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Industrial chillers can not only be used to cool production equipment, but also can be widely used in a variety of processes to ensure the temperature stability of the production environment. However, the high energy consumption of chillers has always been a nuisance to enterprises. Improving the energy efficiency of chillers can not only significantly reduce operating costs, but also reduce the impact on the environment, which is one of the important ways to realize green manufacturing. This paper will explore how to improve the energy efficiency of industrial chillers through a series of optimization measures.
Industrial chillers are mainly composed of a compressor, condenser, evaporator and expansion valve. Its working principle is based on the process of phase change of refrigerant at different pressures to absorb or release heat. This cyclic process consumes a lot of electrical energy, especially when the compressor is running.
Compressor Power Consumption: The compressor is the most energy-intensive component, responsible for compressing low-pressure gas into high-pressure gas.
Cooling Water/Refrigerant Circulation Pump Consumption: Although each pump uses relatively little power, their cumulative energy use over time is significant.
Additional Load from Reduced Heat Exchange Efficiency: If the condenser or evaporator becomes fouled or inefficient, it increases the workload on the compressor, leading to higher overall energy consumption.
Poor Water Treatment Leading to Scaling: Calcium and magnesium ions in makeup water form calcium carbonate and magnesium carbonate when heated, creating scale deposits that severely impair heat transfer.
Improper Load Management: Excessive load causes unnecessary energy waste, while appropriate load adjustment can reduce consumption.
High Condensing Temperature or Low Evaporating Temperature: These conditions directly affect refrigeration efficiency and increase compressor workload.
Lack of Smart Control Systems: Traditional systems cannot dynamically adjust operations according to actual demand, resulting in energy waste.
To prevent and minimize pipe scaling, an effective water treatment program should be implemented first. The addition of scale inhibitors, the use of water softening equipment and pH adjustments can help to inhibit scale formation. In addition, regular automatic cleaning of piping equipment is also a highly effective method that not only removes formed scale, but also keeps the system running efficiently for a long time. For example, one company has succeeded in reducing its energy consumption by about 15 percent after adopting the above measures.
Studies have shown that under the condition of ensuring the safe operation of the chiller, the power consumption per unit of cold capacity is lower when the main unit is running at 70%-80% load than when it is running at 100% load. Therefore, reasonable arrangement of chiller operation plan, combined with the operation of water pumps and cooling water towers, can effectively reduce energy consumption. For example, the time-sharing operation strategy can avoid peak tariff hours without affecting production.
Lowering the condensing temperature can be achieved by upgrading the cooling tower. Increasing the cooling tower’s capacity ensures maximum cooling efficiency. At the same time, regular cleaning and descaling of the condenser reduce compressor workload and improve overall refrigeration performance.
Under the premise of meeting process requirements, appropriately increasing the evaporating temperature reduces the burden on the compressor. This includes optimizing chilled water supply temperature settings to maximize evaporating temperature without compromising product quality.
Variable speed drives (VSDs) adjust the compressor speed based on actual load changes, reducing unnecessary energy consumption. Compared to traditional constant-speed operation, VSD technology significantly lowers startup current and maintains high efficiency throughout the operating cycle.
A scientific maintenance plan is essential for extending equipment life and improving efficiency. Regular tasks include cleaning the condenser and evaporator, checking and refilling refrigerant, replacing filters, and inspecting electrical connections. Introducing IoT-based monitoring systems enables real-time tracking of operational parameters, allowing early detection and preventive maintenance of potential issues.
Different types of chillers have distinct advantages. For example, air-cooled chillers are suitable for areas with limited water resources, while water-cooled models are ideal for applications requiring high-efficiency heat dissipation. Centralized cooling works well for large-scale factories, whereas decentralized cooling better suits small production lines or specific equipment needs. Choosing the right chiller model based on actual production demands helps maximize performance while achieving energy-saving goals.
In summary, implementing a series of optimization measures—including preventing pipe scaling, managing load efficiently, lowering condensing temperature, raising evaporating temperature, applying VSD technology, and strengthening maintenance—can significantly improve chiller energy efficiency. With the development of new eco-friendly refrigerants, AI-assisted intelligent control, and heat recovery technologies, the energy-saving potential of chillers will continue to grow. Enterprises should prioritize chiller energy-saving upgrades and actively adopt new technologies to drive sustainable development in the manufacturing industry.
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