Process Cooling-May 2019

P R O C E S S
May 2019
COOLING
For engineers who specify cooling equipment, components and materials
Cryogenic
Vapor
Cooling
Follow Us On:
process-cooling.com
www.process-cooling.com/connect
May 2019 Vol. 7, No. 4
CONTENTS
COVER STORY
9 FREEZING
Cryogenic Thermal Spray Cooling Improves Coating Process
The search for an efficient cooling approach to generate better coating
properties as well as to improve the productivity of HVOF spray-
coating operations has led to the development of cryogenic gas cooling.
Cryogenic cooling methods offer a significant enhancement in the
ability to remove heat quickly. IIoT-enabled controls allow the cryogenic
vapor-cooling system to be integrated into a production management
system.
FEATURES DEPARTMENTS
14 FREEZING
Understanding Cryogenic Freezing Tunnels
4 Commentary
Cryogenic tunnel freezers are suited for processing large quantities of

6 Cool Products
products in a small footprint while increasing product yield. 40 Design Build News
18 REFRIGERATION SYSTEMS 41 Around the Industry

Factors Driving Change for Industrial Refrigeration Systems 44 Spring Prep Tips
New technologies and new designs are changing — and optimizing — the
future of industrial refrigeration and freezing systems. 46 Classified Advertising
47 Advertising Index
24 FILTRATION
Filtering Oily or Dirty Process Cooling Waters 47 PC Online
Walnut-shell filtration systems take advantage of walnut’s natural affinity
to oil to help remove contaminants from process cooling waters.
ABOUT THE COOLING
P R O
C E S S
27
May 2019
COOLING TOWERS COVER For engineer

s who specify
cooling equipme
nt, compone
nts and material
s
Crossflow Microsand Filtration for Cooling Tower Water Treatment

Technologies that reduce chemical use in process cooling water towers A cryogenic nitrogen
provide many benefits. vapor-cooling system Cryogenic
from Air Products Vapor
Cooling
32 COOLING CAPABILITIES CHART
System Chillers
(www.airproducts.
com) is installed Follow Us
process-c
On:
ooling.co
m
Designed for safe, reliable operation, system chillers deliver the cooling on the high velocity
needed throughout the plant from a single large unit. Find suppliers using oxygen fuel (HVOF) thermal-
our Cooling Capabilities Chart. spray production equipment. The
cryogenic nitrogen vapor-cooling
system uniformly cools thermally
36 HEAT EXCHANGERS
Evaporating Digestate with Heat Exchangers
sprayed coatings by monitoring
the temperature of the coating and
Careful selection of the heat exchanger technology for the process aids in
varying the cooling intensity to match
efficient evaporation operations.
the heat generated in the spraying
process. For more on nitrogen vapor
MEMBER
cooling, turn to page 9.
May 2019 www.process-cooling.com 3

PUBLISHER’S NOTE
P R O C E S S
Valued Readers of
Process Cooling
COOLING
Publishing Staff
Publishing Director,
I
would like to say first, to our readers, Manufacturing and Gaming Groups
advertisers, contributors and partners, THANK Senior Group Publisher • Erik Klingerman
248-833-7341 • Klingermane@bnpmedia.com
YOU! As the new group publisher for the
Associate Publisher & Editor • Linda Becker
Thermal Processing Group at BNP Media, I’m 262-564-0074 • BeckerL@bnpmedia.com
looking forward to continuing to build on our long- Technical Editor • Reed Miller
standing brands. 412-306-4360 • reed@process-cooling.com
Since 1926, BNP (Business News Publishing) has been the leader in Associate Editor • Bill Mayer
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providing business-to-business relevant content and timely news. Our
mission has not changed since the beginning: BNP Media is here to help Contributing Editor • Joy LePree Anderson
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people succeed in business by giving them superior information. Providing
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our readers with the latest trends and technologies is important to us. Our 248-244-6436 • Aduthg@bnpmedia.com
editorial team has been at the forefront of all things thermal processing, and Production Manager • Souzan Azar
we will continue this trend. 248-786-1700 • AzarS@bnpmedia.com
To our readers, Process Cooling will continue to deliver the blend of practical Reprints • Becky McClelland
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how-to articles along with case histories and industry and product news
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4 PROCESSCOOLING May 2019

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Designed for toolless installation and quick filter replacement, Hoffman Type 12 HF
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Additionally, the filter fan line offers protection with a rope gasket that provides a
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Pfannenberg
Air-to-Air Heat Exchangers Can Cool Electrical Enclosures
Designed for indoor, outdoor, remote and washdown applications that require a closed-
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Wittmann Battenfeld Inc.

Single- and Dual-Zone Circulating-Water Temperature Controllers
Due to a smaller heat exchanger in the Tempro Series, there is less circulating water. As a
result, the preheating and cooldown periods are shorter, says the manufacturer. The product
line includes Tempro plus D90, which is designed for temperatures up to 194°F (90°C). The
open system has submersible pumps without pump seals. Tempro plus D140/160/180 models
are designed for temperatures up to 284, 320 and 356°F (140, 160 and 180°C), respectively. The
pressurized systems have magnetically coupled pumps for graduated temperature ranges.
The dual-zone Tempro plus D250 is supplied with thermo-oil for processes to 482°F (250°C).
Microprocessor control provides ±0.5°C accuracy. Other features include a touchscreen display, line evacuating for mold
purge, and a sealless magnetically coupled pump.
860-496-9603 • www.wittmann-group.com

Hemco
HEPA and Carbon Inline Filter Packs
CleanAire filters are designed to be mounted inline in the exhaust ducting from
a fume hood or contaminant source up to 1500 cfm. The HEPA and carbon filter
packs include a galvanized-steel housing with hinged and gasketed access door
to ease filter change-out. Molded-composite resin inlet and outlet plenums and
duct-connection collars are sized to meet specification. Both filters include a 30
percent pleated prefilter and can be paired together for applications that require
particulate and fume removal.
800-779-4362 • www.hemcocorp.com
Delta T Systems
Combination Heater/Chiller
Heater/chiller units offer configurability and compactness via a single combined package.
The integrated system saves space because both circuits are contained in one cabinet and are
managed by a single controller. The standard model has a single controller and program and
is capable of controlling two processes at different temperatures and pumping capacities. It
provides precise temperature control within 0.5°F using modulating valves and PID control
algorithm. The heater/chiller unt can be used in any application where a single chiller and
temperature control units (TCUs) are used in tandem. The energy-efficient control systems
include variable-speed compressors and fan motors to control temperature precisely in many
production processes.
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PRODUCTS
GEA
Ammonia Chiller with a Semi-Hermetic
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BluQ is an ammonia chiller with a semi-hermetic compact screw compressor.
The heart of the system is the GEA CompaX, an ammonia screw compressor
with suction gas-cooled electric motor. Compared to an open solution, the risk of
leakage is minimized by eliminating the mechanical seal, making operation with
ammonia as a refrigerant even more attractive. A 3-in-1 design combines the
motor, compressor and oil separator in a compact and hermetically flanged unit.
To minimize refrigerant charge, the evaporator and the liquid separator are housed in a single housing.
+49 211 9136-1505 • www.gea.com
Heatcraft Worldwide Refrigeration

Refrigeration Controller Provides Evaporator Control
The intelliGen is a factory-mounted electronic control solution for evaporators that
provides automatic superheat adjustment, temperature control and intelligent defrost
control capability for walk-in coolers and freezers. The refrigeration controller allows
users to monitor and track room temperature locally or remotely on any phone, tablet
or laptop with a field-installable optional intelliGen webserver card (iWC). Once
installed on on the evaporator, the controller performs the necessary defrost operations
directly from the electronic control, eliminating wiring back to the condensing unit
when used as an evaporator controller only. Evaporator fan cycling at user adjusted
intervals during the compressor off cycle provides an energy-saving feature.
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Monitor
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FIGURE 1. This cryogenic nitrogen vapor-cooling system is installed on the FREEZING
high velocity oxygen fuel (HVOF) thermal-spray production equipment.
Cryogenic Thermal Spray

Cooling Improves
Coating Process
Cooling approach uses cryogenic nitrogen vapor
for better thermal management of the coating process
in heat-intensive processes.
By Liang He and Ranajit Ghosh, Air Products
T
hermal spray coating is an High velocity oxygen fuel (HVOF) All can occur due to damaging
industrial coating process that thermal spray is widely used for stresses that result from mismatched
consists of a heat source (flame coating critical wear parts like landing thermal expansion coefficients
or other) and a coating material (in gear, bearing races, valves and turbine between the coating and substrate.
powder or wire form). The coating is components. In HVOF, a significant Consequently, thermal
melted into tiny droplets and sprayed amount of thermo-kinetic energy is management of the workpiece is
onto a surface at high velocity. Upon required to deposit a dense coating extremely critical for the spray-
impact, a bond forms with the surface. onto the work surface. A portion of deposition process. Compressed-air
Repeated passes build up the thermal this energy, manifested as heat, is jets are the primary cooling method
spray coating and form a layered absorbed by the workpiece. Improper for most HVOF thermal spray
structure. temperature control during thermal operations; however, air cooling
Thermal spray coatings are used in deposition can lead to: often is insufficient. Oxygen and
industries such as aerospace and power moisture present in the cooling air are
generation. The trend toward more • Coating and workpiece detrimental to the coating quality.
heat-intensive processes, however, has overheating. In spray operations involving
exposed the inadequacy of current • Thermal deformation. tighter temperature control, even with
cooling solutions and highlighted the • Degradation of substrate material an air-cooling solution, manufacturers
need for better thermal management of properties. often are forced to introduce breaks
the coating process. • Spalling of coatings. in the process cycle so that the

