Water Cooled Screw Glycol Chiller

General Description

  • FIDEM Water Cooled Screw Glycol Chillers are engineered for large-capacity process cooling where low outlet temperatures and compact, efficient heat rejection are essential. These systems use glycol as the heat transfer medium, offering robust protection against freezing and allowing sub-zero operation in a variety of industries.

Design Features

  • Cooling Capacity: 30 TR to 500 TR (custom models available)
  • Compressor: Twin Screw, semi-hermetic with capacity control
  • Refrigerant: R134a / R407C / R404A / R513A (low-GWP options)
  • Evaporator: SS-316 Plate Type / Shell & Tube
  • Condenser: Water cooled shell & tube with descaling access
  • Inbuilt Glycol Circuit: SS Piping + Circulating pump
  • Controls: PLC with HMI, remote SCADA/BMS option
  • Glycol Outlet Temp Range: +2°C to -25°C

Unit Safety Protections

  • High/Low Refrigerant Pressure Switch
  • Compressor Motor Overload
  • Anti-Freeze Thermostat , Glycol Flow Sensor
  • High Condenser Water Temp Cutoff
  • Phase Sequence & Phase Failure Relay , Emergency Shutdown

How Does a Water Cooled Chiller Work?

  • Refrigerant is compressed in a screw compressor.
  • Heat is rejected via a shell & tube condenser using cooling tower water.
  • Refrigerant is expanded through a thermal expansion valve.
  • The evaporator absorbs heat from glycol flowing in the secondary loop.
  • Chilled glycol is circulated to the application for process cooling.

Advantages of FIDEM Water Cooled Screw Glycol Chillers

  • High efficiency at steady-state load
  • Compact footprint (no air discharge space needed)
  • Quiet operation with water-side heat rejection
  • Works in high ambient locations (condenser water cooled)
  • Stable low-temperature operation (-25°C glycol)

Applications

  • Breweries, Wineries, Distilleries
  • Pharmaceutical Manufacturing
  • Chemical Reactor Cooling
  • Dairy & Food Process Lines
  • Plastic Molding Plants
  • Central Cooling Plants

Safety System (Detailed)

  • Safety Device Function
  • HP/LP Switch Protects compressor
  • Flow Switch Prevents evaporator freeze damage
  • Anti-Freeze Thermostat Stops below-design temp
  • Phase Monitor Detects phase loss or reverse
  • Overload Relay Trips during high current draw
  • Glycol Temp High Cutoff Protects process equipment
  • Water Side High Temp Alarm Indicates condenser scaling/clogging

Support and Services

  • Site Installation and Startup Assistance
  • Customized BMS/SCADA Integration
  • Preventive Maintenance Contracts
  • Remote Monitoring Options
  • AMC Packages with Spare Parts

About the Water Cooled Screw Glycol Chiller

What is a Glycol Chiller?

  • A glycol chiller cools a glycol-water mixture to sub-zero temperatures for indirect cooling of processes or storage applications. The glycol prevents freezing in the evaporator and pipelines.

Key Features of a Glycol Chiller

  • Sub-zero temperature capability
  • Non-corrosive SS glycol piping
  • Low energy consumption with screw compressor
  • Option to integrate with existing cooling towers
  • High reliability in 24/7 operations

Applications of Glycol Chiller

  • Cold Storage & Ice Cream Lines
  • Beverages & Juice Processing
  • Cosmetics and Paints Industry
  • MRI and Medical Imaging Cooling
  • Ice Rinks, Laser, and Anodizing Plants

Why is Glycol Preferred?

  • Prevents freezing in low-temp applications
  • Enhances safety and longevity of pipelines
  • Provides temperature stability over long loops
  • Compatible with a wide range of materials

Working Principle of Glycol Chiller

  • Chiller lowers the temperature of glycol-water mixture via the evaporator. The mixture is circulated to user loads, absorbing process heat, and returns for recooling in a continuous cycle.

What are the Basic Components?

  • Screw Compressor
  • Shell & Tube Condenser (Water Side)
  • Plate/Shell Evaporator (Glycol Side)
  • Expansion Valve
  • Glycol Pump & Piping
  • Electrical Control Panel (PLC + HMI)

Key Features of a Glycol Chiller

  • Sub-zero temperature capability
  • Non-corrosive SS glycol piping
  • Low energy consumption with screw compressor
  • Option to integrate with existing cooling towers
  • High reliability in 24/7 operations

Applications of Glycol Chiller

  • Cold Storage & Ice Cream Lines
  • Beverages & Juice Processing
  • Cosmetics and Paints Industry
  • MRI and Medical Imaging Cooling
  • Ice Rinks, Laser, and Anodizing Plants

Why is Glycol Preferred?

  • Prevents freezing in low-temp applications
  • Enhances safety and longevity of pipelines
  • Provides temperature stability over long loops
  • Compatible with a wide range of materials

Working Principle of Glycol Chiller

  • Chiller lowers the temperature of glycol-water mixture via the evaporator. The mixture is circulated to user loads, absorbing process heat, and returns for recooling in a continuous cycle.

Advantages of Using a Glycol Chiller

  • Indirect cooling ensures flexibility and safety
  • Works in sub-zero zones where water freezes
  • Easier to maintain constant temperature
  • Allows multiple user points with one chiller

Glycol Chiller vs Water Chiller

  • Feature Glycol Chiller Water Chiller
  • Fluid Medium Glycol-Water Mixture Water Only
  • Operating Temp -25°C to +5°C 5°C to 15°C
  • Applications Low-temp, critical      HVAC or high temp process
  • Corrosion Risk Low (with inhibitors)  Higher

Maintenance Tips

  • Clean condenser tubes every 6 months
  • Monitor glycol concentration monthly
  • Check pump and compressor bearings annually
  • Calibrate sensors every 12 months
  • Replace strainer filters quarterly

Features & Guide

Types Used in Breweries

  • Water Cooled Screw Glycol Chiller
  • Modular Systems with Tank & Pump Skid
  • Dual Circuit Redundant Design

Types Used in Breweries

  • Use a multi-loop header with separate glycol zones controlled via solenoid valves and temperature sensors at each fermenter.

Startup Procedure

  • Verify water and glycol flow
  • Power ON control panel
  • Set outlet temp (e.g., -5°C)
  • Watch pressures and currents
  • Stabilize for 15 minutes before full load

Condensers Used

  • Shell  (water cooled)
  • Copper/Nickel tubes with descaling ports
  • Tube (water cooled)

Anti-Freezing Function

  • Glycol depresses freezing point of water, ensuring no ice forms in the evaporator, tanks, or pipelines.

Installation Procedure

  • Mount on RCC base
  • Connect glycol and condenser water piping
  • Insulate glycol lines properly
  • Connect power panel with earthing
  • Fill glycol mixture and remove air
  • Perform trial run

Sizing a Glycol Chiller

  • Load(kW)=Flow×ΔT×0.07
  • TR = kW ÷ 3.517
  • Always add 15–20{7b18a7080630502dff9462090639c38ac022b53b5ec422b3d0a545a26e2246ad} safety factor

Evaporators Used

  • SS316 Plate Heat Exchanger (PHE)
  • SS316 Shell & Tube(for dirty/viscous liquids)

Troubleshooting Guide

  • Symptom Cause Action
  • Compressor not ON High pressure or no phase    Check trip conditions
  • No cooling Low refrigerant             Check for leaks & recharge
  • Low flow alarm Airlock or clogged filter           Bleed system & clean
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