Industrial Chillers Types And Application Guide

Industrial processes often generate significant amounts of heat, which can negatively impact equipment performance, product quality, and energy efficiency. To address this issue, industrial chillers are widely used across various sectors, providing precise temperature control and stable operation.

This article provides an overview of the most common types of chillers: steam compressor chillers—air-cooled and water-cooled, which are further categorized by compressor technology as screw and scroll chillers—as well as their design principles and practical applications.

Types of Industrial Chillers

Air-cooled and water-cooled chillers operate on the same principle: a compressor circulates refrigerant through the chiller, from the condenser, through the expansion valve, to the evaporator, and back to the compressor. The only difference is that air-cooled chillers use a fan to force air through the exposed condenser tubes, removing heat. Water-cooled chillers use a sealed condenser and remove heat by pumping water through a cooling tower.

1. Air-Cooled Chillers

• Easy installation. Air-cooled chillers are typically smaller and can be installed in more locations, eliminating the need for dedicated space.
• Easy maintenance. Air-cooled chillers have a simpler structure, require fewer components, and require less maintenance.
• Air-cooled chillers have a simpler system, require no separate cooling tower or heat pump, and have lower installation costs.

• Air-cooled chillers produce some noise from their fans and compressors during operation.
• Air-cooled chillers have a shorter lifespan than water-cooled chillers because they are exposed to sunlight, rain, wind, and snow, which can shorten their lifespan.
• Air-cooled chillers require regular dust removal, which can reduce cooling efficiency.
• Air-cooled chillers transfer heat to the air, so ambient temperature affects their efficiency. Efficiency may decrease in hot climates (ambient temperatures > 40°C).

Water-Cooled Chillers

• Water-cooled chillers are more efficient than air-cooled chillers and are suitable for high cooling loads. They use water evaporation to dissipate heat, making them more energy-efficient than air-cooled chillers. Water also dissipates heat more effectively due to its large heat capacity.
• They also have a longer service life. Water-cooled chillers are typically located indoors, reducing the risk of corrosion from foreign matter.
• Water-cooled chillers can accommodate higher heat dissipation intensities and require less floor space.

• Water-cooled chillers require a cooling tower and a stable water supply, making them unsuitable for use in water-scarce areas.
• Water-cooled chillers are located indoors, are larger, and generate considerable noise during operation, requiring a dedicated workstation.
• Maintenance costs are higher than air-cooled chillers due to the increased number of components required.
• Water-cooled chillers also take up more space, making them more suitable for large industrial applications.

Screw Chillers

• Large Cooling Capacity: Screw chillers are suitable for medium- and large-scale industrial applications, offering high cooling capacity and continuous, stable operation.
• High Stability: Screw compressors have fewer operating parts and a relatively simple mechanical structure, resulting in smooth operation and a low failure rate.
• Long Service Life: Screw chillers offer extended operating times and are suitable for high-load, long-duration cooling environments, such as the plastics, chemical, and food freezing industries.
• High Energy Efficiency Ratio: Screw chillers maintain high efficiency even under partial load conditions, resulting in significant energy savings.

• High Initial Investment: Screw chillers are more expensive than scroll chillers, requiring a larger initial investment.
• Large Footprint: Screw chillers are relatively large, requiring more space for installation.
• Relatively Noise: While quieter than piston chillers, they are still noisy compared to scroll units.
• High Maintenance Cost: Professional maintenance is required, resulting in higher maintenance costs.

Scroll Chillers

• Compact Structure: Small size, light weight, small footprint, and flexible installation. Low Noise: Scroll compressors operate smoothly with low vibration and noise, making them suitable for indoor applications or those sensitive to ambient noise.
• Low Cost: Low manufacturing and procurement costs and minimal initial investment make them suitable for small and medium-sized businesses.
• Easy Maintenance: Fewer parts make maintenance relatively easy, and operational reliability is high.

• Limited Cooling Capacity: Scroll chillers generally have cooling capacities limited to small to medium-sized units, making them difficult to meet large-scale cooling needs.
• Low Efficiency Under Sustained High Loads: Energy efficiency drops significantly under sustained high loads.
• Relatively Short Service Life: Compared to screw compressors, scroll compressors are more suitable for intermittent, low- to medium-load conditions.
• Unsuitable for Large Industrial Applications: Primarily used in office buildings, commercial spaces, and small industrial refrigeration, rather than large factories or cold storage facilities.

Industrial Applications of Chillers

• Food and Beverage Industry – Ice making, brewery cooling, dairy processing, and beverage bottling lines.
• Plastics Processing – Injection molding, extrusion, and blow molding.
• Chemical and Pharmaceutical Industry – Reactor jacket cooling, solvent condensation, and cleanroom air treatment.
• Refrigeration and Logistics – Maintaining seafood, meat, fruit, and vaccines at temperatures between -5°C and -35°C.

How to Choose the Right Chiller

• Required cooling capacity (kW/RT) and water outlet temperature
• Energy Efficiency Ratio (EER/COP) to consider long-term operating costs
• Ambient conditions (suitability of air-cooled vs. water-cooled systems)
• Refrigerant type (R410A, R134a, R407C, R404A, low-GWP options)
• Maintenance and lifecycle costs