

Essentially,  the fluid in the baths recirculates around a plate heat exchanger and the process is cooled by a chiller. For example, one end user had a 70kW thermal heat load and needed a coolant supply temperature of -8°C, with the process feeding 3 separate tank systems. For this scenario we supplied a single chiller from our Aqua Pro range and the coolant from it is fed to all 3 tanks. Utilising a single chiller for multiple processes keeps the footprint of the installation to a minimum too.

Aqua Pro chillers are particularly suited to manufacturing applications such as surface finishing. The chillers benefit from innovative evaporator and condenser design and are well equipped to stand up to the conditions that industrial environments can bring. They’re also have great eco credentials, making them highly efficient too.

The ease by which our solution can be customised was a big plus for our OEM. Whether they’re selling single or multiple tank arrangements, the temperature control system can be adapted accordingly. Depending on the end user’s site conditions, enhancements can easily be made. For example, if the baths are being used in an aggressive, heavy industrial environment, the condenser coils can be pre painted to give added protection. Performance modifications can also be incorporated, for example variable fan speed control, enhancing energy efficiency and reducing electricity usage and cost.

Results

“Once installation is complete, our OEM customer now has a very reliable temperature control system which can be scaled up and enhanced depending on their client’s individual requirement” explains Ben. “As an OEM, speed of response and ongoing service support are paramount and really valued. So, as well as our solution, the fact that we could assure the client of 24/7 nationwide support, was important.”

If you’re an OEM looking for support with temperature control, contact Ben Newman, Aqua’s OEM Specialist on 0333 004 4433.  

You might have noticed that we don’t like to follow the crowd at Aqua! When it came to adiabatic cooling, we wanted to offer something different. We wanted that difference to really impact our customers’ businesses, helping them run more effectively and efficiently. That’s why we introduced optimised adiabatic cooling across our range.

What is optimised adiabatic cooling?

Put simply, optimised adiabatic cooling takes things up a gear. It’s designed to give you even better results, when compared to standard adiabatic performance.

Adiabatic cooling has long been recognised as a cost effective, greener alternative to cooling towers and in applications needing a water temperature in-excess of 25°C. An adiabatic system also eliminates the requirement for costly chemicals and water treatment, which are mandatory with cooling towers.

Optimised adiabatic cooling increases energy efficiency, significantly minimises water usage and reduces environmental impact to a new level.

How does optimised adiabatic cooling work?

At the heart of our optimised units is an innovative spray and control management system. Water usage and fan speed are cleverly balanced so that the water spray is only engaged when necessary. An inverter driven spray pump delivers exactly the right amount of water, as and when required. This ensures maximum water evaporation but with minimum water wastage.

Features and benefits

Here’s some additional features & benefits of Aqua’s optimised adiabatic units:

  • Electronically commutated (EC) fans – energy efficient but also give low noise operation, important to clients working in areas where sound levels are a concern.
  • Stainless steel spray pipework – not plastic – so zero risk of corrosion.
  • Spray nozzles are designed for industrial applications, easy to clean.
  • Hydrophilic coated coil – improves surface cooling by attracting water.

Why Aqua?

Our in-house Design & Installation team are on-hand to help as required. Whilst our units are quick and easy to install, our Engineers can look after all aspects from design to delivery, installation & commissioning.

We also have a range of adiabatic coolers for hire from our rental fleet. Aqua were the first UK based rental company to offer adiabatic cooling.

It’s even possible to retro fit adiabatic cooling to your existing temperature control system.

For more information on optimised adiabatic cooling, chat to the team on 0333 004 4433!

Don’t Get Caught Out When Buying Your Next Chiller

You’ve heard the phrase “comparing apples to apples” as shortform for highlighting the importance of comparing on a like for like basis. This certainly applies to chillers, especially if you’re choosing between a HVAC chiller and a process chiller. In this article we’ll explain the differences between the two, to help you choose the best option for your specific needs.

HVAC stands for Heating, Ventilation & Air Conditioning. A HVAC chiller heats and cools air. This type of unit is designed to regulate environmental temperature within a designated area. Often referred to as air conditioning chillers, they are ideal for commercial comfort cooling applications.

The purpose of a process chiller is to directly cool a specific industrial, or manufacturing process.  Chiller applications are endless and so many things that we encounter in day-to-day life rely on temperature control. From the cars we drive, to the food & drinks we consume, the technological infrastructure we rely on daily, the commodities within our homes and even the medicines or MRI scans we might need if feeling unwell, process cooling will have been involved in some point.

The main difference between the two types of chiller is the way they cope with temperature. In a comfort cooling scenario, the change in temperature tends to be quite gradual. However, in a process environment, there’s more fluctuation and temperature extremes. A process isn’t static, so the chiller needs to work much harder – and longer – than it would in a typical HVAC application.

Process chillers work to close approach temperatures, which helps them to efficiently deal with these varying demands. The key component parts, such as the compressor, evaporator, and integral pump(s), are specifically designed for industrial or process use. They also have more thermal mass, to cope with extreme fluctuations of return fluid. If you were to use a non-process chiller on an industrial application, it’s compressor would soon struggle to cope and fail.