FREEZING
Cryogenic Nitrogen Vapor Cooling vs. target surface whenever higher

Air Cooling During 11 Passes of Deposition cooling rates and correspondingly
higher gas flow rates are required.
Cryogenic nitrogen vapor
cooling has been shown to improve
productivity over conventional
air-cooled processes (figure 2). By
eliminating the inter-pass cooling
breaks, the cryogenic nitrogen vapor-
cooling system helps to shorten the
spraying time by as much as half and
to reduce wasted feed powder and
process gases. This cooling system also
allows for tighter temperature control
(±20°F [±11°C]) and a smaller standard
deviation in workpiece temperature
during coating operation.
Subsequent characterization of the
FIGURE 2. Data depicting cryogenic nitrogen vapor cooling versus conventional air
cooling during deposition (11 spray passes) of a WC-Co-Cr coating on aerospace
traditional air-cooled and cryogenic
landing gear demonstrates that cryogenic nitrogen vapor cooling can improve nitrogen vapor-cooled samples shows
productivity over air-cooled processes. that the bond strength, hardness and
surface roughness of the as-sprayed
accumulated heat can dissipate into Cryogenic Nitrogen Cooling coatings were essentially unchanged
the ambient environment. During for Thermal Spray while micro-porosity was reduced
these cooling breaks, the spray gun The search for an efficient cooling from 0.2 to 0.05 percent (figure 3). The
is moved away from the part but approach to generate better coating cryogenic nitrogen-cooled sample also
continues firing, resulting in wasted properties as well as to improve the retained the substrate hardness (420
feed powder, process gas and booth productivity of HVOF spray-coating HV in the case of heat-treated 4340
production time. operations has led to the development steel) better than the air-cooled (395
Another issue affecting of cryogenic gas cooling (figure 1). HV) and non-cooled (390 HV) samples.
productivity in spray-coating Cryogenic cooling methods offer a In addition, oxygen pickup and carbon
operations is the setup time for significant enhancement in the ability loss in the coating were the lowest for
masking and demasking. It is to remove heat quickly. They have the cryogenic nitrogen vapor-cooled
important to mask certain areas of been rarely used in the thermal- sample because of the rapid cooling
the part where the coating is not deposition coating industry, however, and low oxygen concentration in the
needed. The desirable characteristics due to the risk of nonuniform cooling, surrounding atmosphere. In the tests
of a masking tape are flexibility, ease which results in variable levels of with cryogenic cooling involving
of application and removal, quick residual stresses at the substrate/ WC-Co-Cr powder, deposition
cleanup and extended useful life. A coating interface. Such nonuniformly efficiency was shown to increase by
variety of masking tapes are available cooled areas are subject the same an average of 10 to 15 percent over
with materials of construction such issues of coating delamination and conventional air cooling and by more
as fiberglass, polymer and silicone spalling. than 30 percent over non-cooled
rubbers, and metals. Metal tapes Carbon dioxide (CO2) cooling has samples.
usually are difficult to make and been used by the industry with mixed An additional benefit of the
install. While the fiberglass and success. While CO2 has higher heat cryogenic nitrogen vapor-cooling
polymer tapes offer ease of installation, capacity compared to nitrogen, its system is the time and cost savings in
they are difficult to remove and heat-removal rate is constrained by the masking process. The cryogenic
require extensive post-spray cleaning. the smaller temperature differential. gas provides instant cooling of the
Inadequacy of air cooling and (Carbon dioxide has a boiling point hot top layer of the mask, avoiding
temperature buildup are the primary of -109.3°F [-78.5°C] while cryogenic heat buildup and preventing the heat
reasons for tape degradation (e.g., nitrogen boils at -320°F [-196°C]). from reaching the bottom layer of the
thermal decomposition, hardening or Carbon dioxide also has the tendency tape. As a result, the tape bulk stays
tape embrittlement). to form undesired CO2 snow at the flexible and can be removed quickly

with a putty knife following the spray changing how products are designed, capability. When running an IIoT-
operation, leaving a clean, residue-free fabricated, used, operated and enabled cooling system for thermal-
surface. The tape also can be reused serviced post-sale. spray operations, manufacturers can
several times. With the installation of various produce better quality products with
The cryogenic nitrogen vapor- sensors, the cryogenic nitrogen vapor- higher production efficiency and less
cooling system efficiently and cooling system also incorporates a production cost. IIoT technologies
uniformly cools thermally sprayed process-data collection and analysis help integrate production data with
coatings by monitoring the
temperature of the coating and varying
the cooling intensity to match the heat
generated in the spraying process. The
INNOVATE DESIGN APPLY
temperature feedback system can use
a variety of inputs, including single-
OUR BUSINESS
point infrared sensors, 2-D thermo-
imaging infrared cameras and contact
thermocouples. The PLC-controlled
IS COOLING YOURS ª
cooling system maximizes cooling
efficiency by automatically switching
cooling modes — between room
temperature, nitrogen gas, liquid/
gaseous nitrogen mixed flow, and
100 percent liquid nitrogen — based
on user-defined temperature ranges.
Discharged from a spraying nozzle or
multiple sprayers, the liquid nitrogen
is atomized to form rapidly boiling,
microscopic droplets that turn into
cryogenic nitrogen vapor within a
short distance from the discharge
point. This prevents undesired wetting
of the coated surface. In addition, the
multi-zone cooling control algorithm
used allows individual cooling
nozzles to switch independently
between the cooling modes based on
instant average and time-averaged
temperature feedback. The operator
also can choose to manually control the When commercial grade isn’t enough.
cooling process by setting the system
Designing cooling systems for our customers’ unique project needs to maximize
at the desired cooling mode.
uptime and reduce total cost of ownership has made us an industry leader.
Innovative products, reliable solutions and an unwavering commitment to excellence
Digitalization of Process has earned us the reputation as a trusted partner.
Control and Optimization
In the modern factory Chillers For Process Cooling
environment, the use of various • Capacities from 5 – 500 Tons • Optional Adiabatic Efficiency Boosting
sensors in the production equipment • Mission Critical Design System
• Exclusive Integrated Free-Cooling System • Start-up Operation to -40° F
and the products being made enables
• Optional Heat Recovery • Scroll and Screw Compressors
a real-time flow of information • Rapid Restart
regarding the operational status
and condition of the equipment or
product. Just as it is transforming COOLING SOLUTIONS
the operations and processes, the
Industrial Internet of Things (IIoT) is info@motivaircorp.com • www.motivaircorp.com

FREEZING
thermal-spray process knowledge.

With a cryogenic nitrogen cooling
system, such smart controls manage
the cooling process via inputs from
various temperature sensors. After
collecting enough historical data, the
system can be trained to design the
cooling process parameters and predict
any product defects should it see an
abnormal change of process conditions
(i.e., part surface temperature). By
detecting and analyzing the changes in
key process parameters, the condition
of the production equipment also
can be predicted and reported to the
operator. Part-temperature history is
always recorded and can be archived
locally or remotely. This capability
is helpful for audits and provides
necessary information for quality
control.
In addition to the process data,
information about utility and feedstock
also can be collected after installing
additional sensors. By analyzing
information from the sensors, the
system can provide operators with
insights that allow them to better
schedule thermal-spray jobs. For
example, measuring the consumption
rate of liquid nitrogen and monitoring
the liquid nitrogen tank level can help
the operator optimize production
scheduling.
In conclusion, cryogenic nitrogen
cooling is an effective solution for
heat-intensive spraying processes.
Using cryogenic nitrogen vapor as
a supplement to existing air cooling
and varying the cooling intensity
with heat input helps to ensure the
most economical use of the cryogenic
coolant. Cryogenic nitrogen vapor
cooling also can provide important
part-quality benefits. PC
Liang He is a senior principal application

engineer at Air Products. Rana Ghosh is
director of application technology research
and development at Air Products. The
Allentown, Pa.-based company can be
FIGURE 3. The effect of air-cooling (top), cryogenic nitrogen vapor cooling
(center) and no cooling (bottom) are shown on the microstructure of thermal reached at 800-654-4567 or visit
spray bonding area. www.airproducts.com.

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During the Spring, Summer and Fall Seasons, condenser coils, cooling towers, dry coolers and air handlers will inevitably
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United States and Foreign Patents Granted – Protected under one or more of the following U.S. and foreign patents: 5,370,722 • 5,529,593 • 6,197,077 B1 • 2170244 •
95904185.6-2113 • 7,323,028 B2 • 7,416,577 B2 • 7,842,116 B2 • 9561,456 • GB 2510786 B •9,827,521 B2 • 9,827,521B2 • 9,827,522 B2 • 10,040,149,B2 • GB2510786B •
Other Patents Pending.
FREEZING EQUIPM ENT
Dual-belt freezers have two conveyor

belts that operate side by side in one
machine housing.
Understanding Cryogenic
Freezing Tunnels
Cryogenic tunnel freezers are suited for processing large quantities
of products in a small footprint while increasing product yield.
By Johnny Nuttin, CES Inc.
T
he objective of all cryogenic incorporating the processor’s layout cryogen. The energy available in the
tunnel freezers is to quickly and required production capacities. cryogen will depend on a variety of
freeze or cool products in an In its basic form, a cryogenic tunnel factors; however, the most important
efficient manner using a cryogenic freezer consists of four primary variables are the cryogen’s storage
liquid. Suited for processing large parts: pressure and the exhaust vapor
quantities of products in a small temperature of the freezer.
footprint, cryogenic tunnel freezers • An insulated enclosure that For carbon dioxide (CO2), about
can increase product yield compared houses a conveyor belt to carry 85 percent of the refrigeration
to alternative technologies. the products. capacity will be obtained during
Cryogenic tunnel freezers also result • An injection system to inject the the sublimation of the solid CO2
in less product dehydration while cryogenic liquid. (latent heat) and 15 percent in the
retaining product textures. • Circulation fans to improve heat cold vapors (sensible heat). For a
Although these are significant transfer with the products. nitrogen system, about 50 percent of
advantages over mechanical freezing • An exhaust system to evacuate the refrigeration capacity is obtained
systems, the most important excess gases. during the vaporization of the liquid
concern for many food processors (latent heat) and 50 percent from the
remains product freezing cost. It To get the most efficient cryogenic cold vapors (sensible heat). Once it is
is critical, therefore, to design a freezing system, it is necessary to understood where the refrigeration
cryogenic tunnel freezer to operate use as much of the available energy capacity of the cryogen being used
as efficiently as possible while as possible from each pound of is found, it is possible to begin to

The most basic cryogenic tunnel freezer is a linear tunnel freezer, which consists of a single, linear conveyor.

FREEZING EQUIPM ENT
choose a type of freezing tunnel that

will best and most efficiently utilize
the cryogen.
A good distribution of CO2
throughout the tunnel freezer is
important to efficiently use the
refrigeration capacity available in
the CO2 .
For a nitrogen system, it will
be necessary to strategically place
the injection header to allow for
a spray of liquid and, at the same
time, obtain a good recirculation of
the nitrogen gases. The efficiency
of a nitrogen system primarily
is reflected in the exhaust gas
temperature. If the exhaust gas
temperature is too low, there will be
a reduction in the sensible heat of
the nitrogen gases available to freeze
the products. This results in higher
nitrogen consumption and a less-
efficient freezing process.
Comparing Freezing
Tunnel Designs
An efficient tunnel freezer
allows for enough length to provide
a proper heat exchange between
the products to be frozen and the
cryogen injected while maintaining
an exhaust temperature as close as
possible to the products’ required
equilibrated core temperature. The
most basic cryogenic tunnel freezer
is a linear tunnel freezer, which
For a nitrogen system, it is necessary to place the injection header strategically to consists of a single, linear conveyor.
allow for a spray of liquid and, at the same time, obtain good recirculation of the
A linear tunnel freezer can be
nitrogen gases.
configured either as a counterflow
or co-flow system.
Counterflow refers to the fact
that cryogen is injected at the exit
end of the tunnel freezer. The gases
are directed toward the entrance
end of the freezer, in the counter
direction of that of the product flow.
The exhaust gases are extracted
at the entrance side of the freezer.
A counterflow cryogenic freezer
provides the longest cryogen
exposure to the product and,
In some cases, a multi-pass freezer design is more practical such as when the therefore, creates the most efficient
required product dwell times or capacities are too high for a linear tunnel freezer. system.

