Air Cooler Glycol Screw Chiller

General Description:

  • FIDEM Air Cooled Screw Glycol Chillers are robust, energy-efficient refrigeration systems designed for precise low-temperature applications. These units combine screw compressor technology with glycol-based heat transfer, making them ideal for industries requiring antifreeze protection such as breweries, chemical processes, and food storage.

Air Cooled Screw Glycol Chiller

Design Features

  • Cooling Capacity: 30 TR to 500 TR (customizable)
  • Compressor Type: Semi-hermetic twin screw with internal oil separator
  • Refrigerant: R404A / R407C / R134a / R513A (Low-GWP options)
  • Heat Exchanger: Plate or shell & tube type evaporator with SS-316 glycol side
  • Glycol Compatibility: Ethylene/Propylene glycol up to -25°C outlet
  • Ambient Temp Range: Up to 48°C
  • Casing: Powder coated GI or SS-304 (Optional)
  • Controls: PLC with touch HMI + BMS-ready interface

What is a Glycol Chiller?

  • A glycol chiller is a refrigeration unit that uses glycol-water solution as the coolant. It is capable of maintaining sub-zero temperatures for processes needing precise cooling.

What are the Basic Components?

  • Screw Compressor
  • Air Cooled Condenser with Fans
  • SS Plate or Shell & Tube Evaporator
  • Glycol Circulation Pump
  • Expansion Valve
  • Glycol Buffer Tank (Optional)
  • PLC + HMI Control Panel

What are the Basic Components?

  • The compressor compresses the refrigerant to high pressure.
  • The refrigerant moves to the air-cooled condenser, where fans reject heat to the ambient.
  • The cooled liquid refrigerant passes through an expansion valve.
  • It enters the evaporator, where it absorbs heat from glycol circulating from the process load.
  • The chilled glycol is then circulated to the application.

Why is Glycol Preferred?

  • Freezing Protection: Doesn’t freeze easily even at sub-zero temps
  • Stability: Offers thermal stability over long periods
  • Corrosion Inhibitor: Glycol often contains anti-corrosive additives

Key Features of a Glycol Chiller

  • Wide operating range (-25°C to +5°C)
  • Customizable tank and pump configurations
  • Inbuilt redundancy options
  • SCADA/BMS-ready interface
  • Low noise axial fan motors

Applications of Glycol Chiller

(Same as earlier: Breweries, Pharma, Chemicals, Cold Storage, etc.)

Working Principle of Glycol Chiller

Glycol absorbs heat from the process load and is cooled in the evaporator by the refrigerant circuit. This chilled glycol recirculates, continuously removing heat from the process.

Unit Safety Protections

  • HP/LP Pressure Switch
  • Phase Protection Relay
  • Anti-Freeze Thermostat
  • Flow Switch / No Flow Protection
  • Compressor Overload Relay
  • High Glycol Temp Cutoff
  • Emergency Stop Button
  • Automatic Restart on Power Failure

How Does an Air Cooled Chiller Work?

  • The compressor compresses the refrigerant to high pressure.
  • The refrigerant moves to the air-cooled condenser, where fans reject heat to the ambient.
  • The cooled liquid refrigerant passes through an expansion valve.
  • It enters the evaporator, where it absorbs heat from glycol circulating from the process load.

Advantages of FIDEM Air Cooled Screw Glycol Chillers

  • No cooling tower required (air-cooled)
  • High efficiency screw compressor
  • Low-temperature glycol output (-10°C to -25°C)
  • Flow Switch / No Flow Protection
  • Factory-tested and pre-charged
  • Fully automatic with remote monitoring option

Applications

  • Breweries & Distilleries
  • Food Processing & Storage
  • Pharmaceutical Cooling
  • Chemical Batch Reactors
  • Beverage Packaging Lines
  • Ice Rinks & Industrial Freezers

Safety System (Detailed)

  • Safety Device Function
  • HP/LP Switch Prevents compressor overload
  • Anti-Freeze Thermostat Stops glycol from freezing
  • Flow Switch Protects against dry run
  • Phase Failure Relay Stops unit during wrong phase conditions
  • Overload Relay Protects motor from overcurrent

Support and Services

  • 1-Year Standard Warranty
  • On-Site Commissioning & Training
  • Remote Support & Fault Diagnostics
  • Spare Parts Availability (10+ years)
  • AMC & Maintenance Packages
  • Overload Relay Protects motor from overcurrent

Glycol vs Water Chiller

  • Parameter Water Chiller Glycol Chiller
  • Min Temp ~5°C -25°C or lower
  • Medium Water Water + Glycol
  • Cost Lower Higher due to glycol
  • Application HVAC, comfort Industrial, process

Types of Glycol Chillers for Breweries

  • Packaged Air Cooled Screw Glycol Chiller
  • Modular Glycol Chiller Banks
  • Split System Chillers
  • Indoor/Outdoor rated models

Adjusting Multiple Fermenters

  • Use glycol headers with solenoid valves controlled via temperature probes in fermenters. Each zone operates independently.

Condenser Types

  • Air Cooled Fin & Tube Condenser with axial fans

Anti-Freezing Role of Glycol

  • lycol prevents ice formation in pipes and coils, allowing chillers to operate below 0°C safely.

Evaporator Types

  • SS-316 Plate Type (Brazed or Gasketed)
  • SS-316 Shell & Tube for heavy-duty applications

Operation Guidelines

  • Power ON, Check Emergency Stop
  • Ensure glycol circulation
  • Set target temperature on HMI
  • Monitor suction/discharge pressure
  • Let unit stabilize for 15–20 min

Sizing a Glycol Chiller

  • Load(kW)=FlowRate(LPM)×ΔT
  • Convert to TR = kW ÷ 3.517
  • Account for 15–20{7b18a7080630502dff9462090639c38ac022b53b5ec422b3d0a545a26e2246ad} margin for safety

Installation Procedure

  • Provide level foundation with vibration pads
  • Connect glycol piping with insulation
  • Ensure 1 m clearance all around
  • Connect electrical panel (3-phase, earthing)
  • Fill glycol mixture and test circulation
  • Run trial with all safeties checked

Troubleshooting

Maintenance Tips

  • Clean condenser fins monthly
  • Inspect and top-up glycol quarterly
  • Check compressor oil level every 6 months
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