In the UK, a HVAC chiller in an air conditioning system will only need to run in the warmer months. Whereas process chillers are often on production lines manufacturing 24/7, with no room for downtime. If an air conditioning application goes wrong, people get warm, but the impact doesn’t tend to be as far reaching as when a critical process fails. For example, if cooling fails in a data server, access to online services such as banking, business and retailers is compromised casing losses in sales, productivity, and brand reputation.

A HVAC chiller will be less expensive than a process chiller. That’s because they’re designed differently. Process units need to be much more robust, with different component parts. Process chillers are often described as “packaged chillers” because ancillaries like pumps and tanks are included. They also tend to have options for customisation, whether that’s things like non-ferrous water circuit or special paint finishes for aggressive or coastal environments. Whilst the capital outlay will be more, the technical benefits, peace of mind and energy savings offered by a process unit will more than compensate.

So, what type of chiller do you need? This is down to what you’re trying to achieve. If you’re looking for a cost-effective comfort cooling solution, then a HVAC chiller should be fine. But, if your application involves process cooling, you need a unit built for that purpose.

When talking to your chiller specialist, it’s imperative to check exactly what type of chiller they’re suggesting – especially if there’s a drastically difference in price! This case study illustrates how an Aqua client was initially offered a much cheaper cooling system than what we’d proposed.  But, on closer inspection, it became evident that they were being offered HVAC, rather than process chillers. In the end our customer upgraded to free cooling process chillers. Their free cooling upgrade actually incurred a further investment of £60,000, but they’ll save £80,000 every year!

For free advice, technical support and to check you are comparing apples with apples, chat to the team on 0333 004 4433!

The Client –

Dairy farm based in Scotland


The Challenge –

Upgrade cooling system and future proof facility


The Solution –

Custom designed solution with free cooling 

Keeping operational costs low whilst maximising production capacity are key considerations for clients within the food & beverage sector. One of Scotland’s largest, independent dairy farms, invited Aqua to propose a new, energy efficient, cooling system that would support their expanding product range. 

Situation

The dairy had installed a new ultrafiltration (UF) plant to facilitate in production of their protein yoghurt product. Ultrafiltration is one of four different membrane filtration processes used within the industry. There were two legacy chiller units on site, along with heat exchangers. One heat exchanger was being upgraded with a new scrape surface version. As a result of these changes, cooling capacity needed to increase to ensure -3°C glycol could be supplied to the process tanks, UF plant and heat exchangers.  

Solution

Aqua designed and supplied a custom designed solution, comprising two air cooled Aqua Pro Plus packaged chiller units, and a stand-alone free cooler.

Aqua Pro Plus Chillers

Our Aqua Pro Plus chiller units incorporate high efficiency scroll compressors, giving ultimate capacity control when compared to large screw compressors. Each unit has two independent circuits, with 3 scroll compressors on each.

Whilst the chillers are efficient just by themselves, the ability to add free cooling to the system boosted potential energy savings even further.

The dairy process was able to be configured to include a separated return from the ultrafiltration plant and heat exchangers.  This resulted in an average return temperature of 18°C, making free cooling a possibility.

Free Cooling Benefits

The free cooler can be used to precool – or completely cool – the return water. When the ambient temperature is above -6°C (but below 16°C+), partial free cooling is achieved. But, once the ambient hits 7°C, total free cooling occurs. If the process is running with free cooling, it eliminates the need for the chillers to operate which reduces energy consumption, operational costs and carbon footprint.

A significant benefit with the system is that the chillers will work at part load (or less) for most of the time. This subsequently increases equipment lifespan and keeps maintenance costs low.

Low GWP Chillers

But the benefits don’t stop there. Our Aqua Pro Plus chillers use R454b refrigerant, with a Global Warming Potential (GWP) rating of just 466.  That’s an incredible 78% less than the GWP of R410a refrigerant.

The system includes two-way control valves, adding automatic control to the process. Valves installed on each process vessel ensure cooling is automatically directed to where it’s needed. Plus, it allows different vessels to have different temperatures. Because the valves only open to allow fluid in when the tank requires glycol, energy used is considerably less. 

Finally, two inverter driven pumps, on run and standby basis, were incorporated, along with extra connections so that, should production expand further, additional pumps can be easily added.

“This is a great example of how a legacy cooling system can be upgraded to achieve fantastic year on year energy savings” explains Scotland Sales Director, John Lowe. “It also illustrates how our Sales, Hire and Service teams work together admirably to achieve the best result for the customer.  We supplied a chiller from our rental fleet to tide things over whilst we were awaiting arrival of the permanent equipment and our Service department will support the client for years to come with an extended Planned Preventative Maintenance agreement.”

Results

£80,000 Saving Per Year

From the outset, the dairy has a more efficient, robust, and future proofed process. They also achieve an enhanced level of quality control on the end product. The run and standby pump configuration gives reassurance that production can continue, uninterrupted, should a fault ever occur.

As far as energy savings go, the free cooling cost £60,000 in capital outlay.  We predict the dairy will save £80,000 each and every year, giving an extremely short payback term. 

It’s worth noting that our client was offered a less expensive solution by another supplier.  This was based on using chillers that aren’t specifically designed for process applications, and with no provision for free cooling.  Whilst the capital outlay was less initially, the technical benefits and ongoing energy savings achieved by our system offer far more in the medium and long term.

For more information on our energy saving process cooling systems, call the team on 0333 004 4433.