controls for belt speeds, ventilation
and temperature. This is a unique
setup that provides flexibility for
demanding applications.
Plate-belt freezers house a belt
configured of solid stainless steel
plates, allowing processing of soft
and delicate products. By eliminating
the typical wire-mesh belt, product
belt markings also are eliminated.
This type of freezer is especially
useful for high-end products where
product markings are unacceptable.
High performance freezers are
designed with multiple freezing
zones to independently control
airflow and nitrogen injection
while maximizing throughput and
efficiency. These systems are built
to extract the maximum available
energy from each pound of cryogen
and reduce the freezing cost.
For products that are sensitive
to freeze burn, gas-only freezers
prevent product damage by avoiding
product shock from direct liquid
contact. This has been a good
solution for bakery applications, and
Multi-pass freezers are designed to reduce freezer floor-space requirements and gas-only freezing tunnels allow for
boost freezer throughput by housing multiple product conveyors in a single machine.
quick cooling while preventing any
product damage.
With the co-flow freezing tunnel the required product dwell times or A range of snow-removal
design, the cryogen is injected at capacities are too high for a linear systems can be integrated into
the beginning of the tunnel. The tunnel freezer. In comparison to tunnel freezers that process moist
gases travel with the direction of the counterflow designs, however, multi- products. Removing and preventing
product. Typically, the exhaust gases pass freezing tunnels are slightly snow buildup on fan blades and
are evacuated at the exit end of the less efficient due to the reduction in temperature sensors allows for a
freezer and will be much colder. airflow and freezer length. longer and more efficient freezer
For this reason, the system will be Flighted freezers are configured operation.
less efficient. This design is used with multiple staggered conveyors Based on the specific production
primarily with hot products where to promote individually quick requirements, tunnel freezers also
it is important to cool the surface frozen (IQF) freezing of bulk-type can be combined with immersion
of the products quickly to reduce products by continuously agitating freezers or spiral freezers to get the
dehydration. the products. By exposing all sides best layout and capacities needed.
A variety of special designs also of the bulk products to direct spray Given the range of freezing tunnel
are available to meet the needs of and ventilation, the flighted freezer designs, it is clear there are designs
virtually any application. Multi-pass design provides a consistent IQF for nearly any food freezing process.
freezers are another type of tunnel product. PC
freezer. They are designed to reduce Dual-belt freezers have two
floor space and boost throughput by conveyor belts that operate side by Johnny Nuttin is the CEO at CES Inc.
housing multiple product conveyors side in one machine housing. They The Cincinnati-based company can be
in a single machine. In some cases, allow processing of two different reached at 513-761-4200 or visit
this design is practical such as when types of products with independent www.cesgroup.com.

REFRIGERATION SYSTEMS
Transcritical CO2
systems utilize
hybrid heat-
rejection systems
called adiabatic
gas coolers.
Factors Driving Change

for Industrial Refrigeration Systems
New technologies and new designs are changing — and optimizing
— the future of industrial refrigeration and freezing systems.
By Steve Jackson, PermaCold Engineering Inc.
I
ndustrial refrigeration systems systems themselves. the last decade. The move to higher-
have long taken a standardized Innovative technologies and efficiency, leaner systems that rely
approach when it comes to their improved refrigeration systems on natural refrigerants like carbon
design and construction. Over time, that employ natural refrigerants dioxide (CO2) and ammonia (NH3),
industrial cooling trended toward are quickly gaining traction. As at times in low charge designs, will
no longer being engineered so much a result, professionals utilizing soon be the norm. In fact, as occurred
as replicated, using decades-old but industrial process cooling systems decades ago when ozone-depletion
proven designs. This was the case increasingly will see a shift in the concerns affected industrial process
even for new facilities. Ultimately, the approach to industrial refrigeration. cooling as well as commercial
results were that industrial cooling Both the types of systems that refrigeration equipment designs, a
systems were falling behind in terms industrial refrigeration professionals shift in the refrigerants used may
of available technology. are responsible for, and the facility soon be required. Federal regulations
Times are quickly changing, design and operations as a whole, will and market demands — lodged as
however, due to a host of factors. evolve. businesses respond to calls to be
Facilities everywhere are facing This shift includes the more environmentally aware and
higher average ambient temperatures. environmentally critical natural responsible — may change the type
At the same time, facilities need to refrigerant options. Natural of refrigeration systems specified by
reduce energy use and minimize the refrigerants have increasingly processors.
climate impact of the refrigeration proven their value and safety over In the future, the refrigeration

systems operated and maintained
in many facilities will have key
characteristics:
• They will be smaller.

• The will use less power and
resources.
• They will rely on technologies
developed specifically for natural
refrigerants.
The increasing demand for high

efficiency, low maintenance systems
also will inevitably force a change in
the typical approach to refrigeration
systems. Drivers include objectives
such as:
• Lower energy bills.

• Reduced costs for resources such
as water, sewage and chemicals.
• Improved but economical system
construction materials.
Many of these changes will even

carry through to the facility design
itself. In addition, the horsepower
requirements and ongoing energy use
of any refrigeration system will be
impacted by environmental factors.
These include:
• Facility insulation.
• Door and loading area seals.
• Controls.
All of these factors contribute

directly to a refrigeration system’s
Transcritical CO2 systems such as the one featured in the project shown are
initial design and long-term
continuing to grow in capability and size. They offer a solution for cold-storage
performance. freezers. Transcritical CO2 systems utilize racks of small compressors; however, as
Another factor that facility the compressor technology allows them to become larger, the racks will in turn get
managers will need to account for smaller.
is lighting. The move to LEDs vs.
older halogen and other less-efficient that it merits a quick look of its own. especially in cold ambient conditions
lighting for refrigerated facilities is — most facilities leave the bulbs on
a surprisingly important element in LED Lighting and continuously. This continuous use
future system design and operation. Refrigeration imparts a significant amount of heat
LEDs are far more energy efficient. Older facility lighting — halogens into the facility. As such, facilities
Also, they emit only a fraction of the and metal halides — typically puts with process cooling systems seeking
heat of older systems. This, in turn, out a tremendous amount of heat to reduce energy use and optimize
reduces the load requirements for the energy. Also, because halogen and operations may want to include
cooling system on an ongoing basis. metal halide lighting is slow to lighting as a key component of any
In fact, it is such an important factor warm up to full illumination — comprehensive engineering solution.

Optimization trends of current technologies for low charge ammonia (stick built) refrigeration systems are driving such systems
toward reduced ammonia charges for every application. The key is the application of correctly engineered and sized equipment.
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The Dynamic Temperature Control Systems of the Unistat
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5
Inspired by temperature
Modern, industrial-grade LED
lighting systems can help the
performance and efficiency of the
refrigeration systems. They emit just
10 percent of the heat of traditional
warehouse or production facility
bulbs for the same amount of light.
In addition, they consume 90 percent
less electricity.
Also, because LEDs instantly reach
full illumination, they can be turned
on only when the facility or specific
areas are actually in use. LEDs can be
activated by motion-sensors, timers
or manually. As an added benefit
for process cooling facilities, LEDs
last many thousands of hours longer
than halogens or fluorescents, so
bulb replacement costs due to bulbs
burning out are reduced. Likewise,
LEDs will not shatter, and they lose
little to no illumination power over
time, which can improve maintenance
time (and safety) as well.
Natural Refrigeration
Systems
The new higher efficiency, natural-
coolant systems themselves offer
a range of solutions depending on
facility needs and requirements.
Here is a quick look at several of the
systems you can expect to be working
with in the future and some specifics
on each type.
Ammonia/CO 2 Cascade
Cascade systems utilizing
ammonia and carbon dioxide are an
effective cooling solution for large
industrial processes such as food
processing facilities and cold-product
manufacturing. Cascade systems are
especially suited when temperatures
reach below -40°F (-40°C). This
type of system takes advantage of
ammonia for the high side and keeps
the CO2 subcritical. This allows Cascade systems utilizing both ammonia and carbon dioxide offer an excellent cooling
systems designers to maximize the solution for large industrial processes such as food processing facilities and cold-
benefits of the carbon dioxide’s higher product manufacturing. Ammonia/CO2 cascade systems are especially suited for
applications where temperatures reach below -40°F (-40°C). This type of system takes
pressures and density to design
advantage of ammonia for the high side and keeps the CO2 subcritical. This maximizes
in smaller equipment and higher the benefits of the carbon dioxide’s higher pressures and density to allow smaller
efficiencies. equipment and higher efficiencies.

These systems primarily utilize large reciprocating no chemical treatment of the water. Along with such
compressors — although screws are used as well — for systems, it is reasonable to expect to see improvements on
the CO2. These compressors, however, are only capable of the controls side.
subcritical CO2 compression. As a result, the compressors
may look a bit odd to someone familiar with ammonia Low Charge Ammonia (Stick Built)
systems. The compressors themselves are relatively small, Optimization trends of current technologies for low
and the motors are relatively large — the exact opposite of charge ammonia refrigeration systems are moving toward
an ammonia system. reduced ammonia charges for every application. The
Users also can expect to see vessels much like an key is the application of correctly engineered and sized
ammonia recirculator package or chiller package. equipment.
The difference will be that today’s chillers are used to Overall, stick-built low charge ammonia refrigeration
condense the CO2. By contrast, the recirculator package systems will operate like a typical ammonia system in use
will have CO2 in it, with smaller sizes relative to the load today with key exceptions: All components will be smaller
when compared to an ammonia vessel. and a large high pressure receiver typically will not be
used. More precise engineering will mean the ammonia
Transcritical CO 2 charge is no more than necessary to operate the system.
Transcritical CO2 systems are continuing to grow in Expect these systems to continually be optimized,
capability and size. They offer a particularly great solution utilizing less refrigerant while becoming more efficient
for cold-storage freezers. and getting smaller at the same time.
Transcritical CO2 systems utilize racks of small
compressors; however, as compressor technology allows Low Charge Ammonia (Packaged)
them to become larger, the racks will in turn get smaller. Packaged low charge ammonia refrigeration systems
Additionally, these systems commonly use hybrid heat- offer the benefit of faster installation and are excellent for
rejection systems called adiabatic gas coolers that utilize cold storage in high ambient temperatures and coolers.
less water, send less water to the sewer and often require They also eliminate the need for an engine room; instead,
they use localized systems.
As the name indicates, the charge for these systems
typically is lower, and the systems are even smaller than
stick-built ammonia systems. Some employ special feed
and control techniques to keep the charge to an absolute
minimum. In practice, these systems will often appear as a
sort of miniaturized engine room located on a facility roof
or on a concrete pad outside.
In conclusion, these trends in system design are the

wave of the future — but only in the sense that they are
not yet widely in place. Part of this is due to the fact that
system designers and engineers are still pushing back
against change and not actively working to employ these
new approaches and technologies.
Many industry insiders, however, believe this
industry-wide shift will take place and is in fact already
building momentum. Such professionals assert the higher
efficiency systems described will become the industry
norm sooner than most expect. For those involved with
specifying process cooling systems, or their operation and
maintenance, now may be the best time to get ahead of the
curve in learning about these new approaches as well as
all the benefits that they provide. PC
Steve Jackson is co-founder and president of PermaCold

Engineering Inc. The Portland-based company can be reached at
800-455-8585 or visit www.permacold.com.

