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General industry

Glycol saving


Glycol is used in systems with outside piping when there is a risk of the ambient temperature dropping below 0C/32F. Another cooling application where a Plate Heat Exchanger can be installed is as a glycol saver. The sketch above shows an example where a dry liquid cooler is used instead of a cooling tower. In order to avoid the risk of bacteria in the cooling tower water, this is increasingly required by law in many countries. In cases where the dry liquid cooled condenser is situated far away from the chiller and glycol is used, the amount of glycol that has to be added to the system is high and so is the cost. An intermediate Plate Heat Exchanger will minimize the glycol circuit, thus acting as a glycol saver and cutting expenses.



Cooling tower


Today water qualities are deteriorating because of different kinds of pollution. This increases the risk of chiller shutdowns due to operation problems of the condenser. The condenser is subject to attacks from either chlorides that will cause cor¬rosion or impurities or biological activities in the water that will cause fouling. As the expectations of trouble-free cooling operations have increased, it has become more and more interesting to look at alternative solutions where these problems can be avoided. 

One solution is an indirect system using a heat exchanger in combination with the open cooling tower. The advantages of this are:

  Low system cost: Cost calculations show that the payback period of the heat exchanger is very short.

  Material savings on condenser: Less expensive materials can be used.

  With an intermediate heat exchanger, chillers as well as cooling towers can be run at an optimal temperature.

  An intermediate heat exchanger means that the use of water treatment chemicals, for example chromates used for the cooling tower water, can be minimized.

  Less maintenance of condenser.



Dry liquid cooler


Dry liquid coolers are an energy-saving cooling source option and an alternative to cooling towers in smaller, indirect cooling systems, up to approx¬imately 1 MW. Dry liquid coolers or other closed-circuit coolers must also be used where cooling water is in short supply or nonexistent, or where legislation renders the use of sufficiently large quan-tities of water impossible. They are also a source of free cooling during the cold season. Baode offers a wide range of robust, heavy-duty dry liquid coolers for the cooling of water, water mixtures, brine and several kinds of oil. The high cooling efficiency combined with high fan efficiency has made it possible for us to construct very com¬pact coolers. Different models are available for both blowing and sucking air across the coil, and there are many customizing options, so we will be able to supply the right cooler for your system.



Free cooling


Free cooling combines an environment-friendly alternative for producing cold with economical benefits. Cooling applications relying on free cooling have been installed with good results in many countries around the world. When utilizing free cooling as cooling source in an application, the use of ecologically harmful refrigerants can be reduced. Free cooling is also a way to cut down on electricity costs C in some cases the cut might exceed 75 percent, resulting in great savings. Reduction in electricity consump¬tion also has environment-friendly effects, as elec¬tricity power production often involves air pollution. 

Free cooling is used mainly for air conditioning and process cooling. It can cover the cooling re-quirements during the period when the free cooling source has lower temperature than the cold water, for example during winter. In spring and autumn a combination of free cooling and chiller-produced cold is used. In the summertime the chiller supplies the total cooling requirement. Suitable free cooling sources are water from for example rivers, lakes, (deep) oceans or ground water, ice and snow storage, or air.



Products for free cooling


GHE's continuous research and development strategy means we are able to supply products for any cooling application, regardless of cooling media and cooling source. This makes it possible to utilize aggressive cooling media such as sea-water, brackish water, or water from rivers and wells. By installing a Plate Heat Exchanger , the chilled water (loop) can be totally isolated from sensitive equipment like air conditioners, thereby eliminating corrosion, scaling and constant maintenance. In seawater and fresh water applications, installation of a filter for protecting the Plate Heat Exchanger is recommended. A cooling system using free cooling in combination with a Plate Heat Exchanger will also require less space, creating an ex-tremely compact solution. 

But Baode is more than outstanding products and optimized systems. Based on our vast experi-ence we are always able to provide quality solutions.



Chiller bypass


Traditionally the chiller in an air conditioning system runs continuously during the entire cooling season, even when full capacity is not required. Previously, the only alternative to constant chiller operation has been a chiller bypass system using a strainer. This strainer removes impurities, but at the same time it requires costly maintenance, chlorination and other chemical treatment.

By installing a Plate Heat Exchanger C and sometimes a filter to protect it C in the chiller bypass system, corrosion, scaling and constant maintenance can practically be eliminated. Another advantage is that this sys-tem can use any type of cooling, such as a cooling tower or free cooling with river or well water, even seawater or brackish water, without ruining sensi¬tive equipment like air conditioners.

As soon as the bulb drops below the required condenser temperature (min. 1C/1,8F), the Plate Heat Exchanger makes it possible to cut off chiller temperature. This means that a large amount of electricity can be saved during the cold season. It also means that the chiller will not have to operate at a low and inef¬ficient capacity, and that chiller maintenance can be efficiently scheduled during this period. Total invest¬ment costs are generally paid back in six months to three years, depending on local conditions.



Ice accumulator/storage


An ice accumulator/storage is a tank where ice can be accumulated during one period, stored and then thawed and used during another. There are two main reasons for using an ice accumulator/storage:

  Where the cooling effect demand varies during the day a smaller chiller can be used. As a result the initial cost of cooling equipment can be reduced considerably.

  Energy can be purchased during the night or off-peak hours. In many countries this means that it can be obtained at a lower price.

Since it has been shown that payback periods for ice accumulators will be as low as two years, it is an increasingly worthwhile investment. There are two main applications for ice accumulators: air conditioning and industry.

Especially in industry, the cooling demand is often variable, for example in a dairy where the milk will be brought in in the morning.

Types of ice accumulators


There are two main types of ice accumulator systems:

  Systems with internal melting consist of a poly- ethylene tank containing coils of the same mate- rial. The container is filled with water. When ice is accumulated, a -5C/41F glycol solution is run through the coil. The water will gradually freeze into ice, first around the coils and then further and further out in the tank. When the extra cooling capacity is required, the glycol solution in the coils will be led through the system and returned to the tank at a higher temperature. The ice accumulated in the tank will then melt, and the glycol solution will be recooled until all the ice is consumed.

  In systems with external melting the tank is made of steel or concrete. Here too are coils with glycol or a CFC/HCFC coolant, and ice is accumulated to a thickness of 35 mm/ 1,4 inches around each coil. The rest of the tank will be filled with water. When there is a need for cooling energy, ice water is pumped out from the bottom of the tank to the system. When it returns to the ice accumulator it will be forced to circulate around the ice. In this system, the ice water that is pumped into the system will always retain the same temperature.

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