Speaker: John Sherrill
Training / Compliance
Engineer
Wagner-Meinert LLC, Tex
Hildebrand Training Center
FREE WEBINAR
Wednesday, May 29th, 2019 at 2pm ET
Industrial Refrigeration Operating Tips
Why Doesn’t my Saturated Pressure Temperature Chart Work on my System?
Scenario 1: I set the compressor to maintain the pressure my chart indicates I need to achieve the temperature I
want in my evaporator, but the evaporator is operating at a warmer temperature! I must set the compressor set
point to a lower pressure to get the temperature I need. Why doesn’t “temperature follow pressure” like I have
been taught?
Scenario 2: I understand why I must set my compressor to a lower pressure than the P-T chart shows, but my
temperature is gradually rising even though I maintain the pressure setting that use to work?
Two different scenarios, two different causes for the same problem. The pressure and temperature relationship
for a specific refrigerant is the basis of our operation of our refrigeration system. In this webinar we will spend
time looking at the factors that affect the application of this basic principle and explain how Pressure drop and
static head pressure will affect the operation of your system. Then we will take a look at possible sources of
water in your system and the effect that water will have on system operation and operating costs.
Also, we will take an up-to-the-minute look at the EPA Risk Management Program in this ongoing battle the EPA
is waging to reduce the major impact of the revised RMP regulation. Some were scheduled in the revision to be
delayed until March 15 of 2021. Some elements of the revision have now been in effect since early December of
2018. Learn where it stands today.
Register for free at www.Process-Cooling.com/events

FILTRATION This modular water-processing train has
a pressure-vessel design with walnut-
shell media filter.
Filtering Oily or Dirty

Process Cooling Waters
Walnut-shell filtration systems take advantage of walnut’s natural
affinity to oil to help remove contaminants from process cooling waters.
By Andrew Knapp, Filtra-Systems Co. LLC
I
n the 1960s, the steel production required replacement prematurely. shell filters. The increasing volumes
industry sought a way to filter the (After all, mixing sand and oil while of water that the industry was using
cooling water used to cool steel adding heat is basically the recipe — exacerbated by the rise of water-
production. During production, both for producing asphalt.) Because these intensive, enhanced oil-recovery
free solid material from the line, and filters typically operated at elevated processes — meant that producers
residual oils from previous formation temperatures, the use of sand became could save money by removing oil
steps, would be on the materials problematic. from produced or flow-back water.
being cooled. This oil and particulate As an alternative, the steel industry Most oil producers either reused or
would migrate to the cooling water looked at walnut-shell filters for disposed of the filtered water.
during quenching and other cooling filtering the cooling water. Crushed The walnut-shell filter was a good
operations. To reuse the water, this walnut shells were selected as a media fit for these processes and became
material had to be removed via replacement for sand filters because a widely used polishing filter. Over
filtration. walnut shells have an affinity for oil. time, and with the development
Originally, sand filters were used Yet, when vigorously backwashed, of more cost-effective and efficient
on cooling-water lines. When the the crushed shells also released the filter designs, the walnut-shell filter
sand was exposed to oil, however, it trapped oil. began to be used in many diverse
stuck together. This reduced filtration Early in the 1970s, the oil industry industries, from aluminum mills to the
effectiveness, and the fouled sand discovered the benefits of walnut- remediation of contaminated soil.

Modern Uses for Many modern walnut-shell filters Other filtration design advances
Walnut-Shell Filters use a mixer to agitate the shells. The include the ability to build nutshell
Walnut-shell filter manufacturers mixer eliminates the issues found with filters using atmospheric tanks. Most
have tested and revised their designs earlier designs. Design validation via of the early uses of walnut-shell
many times, minimizing waste the continuous-stirred tank reactor filters required pressure vessels with
volumes while keeping the filter’s helps ensure full contaminant removal rigorous design criteria, but this is not
efficiency as high as possible. Most of and cleaning of media bed and vessel. the case for every industry. While oil
these changes have come in the form of
upgrades to the filter backwash.
When a walnut-shell filter is full
of contaminants, it will backwash to
remove the captured contaminants
before returning to its normal
filtration mode. Keeping the liquid
waste to a minimum while removing
all contaminants is the goal of the
backwash method and regeneration
optimization.
Early walnut-shell filtration designs
used a pump to remove the shells from
the vessel. Issues with this approach
were a much larger footprint and
a shorter operating lifespan for the
shells. Other early designs used air
sparging, which required large air
compressors and resulted in less media
fluidization.
A walnut-shell filter in an atmospheric

vessel is used for this cooling-water
filtration application.

FILTRATION
walnut-shell media and its ability

to recover after experiencing upset
conditions.
After the membrane-protection
walnut-shell filter was installed,
oil levels in the process water
system were substantially reduced.
The walnut-shell filter provided
a 95 percent reduction of oil in
the cooling water, which allowed
the nanofiltration membranes
to be reinstalled. Following the
adjustments, the process is able to
work as originally planned. Process
water can be recycled at temperature,
reducing city water demands and
A process-flow diagram shows how the walnut-shell filter was added to the existing water-heating costs.
cooling-water filtration system at the cellulose producer to remove suspended Cellulose Production Facility. The
solids and extend the life of the ultrafiltration membranes. AV Cell facility in New Brunswick
is a cellulose production facility.
and gas installations typically require boilers is used to quench the During cellulose production,
ASME-stamped pressure vessels, many rubber products (mainly tires for contaminated condensate acid (CCA)
process cooling jobs do not. automobiles). For this process, the is sent to the facility’s evaporators
Atmospheric tank designs water must be kept around 140°F for waste disposal. Yet, the cellulose
help minimize the capital-cost (60°C) and be reasonably free of manufacturer knew that if solid
concerns that pressure vessels debris. contaminants were removed from
pose. Atmospheric tank designs To keep the filtration water the acid stream, it could be reused in
use a vacuum pump to pull water clean, the tire manufacturer initially the process. To do this, ultrafiltration
through the media instead of a high installed nanofiltration membranes. membranes were installed. However,
pressure pump pushing water into The system was intended to remove the free-solids levels in the CCA were
the filter. The vacuum filters can any oil and solids buildup that was too high for ultrafiltration to be an
reduce the capital cost of a walnut- introduced as the cooling water was efficient solution on its own.
shell filter by as much as 25 percent exposed to the rubber-curing process. A walnut-shell filter was evaluated
when compared to a pressure vessel. Unfortunately, the nanofiltration was to clean the CCA stream prior to
Atmospheric tank designs frequently not suited to handle the particulate the ultrafiltration membranes. The
are used in ambient temperature present. The membranes would foul walnut-shell filter is able to remove
applications. Most membrane- and require replacement when they solids sized 2 microns and larger.
protection walnut-shell filters in came in contact with oil. For this As a result, the facility reduced total
service today use this design. reason, the nanofiltration membranes suspended solids (TSS) going to the
were taken offline. ultrafiltration system from 25 ppm
Case Histories Illustrate Next, the tire manufacturer to less than 1 ppm. As an added
Walnut-Shell Filtration revamped the cooling process to use benefit, the addition of the walnut-
Efficiency city water. The city water needed to shell filtration system reduced the
Two brief case histories can help be brought to operating temperature, amount of time the cellulose producer
illustration how walnut-shell filters which resulted in high water bills and spent replacing membranes and
— and more specifically, membrane- heating costs. greatly reducing the number of new
protection walnut-shell filters To resolve these concerns, the membranes purchased. PC
— can be used in process cooling tire manufacturer consulted with a
operations. manufacturer of walnut-shell filtration Andrew Knapp is a senior applications
Tire Manufacturer. A tire products to protect its nanofiltration engineer with Filtra-Systems Co. LLC.
manufacturer in Ohio has a closed- membranes. The walnut-shell filter The Farmington Hills, Mich.-based
loop steam boiler water circuit. was selected due to its ability to easily company can be reached at 248-427-
Process water from the steam remove oil from water, its permanent 9090 or visit www.filtrasystems.com.

COOLING TOWERS
Cooling towers absorb heat

from process cooling systems
and eject it into the atmosphere.
Proper maintenance is essential
for reducing bacteria and
increasing efficiency.
Crossflow Microsand Filtration for

Cooling Tower
Water Treatment
Technologies that reduce chemical use in process cooling water
towers provide many benefits.
By Obaidullah Mohiuddin, Ph.D., Eneref Institute
I
t is critical that process cooling any industrial process consider its During cooling tower operation —
systems relying on cooling towers impact on the local water supply. To in order to reduce the concentration
have robust but cost-effective protect the ecosystem, technologies of contaminants in the cooling towers
filtration equipment for water reuse. that can reduce the chemicals used in for process cooling — a substantial
Cooling tower water frequently process cooling water towers should amount of water must be discharged
contains hazardous materials be implemented wherever practicable. periodically. This discharged water,
that should be managed to avoid One technology that can help mitigate or blowdown, contains anti-scaling,
reintroducing them into the process the use of water treatment chemicals anti-corrosion and anti-microbiological
cooling equipment or system. is effective filtration via crossflow chemicals (used, not coincidentally, to
At the same time, it is crucial that microsand units. control scaling, corrosion and fouling).

COOLING TOWERS
The blowdown water typically is

discharged into local sewage or storm-
water systems. Due to the variation
of chemicals used in cooling towers,
it is not possible to quantify the exact
amount of pollutants discharged
globally.
How Filtration Affects

Water Treatment
Cooling towers absorb heat from
water cooling systems and eject it into
the atmosphere. Proper maintenance
of cooling towers is essential for
reducing bacteria and increasing
efficiency. Bacteria such as Legionella
as well as protozoans and algae can
colonize in cooling tower systems.
Crossflow microsand filtration
technologies have become
commercially available to treat the
water in cooling towers used for
It is crucial that any industrial process consider its impact on local water supply. process cooling. These systems
Technologies that can reduce the chemicals used in process cooling water towers can maximize efficiency and minimize
help protect the ecosystem. the spread of microorganisms while
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also reducing the need for chemical
treatments. Crossflow microsand
filtration (CMF) captures microscopic
and even submicron particles.
systems can improve the efficiency of
chemicals while allowing the use of
fewer chemicals to achieve the same
results.
As a global research organization
— focused on advocacy for water,
energy and other critical issues at
the intersection of the environment
and development — Eneref Institute
examined the benefits of crossflow
microsand filtration technology for
process cooling waters.
Traditional deep-bed multimedia
— or sand — filters in water cooling Crossflow microsand filtration technologies have become commercially available
towers typically capture particles of to treat the water in cooling towers used for process cooling. These systems can
20 microns and above. While such help minimize the spread of microorganisms while also reducing the need for
chemical treatments.
systems can remove up to 90 percent
of contaminant particles by weight,
they leave unchecked all fine particles
— the particulates most responsible
for the fouling that supports Legionella
and system inefficiency.
Cooling tower water-analysis
reports typically show that 95 percent
of particulates are less than 5 microns
in size. When measured by mass,
however, 80 percent of the bulk is
comprised of particles greater than 15
microns. Traditional filtration systems
reduce the quantity of larger particles
but not the smaller particles that cause
fouling — demonstrating why parts
per million (ppm) is an incomplete
measure of total suspended solid (TSS)
in water.
systems differ from traditional-flow
media filters in a number of ways. Cooling towers consume a great deal of water, and competition with agriculture,
Rather than a simple vertical flow, industry and municipalities will only exacerbate water scarcity concerns. An
understanding of water filtration systems may help reduce the amount chemicals
water is crossflowed, tangentially,
discharged into the environment.
across the top layer of the media bed
by an injector. The flow scours the filtration technology allows for risk of fouling, scaling and corrosion.
media’s top surface layer, preventing optimal use of the media surface Filtration systems cannot remove
surface blinding by lifting larger area and removes particles down to dissolved solids or increase the cycle
particles into suspension. The media submicron levels — smaller than one of concentration (the ratio of dissolved
bed then becomes a clean, free space micron. Thus, the technology helps solids in the cooling tower to dissolved
in which fine particulates are trapped. protect the cooling tower that is used solids in the makeup water). Because
In this way, crossflow microsand for the process cooling by reducing the dissolved solids are removed by

COOLING TOWERS
Filtration technologies can help reduce the chemicals used in process cooling water towers. The Eneref Institute conducted
research to identify methods that can help mitigate fouling, scaling and microbiological growth while also reducing chemical use.
purging water and topping up the More significantly, lessening chemical equipment efficiency designed by
tower with fresh makeup water, use offers environmental benefits by manufacturers.
frequent blowdown is the only viable decreasing the number of chemicals Reduced Conductivity. In process
solution to reduce the concentration released into the ecosystem. cooling, anything that affects thermal
of total dissolved solids (TDS). Fouling and Scaling. When conductivity is critical. While both
However, frequent blowdown sends suspended solid particles accumulate fouling and scaling reduce thermal
water treatment chemicals into the and settle on heat transfer surfaces, conductivity (or heat transfer), fouling
environment, perpetuating the cycle. or heat exchangers, fouling occurs. has the greater impact on conductivity.
Fouling decreases the efficiency Every thousandth-of-an-inch increase
Filtration Effect on of heat exchangers, increases in fouling necessitates a 10 percent
Chemical Treatments maintenance and forces shutdowns of increase in power from the system:
Unlike total dissolved solids, the process cooling system. The deposits insulate the heat transfer
total suspended solids (TSS) can be Biofilm is another source of surfaces, impeding heat exchange.
reduced by filtration. Reducing total fouling. It creates a layer that protects While the thermal conductivity
suspended solids makes chlorine and microorganisms from disinfectant of copper pipes can be as high as 398
other disinfectants more effective. chemicals, which makes cleaning W/m2K, the thermal conductivity
This allows chemical treatments to difficult. Biofilm also prevents anti- of calcium carbonate — the most
be reduced by as much as 35 percent. corrosion chemicals from reaching common cause of scaling — is just
Therefore, the rate of corrosion the heat exchanger’s surface. 2.26 W/m2K. In other words, calcium
from oxidizing chemicals as well Moreover, biofilm formation prevents carbonate’s thermal conductivity is
as the chemical odor are reduced. microorganisms from being flushed 1 percent of that of copper. Calcium
Furthermore, it may no longer be away easily during cooling tower sulfate and calcium phosphate — also
necessary to use coagulants to fuse blowdown. By filtering particulates common scaling sources — have
and jettison small particulates. less than 5 microns in size, crossflow low conductivity similar to calcium
In addition, reducing chemical microsand filtration helps reduce carbonate. Yet biofilm — a root
use reduces material and labor costs. fouling, thereby maintaining the cause of fouling — has a thermal

The rate of fouling is much faster when smaller particles are present in the water than it is when larger particles are present,
explaining why fine filtration is essential.
conductivity significantly lower than concentration of 8-micron-sized of crossflow microsand filtration

the salts that cause scaling, just 0.63 particles were to double, the fouling users reported reduced maintenance
W/m2K. This is why Eneref Institute heat transfer resistance in the system of their heat exchangers. Users
advocates for crossflow microsand would increase by only 5 percent. also reported that their process
filtration as a means to maintain heat By contrast, if the concentration of cooling systems operated for longer
transfer efficiency. 1-micron-sized particles were to durations, uninterrupted, with
Fouling Particles. The rate of double, the fouling heat transfer minimal upkeep costs and at higher
fouling is much faster when smaller resistance could increase by as much levels of performance.
particles are present in the water than as 150 percent. In conclusion, saving water is
it is when larger particles are present. Microbial Growth. While no a critical benefit of such filtration
This is why fine filtration is important. filtration system eliminates Legionella, systems. According to the U.S.
Because the surface of metal is jagged reducing fine particles can break Government Accountability Office, 40
at microscopic sizes, fouling buildup up the shelters where microbes hide states expect water shortages (under
primarily is dependent upon particle from disinfecting chemicals. In this average weather conditions) in some
size. way, crossflow microsand filtration portion of their land within the next
As water flows across the metallic technology helps maximizes the 10 years. Cooling towers consume a
surface of the heat exchanger, larger effectiveness of chemicals used great deal of water, and competition
particles will not initially attach. to treat process cooling towers. with agriculture, industry and
Instead, they roll and bounce off. They diminish the opportunity for municipalities will only exacerbate
However, the fine particles — microbes — including protozoa, water scarcity in the future. PC
those that crossflow microsand algae, fungi and Legionella — to
filtration systems are designed to cultivate and multiply. Reducing fine Obaidullah Mohiuddin, Ph.D., is an
capture — are the first to cling to particles also removes the nutrient environmental scientist with Eneref
surfaces, according to research by source for bacterial growth. Institute. The Doylestown, Pa.-based
Müller-Steinhagen published in Performance. Beyond savings research and advocacy organization for
The Canadian Journal of Chemical in energy and water use, Eneref sustainable development can be reached at
Engineering. By that measure, if the Institute found a significant number 917-779-8600 or visit eneref.org.

COOLING CAPABILITIES: SYSTEM CHILLERS
O
ur Cooling Capabilities on System Chillers offers a view an overview of each manufacturer’s capabilities, see
side-by-side comparison of system chiller makers all manufacturers that offer certain features, or search by
to help you narrow your choices. Read on to learn keyword. Also online, some manufacturers have upgraded
about those chillers that must be hard-wired, moved with listings that include a link to the company website as well as
equipment (rather than human power) and have more than datasheets and other product information.
5 tons of cooling capacity. Use our RFP Builder to collect information from multiple
To view the matrix of system chillers online, visit www. suppliers. To do so, go to any Equipment Overview page
process-cooling.com/coolingcapabilities and click on and click the plus sign next to those suppliers you wish to
Cooling Capabilities: Chiller Systems. Online, you can add to your list, or the Add an Info Request button on any
Configuration Condenser/Evaporator
You also can conduct your
d
r-Coole
Cooled
supplier search online!
ooled
led
it
e
sing Un
nd-Fram
Air-Coo
l System
www.process-cooling.com/coolingcapabilities
e
r, Wate
r, Air-C
Water-
nd-Tub
-Tube
-Tube
Plate
stem
ent
Conden
Outdoo
Outdoo
Perman
Split Sy
Fin-and
Tube-in
Indoor,
Indoor,
Plate-a
Brazed
Shell-a
Centra
Other
Other
Plate
Coil
Company Name
AEC
• • • • • • • • • • •
262-641-8600, www.aecinternet.com
Dimplex Thermal Systems
• • • • • • • • • • • • • • •
269-349-6800, www.dimplexthermal.com
Frick Industrial Refrigeration
• • • •
717-762-2121, www.johnsoncontrols.com/frick
Huber USA Inc.
• • • • •
800-726-4877, www.huber-usa.com
Motivair Corp.
716-691-9222, www.motivaircorp.com • • • • • • • • • • •
Redi Controls Inc.

• •
317-494-6600, www.redicontrols.com
Sterling Products Inc.
• • • • • • • • • • •
262-641-8600, www.sterlco.com
Thermal Care Inc.
• • • • • • • • • • • • • • •
847-966-2260, www.thermalcare.com
Alfa Laval Inc., 866-253-2528, www.alfalaval.us • • • • • • • •
American Chillers and Cooling Tower Systems Inc., 803-822-3860, www.amchiller.com • • • • • • • • • • •
Berg Chilling Systems Inc., 416-755-2221, www.berg-group.com • • • • • • • • • • • • • • •
BluChill Inc., 302-658-2638, www.bluchill.com • • • • • • • • • • • •
BV Thermal Systems, Budzar Ind., 209-522-3701, www.bvthermal.com • • • • • • • • • • • • •
Chester-Jensen Co., 610-876-6276, www.chester-jensen.com • • •
Chillking Chillers Inc., 512-303-1529, www.chillking.com • • • • • • • • • • • • • • • • •

Cold Shot Chillers, 281-227-8400, www.waterchillers.com • • • • • • • • •
Conair Group, 724-584-5500, www.conairgroup.com • • • • • • • • • • • • •
Cooling Technology Inc., 704-596-4109, www.coolingtechnology.com • • • • • • • • • • • • • • • •
Companies with in front of their names have an advertisement in this issue.
Disclaimer: Manufacturers listed in this Cooling Capabilities chart responded to a special mailing by Process Cooling and do not necessarily represent the entire
market. To be included in future listings, contact Linda Becker at BeckerL@bnpmedia.com.

manufacturer’s listing. Continue adding companies until you’re ready
to submit your list. Once you’ve selected those you are interested in,
click on the Submit an Info Request button to create a prepopulated
form. Fill in your contact information and send it. All responses from
suppliers will be sent directly to you or the contact(s) designated by
you.
If you need more information and want to contact a system chiller
manufacturer directly, visit www.process-cooling.com/buyersguide
and search for the company’s name.
Compressor/Cooling Method Heat Exchanger Material Process Fluid Industries Served
als
nd
g
r Chillin
ochemic
cture a
s
rts for
ment/
tems?
grance
ery
n Proof?
g
ls
its
g
ed Wate
manufa
leaners
ge/Brew
rket pa
iller sys
rocessin
replace
electric
ceutica
t Coolin
als/Petr
ermetic
Chilling
tics/Fra
le Circu
ss Stee
Plants
ooling
Screw
Steel
ickel
oods
ugal
tate
nics
um
tic
Explosio
Soaps/C
Cupro-N
afterma
Pharma
your ch
Thermo
Deioniz
Do you
Plastics
market
Chemic
Copper
Carbon
Alumin
Dairy F
Semi-H
Electro
Bevera
Food P
Stainle
Fluid C
Solven
Cosme
Solid S
Centrif
Power
Rotary
Multip
Herme
Water
Nickel
Screw
Other
Other
Other
Scroll
• • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • * Yes
• • • • • • • • • • • • * *
• • • • • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • Yes Yes
• • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
*Contact Manufacturer

COOLING CAPABILITIES: SYSTEM CHILLERS
Configuration Condenser/Evaporator
d
r-Coole
Cooled
ooled
led
it
e
sing Un
nd-Fram
Air-Coo
l System
e
r, Wate
r, Air-C
Water-
nd-Tub
-Tube
-Tube
Plate
stem
ent
Conden
Outdoo
Outdoo
Perman
Split Sy
Fin-and
Tube-in
Indoor,
Indoor,
Plate-a
Brazed
Shell-a
Centra
Other
Other
Plate
Coil
Company Name
Delta T Systems, 262-628-0331, www.deltatsys.com • • • • • • • • • • • •

Dry Coolers Inc., 248-969-3400, www.drycoolers.com • • • • • • • • • • • • • •
Fluid Industrial Manufacturing Inc., 408-782-9900, www.fluidindmfg.com • • • • • • • • •
Frigel North America, 847-540-0160, www.frigel.com • • • • •
G&D Chillers Inc., 800-555-0973, www.gdchillers.com • • • • • • • • •
GEA Systems North America, 717-767-6411, www.gea.com • •
General Air Products Inc., 888-863-7389, www.generalairproducts.com • • • • • • • • • • • • •
HydroThrift, 330-837-5141, www.hydrothrift.com • • • • • • • • • • • •
Ice Qube Inc., 724-837-7600, www.iceqube.com • • • • • •
J&M Fluidics Inc., 888-539-1731, www.jmchillers.com • • • • • • • • • • • •
Julabo USA Inc., 800-458-5226, www.julabo.us • • • • •
KoolJet, 519-688-6803, www.kooljet.com • • • • • • •
KR Products Inc., 314-353-1712, www.krproductsinc.com • • • • • •
Mokon, 716-876-9951, www.mokon.com • • • • • • • • • • •
Multistack LLC, 608-366-2400, www.multistack.com • • • • • • • •
Mydax Inc., 530-888-6662, www.mydax.com • • • • • • • •
OptiTemp Inc., 231-946-2931, www.optitemp.com • • • • • •
Paul Mueller Co., 417-575-9000, www.paulmueller.com • • • • • • • • • •
Pfannenberg Inc., 716-685-6866, www.pfannenbergusa.com • • • • • • • • • • • •
PolyScience, 847-647-0611, www.polyscience.com • • • •
Pro Refrigeration Inc., 253-735-9466, www.prochiller.com • • • • • • • • • •
Rite-Temp Mfg., 800-462-3120, www.ritetemp.com • • • • • •
Rittal Corp., 800-477-4000, www.rittal.us • • • • • •
Spaltech International Inc., 289-891-6690, www.spaltech.com • • • •
Spirec N.A. Inc., 800-910-7330, www.spirec.com • • •
Swep North America Inc., 877-602-2989, www.swep.net •
Tek-Temp Instruments Inc., 215-788-5528, www.tek-tempinstruments.com • • • • • •
Temp-Air Inc., 952-707-5050, www.temp-air.com • • •
Temperature Corp., 877-513-8310, https://temperaturecorporation.com/applications • • • • • • • • • • •
Tempest, 216-883-6500, www.tempest-eng.com • • • • • • • • • • • • • • •
ThermoElectric Cooling America Corp., 773-342-4900, www.thermoelectric.com • •
Thermonics, an inTEST Co., 781-688-2300, www.thermonics-chillers.com • • • • • • • •
Vogt Ice LLC, 502-635-3000, www.vogtice.com • • • • • • • • •
Wechsler Technologies, 404-263-0924, www.wechslertech.com • • • •
Companies with in front of their names have an advertisement in this issue.
Disclaimer: Manufacturers listed in this Cooling Capabilities chart responded to a special mailing by Process Cooling and do not necessarily represent the entire
market. To be included in future listings, contact Linda Becker at BeckerL@bnpmedia.com.

Compressor/Cooling Method Heat Exchanger Material Process Fluid Industries Served
als
nd
g
r Chillin
ochemic
cture a
s
rts for
ment/
tems?
grance
ery
n Proof?
g
ls
its
g
ed Wate
manufa
leaners
ge/Brew
rket pa
iller sys
rocessin
replace
electric
ceutica
t Coolin
als/Petr
ermetic
Chilling
tics/Fra
le Circu
ss Stee
Plants
ooling
Screw
Steel
ickel
oods
ugal
tate
nics
um
tic
Explosio
Soaps/C
Cupro-N
afterma
Pharma
your ch
Thermo
Deioniz
Do you
Plastics
market
Chemic
Copper
Carbon
Alumin
Dairy F
Semi-H
Electro
Bevera
Food P
Stainle
Fluid C
Solven
Cosme
Solid S
Centrif
Power
Rotary
Multip
Herme
Water
Nickel
Screw
Other
Other
Other
Scroll
• • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • • • • * Yes
• • • * *
• • • • • • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • • • • • • • • • • • • • • Yes Yes
• • • • • • • • • • • • • • • • • • • • • Yes *
• • • • • • • • • • • • • • • • Yes *
• • • • • • • • • • • • • * *
• • • • • • • • • • • • • • • • • * Yes
• • • • • • • • * Yes
• • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • * *
• • • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • * *
• • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • * *
• • • • • • • • • • • • * *
• • • • • • • • • • • • • • • * *
• • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • * *
• • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • • • • • • • • • • Yes *
• • • • • • • • • • • • * *
• • • • • • • • • • • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • * Yes
• • • • • • • • • • • • • • • * *
*Contact Manufacturer

HEAT EXCHANGERS Scraped-surface heat exchangers can be
used in evaporation systems like the one
pictured here.
Evaporating Digestate with

Heat Exchangers
Careful selection of the heat exchanger technology for the
process aids in efficient evaporation operations.
By Matt Hale, HRS Heat Exchangers
W
hen treating wastewater, • To produce materials such as some other methods of concentration
sludge and digestate, it liquid and solid fractions of such as reverse osmosis and ultra-
often can be beneficial digestate, which have distinct filtration.
to reduce the volume of material properties. The materials then can Evaporation can be used as the
or increase the solids content as be stored and used in the most initial step in producing a dried
well. Mechanical dewatering via a appropriate way. product if the liquid concentrate
centrifuge or belt press — to separate then undergoes a drying process
solids and liquids — is standard for Traditionally, there have been such as spray drying. Conventional
the water treatment and anaerobic two ways to achieve this: drying evaporation techniques require
digestion sectors. But, what if you and evaporation. Drying usually temperatures in excess of 212°F
want to further reduce the water requires large quantities of heat and (100°C), which is usually provided
content of the remaining liquid energy, is costly and inefficient and by boiling water or steam. Due to the
fraction? is unsuitable for materials with high low temperatures used in wastewater
The two main reasons to remove or water content. treatment and aerobic digestion,
reduce water from effluent and waste Evaporation differs from however, such energy is not usually
are: drying (and dehydration) because available without additional fuel
it produces a concentrated liquid inputs, making evaporation a high
• To reduce the volume of material rather than a solid. Evaporation also energy option.
in order to cut storage, handling produces a higher concentration of It should be remembered that,
and disposal costs. solids in the resulting liquid than scientifically, evaporation and

boiling are two different processes.
Evaporation rates depend on a
number of factors and not just the
temperature of the fluid. That said,
most commercial waste-evaporation
systems actually boil off the fluid
even if they are operating well below
the normal boiling point of water at
212°F (100°C).
Energy-Efficient
Evaporation
For many types of effluent, low
temperature evaporation can be an
energy-efficient method of water
removal. Where process temperatures
are 185 to 195°F (85 to 91°C), low
temperature evaporation combines
the use of a vacuum — to reduce
the boiling point of the liquid to
be removed — together with high
temperature evaporators based on
heat exchanger technology. Where the
temperature of the effluent or digestate
falls below the necessary temperature,
it typically can be increased via heat
exchangers utilizing surplus heat from
heaters and combined heat and power
(CHP) engines.
Heat exchangers are capable of
recovering heat from other sources
and using this as the basis for an
evaporation system. This can further
improve overall process efficiency.
Additionally, using a vacuum in the
system to reduce the boiling point
These heat exchangers are being used for low temperature evaporation.
minimizes the amount of energy
required.
Combining systems into a Selecting a Heat Exchanger are less susceptible to fouling — and
multiple-effect evaporator allows for Evaporation the materials used in its construction.
larger quantities of water to be The type of heat exchanger used For example, stainless steel provides
removed for the same initial heat for evaporation will depend on the long-term resistance to corrosion
input. Each evaporator is held at a nature of the products being treated. and aggressive chemicals while also
lower pressure than the previous For materials with low or medium providing the necessary thermal
one. Because the boiling temperature viscosities such as wastewater and properties.
of water decreases as pressure effluent with low concentrations of For more viscous materials
decreases, the vapor boiled off in organic solids, using a tubular heat such as thicker effluents, digestate
one vessel can be used to heat the exchanger as an evaporator module and solids with higher dry-matter
next. As a result, only the first vessel provides high heat transfer rates concentrations, the use of a scraped-
requires an external source of heat, with good resistance to fouling. surface heat exchanger may be
which can be taken from another Things to look for include the tube necessary. These generally either
process elsewhere or generated architecture — corrugated tubes are operate with a rotating (screw-type)
specifically for the purpose. more efficient than smooth tubes and or a reciprocating (back-and-forth)

HEAT EXCHANGERS
to a compressor, where it increases

in pressure and temperature. The
steam is used as the thermal energy
source in the evaporation process.
Only electrical energy (for driving the
compressor) is used in this case.
By contrast, in TVR setups, boiler
steam can be mixed with evaporated
steam in a thermo-compressor.
This leads to considerable energy
savings. Combinations of multi-effect
evaporation and steam compression
(MVR or TVR) can be used to further
increase the energy efficiency of an
evaporation process.
One way to assess and compare
the performance of different
evaporation systems is to compare
the amount of water evaporated per
unit of steam consumed — known
as the steam economy (SE). This is
commonly expressed as the ratio of
water evaporated to steam consumed.
SE ratios for conventional single-
effect evaporators are usually just
under 1.0 (0.90 to 0.98) while for a
multi-effect unit combined with
MVR, SE ratios of 10.0 or greater can
be achieved.
Heat exchangers for low
temperature evaporation also can be
incorporated in an integrated unit
to process materials. One example is
concentrating the digestate produced
by anaerobic digestion using a
purpose-designed system. This
uses multiple evaporation effects
to increase the solids present in
liquid digestate. Whether you want
to minimize effluent and digestate
Combining systems into a multiple-effect evaporator allows larger quantities of volumes using such a system or
water to be removed for the same initial heat input.
simply reduce them in a more
type mechanism. Scraped-surface exchanger are commonly used in energy efficient way, heat exchangers
heat exchangers reduce fouling and the type of multi-effect evaporation can provide a low temperature
maintain heat transfer rates (and, system described, both heat evaporation solution to achieve the
therefore, operational efficiency) by exchanger types also can be used required results. PC
continually, mechanically removing in other forms of evaporators.
product from the tube walls to These include mechanical vapor Matt Hale is the international sales and
prevent fouling. In some installations, recompression (MVR) or thermal marketing director with HRS Group.
units with a reciprocating design have vapor recompression (TVR) systems, The company has locations in Phoenix,
been shown to be effective in sludge- depending on the needs of the Ariz., and Atlanta, Ga., and can be
evaporation applications. product or application. In MVR reached at 770-726-3540 or visit
While both designs of heat setups, the evaporated steam is sent www.hrs-heatexchangers.com.

P R O C E S S
COOLING
MUST SEE
P R O C E S S
Watch all available free webinars at:
COOLING process-cooling.com/webinars
Watch anywhere, live Expand your knowledge on topics from

or on demand system maintenance to insider industry tips.
Engage with interactive polls, Get your questions answered

surveys, and chat by our expert speakers
DESIGN/BUILD
Design
BUILD
Lineage Logistics Acquires Preferred Freezer Services
L ineage Logistics, a provider of
temperature-controlled logistics
solutions, signed a definitive
across 200 facilities in North
America, Europe and Asia.
The deal will increase Lineage’s
800,000 automated pallet positions,
including what it says are the two
largest automated facilities in the
agreement to acquire Preferred ability to invest in new technologies world.
Freezer Services, a global network of while advancing the companies’ Chatham, N.J.-based Preferred
temperature-controlled warehouses. combined intellectual property. Freezer Services operates 39
The combined company will After the combination, Novi, locations throughout the United
operate more than 1.3 billion ft 3 of Mich.-based Lineage will have 17 States with additional international
temperature-controlled capacity automated facilities with more than sites in China and Vietnam.
Pie Maker Breaks Ground on Cold Phase Two of

Storage Facility Cold Storage
T ippmann Innovation and Table
Talk Pies broke ground on a
able to store finished goods on-site
instead of using outside public Facility Complete
34,000 ft 2 cold storage facility in
Worcester, Mass., that sits adjacent
cold storage in approximately nine
months. Table Talk Pies produces T he second phase of a 330,000 ft2
cold storage distribution center
in Sioux Falls, S.D., a project that will
to the pie maker’s 150,000 ft 2 over 4 million snack pies and
manufacturing facility. The -10°F 600,000 traditional 8” pies per week. create over 100 new jobs, is complete.
freezer warehouse with 3,440 pallet The 57’ tall facility includes freezers
positions will enable Table Talk with temperatures from 0°F to -20°F
to streamline its production and that hold over 54,500 pallet positions,
distribution processes. storing frozen protein products.
The manufacturing facility will be Win Chill Cold Storage can now
service food manufacturers in a 200-
mile radius. Tippman Innovation,
North Carolina Distribution Center the project’s contractor, installed 812
pallets of QuickFreeze in-rack freezing
Includes Cold Storage system. According to Win Chill, the
system cuts down freeze time by 25 to
I n late 2018, Smithfield Foods Inc.

invested more than $100 million in
a distribution center in Tar Heel, N.C.
capabilities.
The facility also includes nearly
50,000 pallet positions and has an
30 percent depending on the product.
The 500,000 ft2 facility, which is annual capacity of more than 1 billion
expected to create approximately 250 lb. It is located adjacent to one of the
new jobs and is now fully operational, company’s meat processing facilities,
includes blast cell cold storage which produces fresh pork products.

Around the
INDUSTRY
Testing Facility Ensures Pumps Meet Requirements

A recently opened testing facility
in Merate, Italy, will verify
a pump’s capacity as well as its
includes three stiff platforms that can
accommodate horizontal pump and
skid installations. These platforms
plunger pumps as well as liquid ring
vacuum pumps and systems. The
company’s after-sales department
net positive suction head (NPSH) allow for precise vibration tests, and supplies original spare parts, integrates
behavior, vibration and noise levels, two independent areas have the technological consulting services and
and overall operational efficiency. The capability to test vertical pumps with provides technical maintenance.
development of the 16,145 ft2 (1,500 m2) shaft lengths up to 40’ (12 m). The
building, located at Finder Pompe’s facility also is equipped with a testing
headquarters, was driven by the circuit for lube oil pumps and another
growth in size and complexity of the one that is dedicated to the testing of
company’s pump models along with liquid ring vacuum pumps. On-site
expanding customer expectations in cranes are capable of lifting pumps
pump performance. that weigh up to 20 tons.
The facility’s larger footprint makes Finder Pompe, part of PSG, a Dover
it suited for testing pumps with higher company, designs and manufactures
capacities and at higher pressures. It API-engineered centrifugal and
5 Steps to Proper Cooling Tower Maintenance
I f you operate cooling towers on

industrial systems, you need
to know how to perform proper
manufacturer of industrial cleaning
equipment, compiled a five-step list to
optimize cooling tower maintenance
provides the perfect environment
for bacterial growth, especially
Legionella. A descaler will dissolve
maintenance. Without it, energy costs and cleaning. the scale and mineral deposits that
can rise and equipment lifespan can Legionella like to hide in, leaving
decrease. • Inspect towers at least monthly. the surface ready for cleaning.
Another factor is Legionella Sediment, scale and slime can • Clean the fill. A cooling tower
prevention, which has become lead to buildup and help Legionella fill cleaner will remove dirt and
an industry-wide focus because grow and thrive. Regular debris and inhibit the growth
of ASHRAE Standard 188-2015. inspections will help determine of other bacteria when utilized
Because cooling towers are one of the when to schedule cleaning. in conjunction with appropriate
more common sources for growth • Clean tower basin surfaces. If biocides.
of bacteria, proper maintenance sediment is visible, the basin • Disinfect the tower. Cooling
(including cleaning and disinfecting) needs to be cleaned. Cooling tower towers can be a dangerous
is crucial. vacuums make it easier to remove breeding ground for bacteria,
To help plants and facilities contaminants without shutting which makes it important to
optimize their cooling tower cleaning down or draining your system. reduce the nutrients available for
operations, Goodway Technologies, a • Descale the fill. The tower fill Legionella growth.

NEWS
Case History Details AMCA Publication 802 for Industrial Fans Revised
Industrial Refrigeration Recently revised AMCA fan ratings and establishes rules
Publication 802, Industrial Process/ to be used to convert performance
Project for Warehouse as
Power Generation Fans: Establishing from one fan to a geometrically
Part of White Paper Library Performance Using Laboratory similar fan. In addition, it defines
A case history from Hillphoenix Models, outlines methods used by dimensional tolerances that must
details how the company supplied manufacturers to determine the exist for two fans to be considered
several industrial systems for a North performance of full-size industrial- geometrically similar.
American customer. In total, 250,000 process and power-generation fans. Learn more at www.amca.org.
ft2 of refrigeration space was created Changes to it include:
for a warehouse distribution center.
Hillphoenix, a manufacturer of • Updated terminology (fan total
refrigeration and power systems, has pressure vs. fan stagnation
compiled a white paper library that pressure).
includes other case histories as well • Updated I-P formulas to be
as information on new trends, ideas, consistent with ANSI/AMCA
innovations and customer insights. Standard 210/ASHRAE Standard
Visit www.hillphoenix.com/ 51, Laboratory Methods of Testing
insights-library for more information. Fans for Certified Aerodynamic
Performance Rating.
On-Display Compressors Produced by the Air Movement

Provide Cooling and Control Association Intl.,
Demonstration Publication 802-19 provides detailed
Three large compressors have been insight into variables that influence
installed behind a glass wall in the
meeting center at Danfoss headquarters
in Denmark so customers and guests
Industrial Refrigeration Consortium Set for May
The 2019 R&T Forum will be The IRC is a partnership between the
can see the product in operation. The
held at the Pyle Center on the University of Wisconsin-Madison and
Turbocor units provide cooling for the
campus of the University of industry. It seeks to improve the safety,
ventilation system and other cooling
Wisconsin in Madison. The annual efficiency and productivity of industrial
systems in the main office building.
training meeting of the Industrial refrigeration systems and technologies.
The compressors replace an old
Refrigeration Consortium, planned Participating organizations include
ammonia-based refrigeration plant and
for May 8-9, includes an agenda that refrigeration end-users, regulatory
have three times higher efficiency, saving
explores ways to improve industrial agencies and energy service providers.
the company 165,000 kWh annually on
ammonia refrigeration systems. To learn more and to register for the
electricity and almost 40 metric tons of
Among the planned sessions are: forum, visit www.irc.wisc.edu.
CO2. The smallest chiller delivers 250 kW
cooling, and the largest delivers 466 kW.
• Fernie Memorial Ice Arena: What
They use the environmentally friendly
happened and what did we
refrigerant R-1234ze with a global
learn?
warming potential (GWP) number of 7.
• Pressure vessel fabrication
The showroom is an active Application
practices.
Development Center used for customer
• Dealing with fugitive emissions.
visits.
• Compressor oil carryover: causes
and impacts.
• Effects of backpressure on
pressure-relief valves.
• Thermal energy storage for cold
storage warehouses.
• Regulatory updates, including
EPA RMP rule changes and IIAR
RAGAGEP. Source:Wikimedia Commons

Finned Coils Boost Capacity of Fluid Cooler Registration Open for
A fluid cooler model incorporates treatment and pump energy. International Congress
finned coils to expand thermal In colder weather conditions, of Refrigeration
performance and permit dry the fluid cooler offers higher dry The 25th IIR International Congress
operation during a broader range of operation capacity than fill/coil of Refrigeration (ICR 2019) will be
ambient temperatures. Marley DT can hybrid coolers. Manufactured by held August 24-30 in Montreal. The
more effectively reject heat without SPX Cooling Technologies, it delivers event’s theme, “Refrigeration for
evaporating water at ambient lower fan energy costs compared Human Health and Future Prosperity,”
temperatures up to 20 degrees higher to forced-draft coolers and reduces will focus on energy saving and
than with bare tube coils, says the system components compared to energy efficiency, food supply, health,
manufacturer. This helps reduce costs combination open tower and plate reduction of global warming and
associated with water usage, water heat exchanger (PHE) systems. protection of the ozone layer.
Montreal is the city where the
original Montreal Protocol on
substances that deplete the ozone
layer (such as CFCs and HFCs) was
signed in 1987. The adoption of this
protocol by 196 countries in 2009 put
refrigeration technologies at the core of
energy and environmental concerns.
Visit www.icr2019.org to register
for ICR 2019, which is hosted
by the International Institute of
Refrigeration (IIR).
Finned Coils Boost Industrial Refrigeration App Available

Capacity of Fluid Cooler Designed for installers and service information to help users find spare
Operators, system engineers and technicians in the industrial refrigeration parts and build lists in remote locations
planners will gather June 27-28 in space, an industrial refrigeration without internet coverage. Switching
Schaffhausen, Switzerland, for the app helps users navigate different back to online mode ensures the app
eurammon Symposium 2019. The event, product categories and types to find always has the most up-to-date catalog
in lectures and a panel discussion, will the right spare part kit. They can view information. Industrial Refrigeration is
deal with questions of future-proof images and data sheets, in addition to available for Android and iPhone.
solutions in cooling applications. previously available illustrations and
International speakers will show how documentation, to see which parts are
increased ecological requirements can be included and their specifications.
better achieved by refrigeration systems The Danfoss Industrial Refrigeration
with natural refrigerants. Attendees will app also has the ability to toggle between
gain insight into current legislation and online and offline mode. In offline
technical regulations and learn about mode, the app will use stored product
new solutions for charge reduction in
ammonia refrigeration systems. Compact Screw Compressors Awarded
Visit www.eurammon.com for more Bitzer’s CSVH compact screw compressors
information. compressors won the Best Application design is said
Compressor award at the Global to simplify the
Logistics Excellence Awards in installation
Hyderabad, India. The inverter-driven and safe use
compressors have a displacement of speed-controlled compressors in
of up to 1,156 m³/h (50 Hz) and are process cooling applications. The
optimized for air-cooled liquid chillers series enables a choice of refrigerants,
and heat pumps. Equipped with an including low GWP HFO and HFO/
integrated frequency inverter, the HFC blends.

BONUS
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Tekleen Automatic
CSF-ABW Filter Series
A new line of high quality, two-stage,
automatic self-cleaning water filtration
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process is a coarse-screen flushing filter and Premature Equipment
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fine filter with a screen down to 75µ. The Intelligent Control BCP™ 1015 Chemistry
CSF-ABW two-stage fully automatic filters The historically dependable Sterlco® TC130 BCP™ 1015 chemistry penetrates, disperses
offer direct filtration to dirty water sources Series Temperature Control Units have and cleans organic deposits in industrial
like rivers, lakes, wastewater, dirty cooling been updated to minimize or eliminate process and building comfort cooling
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features include: These advanced controls provide predictive loop systems. Dosing BCP™ 1015 as a
maintenance features as well as intelligent part of a regular maintenance program in
• Line sizes: 2 to 16" capabilities like Pressure Adaptive conjunction with other industrial water
• Flow rate: 10 to 6,000 gpm Technology utilizing digital pressure treatment chemicals, keeps surfaces clean.
• Screen opening: 75µ to 1/2" transducers. Troubleshooting is made easy BCP™ 1015 is compatible with oxidizing
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Tekleen Automatic Filters Inc. Sterling AMSA, Inc.

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www.tekleen.com www.sterlco.com www.amsainc.com

Hybrid Evaporative Design Combines
Chiller with Centrifugal 3 Filters in 1 Unit
Compressor Easily and efficiently remove springtime Universal Flow Meters'
New Accuchiller TCF hybrid film evaporator pollen and plant debris and address all CoolPointTM Flow &
chiller with a centrifugal compressor seasonal challenges with your system Temperature Measurement
reduces energy consumption by 34% and utilizing Harmsco’s Hurricane XP swing The UFM CoolPointTM CT Series Flow Meter
uses less refrigerant than competitive wet bolt & Hurricane HiFlow filter housings. is made for process cooling systems by
(flooded) chillers. Unlike current flooded These proven products provide effective combining the temperature transmitter with
evaporative systems which immerse copper performance with up to 20% reduction the flow meter measurement. The advantage
water tubes in liquid refrigerant, hybrid in energy costs. Their intelligent design is receiving the necessary process outputs
film evaporation systems use a thin film of combines three filters into one compact for two functions with the benefit of plumbing
refrigerant to achieve more energy efficiency housing with flow rates up to 2,400 gpm and wiring for only one device. This reduces
with a reduced amount of refrigerant. The per housing with operating pressures up to the overall size and complexity of the system
TCF also features a unique advanced PLC 235 PSI (XXP). The outer chamber induces and saves costs by removing components
control system which controls, monitors, cyclonic separation of dense solids prior to and unnecessary installation labor.
and maintains stable and reliable operation. Up-flow and Cartridge filtration for extended Simultaneously monitor outputs through the
Combine the energy savings of the TCF cartridge life and increased dirt-holding LED digital display and the 4-20 mA signal or
chiller with other Thermal Care energy capacity. This patented design results in set alarms through the solid state relays for
savings technologies like adiabatic fluid fewer maintenance intervals and reduces temperature and flow.
coolers and free cooling systems . overall operating costs.
Thermal Care Harmsco Filtration Products Universal Flow Monitors, Inc.

800-383-8108 800-327-3248 888-569-3090
www.thermalcare.com www.harmsco.com www.flowmeters.com
Get Social. Connect With Us!
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Machine Tools Need Find us on Facebook, Twitter,
Cooling to Maintain Critical Cottonwood Filter Screens LinkedIn and YouTube!
Competitive Advantage Stops Airborne Debris Like • Follow • Join • Subscribe
Machine tool processes depend on reputable From Fouling Equipment
cooling system to provide tight tolerances In springtime, cottonwood seed, bugs, pollen
and consistent temperatures for quality and other airborne debris in the air will
workpieces and uptime of equipment. For foul your condenser coils, cooling towers,
more than 60 years, customers have found air-handling units and more — costing you
the Koolant Koolers brand chiller to be a thousands each season in maintenance,
workhorse due to its robust design for the downtime, lost productivity and energy cost.
machine tool industry. Known for its ability Cottonwood Filter Screens with specially
to withstand high ambient temperatures, engineered HVAC MESH helps put an end to
and cool water-soluble coolant directly all of that by stopping airborne debris on the
or oil coolants indirectly, the expertise outside of your equipment, before it becomes
of designing chillers has provided the a problem. Easy Clean without removal using
knowledge to customize the chiller to each a broom, brush, leaf blower or garden hose.
application’s specific requirements. Even the rain will rinse them clean!
Glen Dimplex Thermal Solutions Air Solution Company
800-968-5665 800-819-2869
www.dimplexthermal.com www.airsolutioncompany.com

CLASSIFIED MARKETPLACE
Design/Build Contracting
HEAT EXCHANGERS Do You Have Used Equipment

Liquid Cooled to Sell, or Offer Consulting
▼ or Repair Services?
Contact Becky McClelland
Air Cooled for details about our new PC Classified
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FOR G ASES & L IQUIDS !
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PHONE: 412-306-4355
FAX: 248-502-1076
(952) 933-2559 info@xchanger.com
Becky@bnpmedia.com
Take a moment to check out our new responsive website!

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January/February 2017
For engineers who specify cooling equipment, components and materials For engineers who specify cooling equipment, components and materials For engineers who specify cooling equipment, components and materials
COOLING
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For engineers who specify cooling equipment, components and materials
Protecting Water Quality: Quick Chilling Sizing Piping

Tunnel Cooling Systems
2016
Essential to Cooling Tower
or Freezing & Valves Compare
Cooling Tower Makeup
2017
Health and Operation
from Corrosion during
Winter Layup Product Guide Water Options
BUYERS
GUIDE
24 Alleviating the Heat Burden Created by
Process Chillers
20 Low Charge 13 4 Tips for Ensuring
Ammonia Refrigeration Top Cooling Tower Performance 28 Monitor Flow Parameters to
16 Evaporative Cooling Strategies for 14 Tips for Selecting a 14 Selecting Sensors Improve Efficiency Your Best Source For Industrial
Nontraditional Products Process Chiller to Probe Cold Temperatures
32 Using Data Analytics to Improve 24 Mitigating the Impact of the Process Cooling Equipment
Process Plant Operations Cooling-Water Intake on Aquatic Life
36 Cooling Technology Institute Heads to 26 Water Screen Filtration 28 Tips for Chlorine-Based
the Big Easy for Cooling Towers Water Treatment
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WEB EXCLUSIVES
May 2019
ONLINE
THE FUTURE OF WALNUT-SHELL FILTERS
Read more at
Due to the resurgence of the oil industry, these filters are more common than
they have ever been. However, their uses and benefits are not limited to oil and
steel production.
PERMACOLD ENGINEERING REFOCUSES BUSINESS

APPROACH WITH COMMITMENT TO ENVIRONMENTALLY
FRIENDLY SYSTEMS
In addition to optimizing engineering refrigeration systems for maximum efficiency, the company is pursuing a range of
initiatives involving more environmentally sound refrigeration systems.
SUSTAINABLE WATER TREATMENT REPORT

Download Eneref Institute’s full report on sustainable technologies in water management.
Always Online
Article Archives • News • Products • Digital Editions • Calendar • Cooling Capabilities • Buyers Guide
AdIndex
Page # Company Phone Website
7 ACS Group 262-641-8600 www.aecinternet.com
13 Air Solutions Co. 800-819-2869 www.airsolutionscompany.com
2 AMSA, Inc. 888-739-0377 www.amsainc.com
5 Analytical Technology, Inc. 800-959-0299 www.analyticaltechnology.com
39 APEX Engineeering Products Corp. 630-820-8888 www.ApexEngineeringProducts.com
22 Glen Dimplex Thermal Solutions 800-968-5665 www.dimplexthermal.com
8 Harmsco Filtration Products 800-327-3248 www.harmsco.com
20 Huber USA, Inc. 800-726-4877 www.huber-usa.com
48 Johnson Controls/Frick 717-762-2121 www.FrickCold.com
11 Motivair Corp. 716-691-9222 www.motivaircorp.com
28 Redi Controls Inc. 800-626-8640 www.redicontrols.com
15 Tekleen Automatic Filters Inc. 800-336-1942 www.tekleen.com
25 Thermal Care, Inc. 888-383-8108 www.thermalcare.com
39 Turner Designs Hydro Carbon Instruments 559-253-1414 www.oilinwatermonitors.com
8 Universal Flow Monitors Inc. 888-569-3090 www.flowmeters.com
28 Winton Products Corp. 704-399-5151 www.wintonproducts.com

Committed to Cold.
TM
SINGLE SOURCE INDUSTRIAL

REFRIGERATION SOLUTIONS.
Committed to cold? More like consumed
by it. That’s how we’ve become the world’s
leading supplier of industrial refrigeration
and compression equipment to the food
and beverage industry.
Our passion compels us to engineer more

precisely, control more predictably, and support
more thoroughly, so you can count on the cold.
Our team of FRICK Factors includes the most
elite refrigeration installation contractors in
North America. So specify FRICK® and find a
FRICK Factor near you at www.FrickCold.com.
www.FrickCold.com
© 2018 Johnson Controls International PLC - ALL RIGHTS RESERVED

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P R O C E S S

Cryogenic tunnel freezers are suited for processing large quantities of

18 REFRIGERATION SYSTEMS 41 Around the Industry

COOLING TOWERS COVER For engineer

Crossﬂow Microsand Filtration for Cooling Tower Water Treatment

May 2019 www.process-cooling.com 3

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Manning/honeywell portable sensor

• Economical, Dependable, and Direct from the Manufacturer.

LOCATE NH3 LEAKS

www.entechdesign.com www.analyticaltechnology.com 800-959-0299

Wittmann Battenfeld Inc.

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Heatcraft Worldwide Refrigeration

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Cryogenic Thermal Spray

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Cryogenic Nitrogen Vapor Cooling vs. target surface whenever higher

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thermal-spray process knowledge.

Liang He is a senior principal application

12 PROCESSCOOLING May 2019

Compatible With All Equipment Makes and Models

PROTECTING and CLEANING YOUR EQUIPMENT

Call: 800-819-2869 www.airsolutioncompany.com

Dual-belt freezers have two conveyor

14 PROCESSCOOLING May 2019

May 2019 www.process-cooling.com 15

choose a type of freezing tunnel that

16 PROCESSCOOLING May 2019

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Factors Driving Change

18 PROCESSCOOLING May 2019

• They will be smaller.

The increasing demand for high

• Lower energy bills.

Many of these changes will even

All of these factors contribute

May 2019 www.process-cooling.com 19

Working temperatures from -125°C to +425°C, cooling

Find out more: www.huber-usa.com

Huber USA, Inc.

May 2019 www.process-cooling.com 21

In conclusion, these trends in system design are the

Steve Jackson is co-founder and president of PermaCold

22 PROCESSCOOLING May 2019

Register for free at www.Process-Cooling.com/events

Filtering Oily or Dirty

24 PROCESSCOOLING May 2019

A walnut-shell filter in an atmospheric

May 2019 www.process-cooling.com 25

walnut-shell media and its ability

26 PROCESSCOOLING May 2019

Cooling towers absorb heat

Crossflow Microsand Filtration for

May 2019 www.process-cooling.com 27

The blowdown water typically is