What's Is the Falling Film Water Cooling Technology ??
Falling Film Chiller
Falling Film Chiller Process reliability to produce constant cooling of ice water near freezing point.
The Falling Film Chiller is a water cooler based on Pillow Plate technology. With the ice water at temperature (<0.5?°C)?from a Falling Film Chiller you can cool large amounts of product in a short time. This (recirculating) water cooler, which cools the water at a constant temperature, is a suitable solution for the continuous cooling of your products.
It’s ice water cooler?that’s mainly designed for cooling water down to 0.5°C near freezing point. Especially Ice water (near 0°C) has a very good heat capacity, i.e. by contrast with other cooling agents, relatively small quantities can convey a large amount of heat. What makes the falling-film chiller so interesting is its relatively simple and reliable operation including?a?high cooling performance?to represent the ideal?industrial water chiller.?Water flows down the vertical plates. It is an open system that is accessible for cleaning, even during operation. Completely made of stainless steel.
What is a Falling Film Chiller?
A Falling Film Chiller is suitable for cooling water to a certain desired temperature. Ice water is used to cool large quantities of your product in a short amount of time, for example to blanch vegetables or to mix with concrete in prevention to dry quickly. Due to the open system, it is also suitable for cooling contaminated liquids. It’s also possible to recirculate the water and let the Pillow Plates cool the water down again to the right temperature. With this recirculating Falling Film Chiller your products are continuously cooled to an even temperature.
?How does a Falling Film Chiller work?
In the upper container of the appliance, the water will be divided into small holes to the double embossed Pillow Plates, hanging underneath. A thin layer of water falls over the plate and is cooled to the desired temperature. The water can be cooled to 0,5 °C with a Falling Film Chiller.
This cooled water is pumped into a container and distributed to the user(s), such as a plate heat exchanger or process tank. The used water is collected in a reservoir and pumped back to the top of the Falling Film Chiller. The water is cooled again in the same way.
The process water flows in a thin film over the outer surface down on the panels and obtains the highest possible outside film coefficient. By highest descent speed, highest U transmission coefficients are reached. In order to avoid building of ice at the panels, the suction gas pressure at the evaporator suction header must be regulated. To keep the evaporation temperature not lower than the designed one, e. g. -3°C, as well as the water temperatures and flow. At systems used with e. g. glycol inside, the glycol inlet temperature must be controlled.?
A high flow velocity ensures highly efficient heat transfer and a kind of helpful self-cleaning effect, which allows the operation with polluted liquids as well. Completely made of stainless steel, it assures all required sanitary requirements, as the Ice water is always in contact with stainless steel parts AISI 304 or 316L or higher stainless-steel grades up to titanium. An industrial Falling Film cold-water chiller consists of essential components including compressors, condensers, expansion valves, and evaporators. The process operates as follows:
?The compressor compresses the refrigerant gas, increasing its pressure and temperature. The high-pressure and high-temperature refrigerant gas then flows to the condenser, where it releases heat and condenses into a high-pressure liquid. The liquid high-pressure refrigerant passes through the expansion valve to decrease its pressure and temperature. The resulting substance flows to the evaporator, where it absorbs the heat from the water to be cooled. This heat transfer occurs as the water passes through a falling film chiller. The chilled water circulates back to the application (process) that needs to be cooled. The low-pressure and low-temperature refrigerant gas then returns to the compressor. The cycle can be repeated as needed.
Falling Film Chiller advantages
·??????? Efficient cooling to very low temperatures (<0,5?°C) without the risk of freezing?
·??????? Water chiller with low cost per kWh,?High efficiency & low pressure drop.?
·??????? High efficiency, low pressure drops of this industrial water chiller
·??????? Suitable chiller for contaminated liquids (for example greywater or red water)
·??????? Easy to clean industrial cooling chiller.
·??????? Cleaning during operation possible with this industrial water chiller
·??????? Low tendency to foul chiller.
·??????? Fully welded, no spare parts such as seals in this industrial water cooling chiller
·??????? No destruction of the apparatus in case of ice formation of this industrial water chiller
·??????? Special falling film chiller versions as ice water chillers possible
·??????? No risk of freezing with ice water of 0.5 °C and destruction of the apparatus
·??????? Simplicity of control
·??????? Easy access to the open system industrial water chiller and easy to clean even during operation
·??????? Industrial water chiller completely made of stainless steel, also for salt water
·??????? Constant temperature of the chilled water
·??????? Custom-made to your needs
·??????? Easy to maintain open construction. Occasional cleaning with high pressure
·??????? Full construction of stainless steel
·??????? Can cool slightly polluted water (particles smaller than 8 mm)
·??????? Capacities up to 2500 kW per unit
SPECIFICATIONS
All Falling Film Chillers are custom-made:-
Capacity
Depending on your expectations, the coolers can be produced with a capacity of 10 to 2,500 K. watt per unit. The water can be cooled over a wide temperature range: ΔT 30 °C is possible with recirculation.
Cooling medium
Almost all cooling media can be used with this Falling Film Chiller, such as R717, CO2, Propylene glycol, Ethylene glycol, R22, R134A and R404A.
Material
The Falling Film Chiller is made of stainless steel, such as 304, 316, SMO-254 and Duplex 2205.
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Applications
In many production processes where the cooling of large quantities of product is required, the Falling Film Chiller is a solution.
Examples of where our coolers are used are:
?Comparison of Falling Film Chillers and Plate Heat Exchangers
If you are an engineer,?looking for the most efficient and effective process cooling solutions of ice water near freezing point of 0,5°C, then you should consider the advantages of a falling film chiller versus a plate heat exchanger.?This type of chiller offers some very distinct benefits when compared to plate heat exchangers and could be just what your application needs.
The Falling Film Chiller is a specialized engineering solution, designed with Pillow Plates arranged side-by-side in an efficient frame. As the interior of each plate undergoes evaporation with ammonia or refrigerant, water streams down along the exterior to create thin films for heat exchange - enabling temperatures near freezing point and optimized efficiency far beyond HVAC applications. With precisely spaced plates at 50/150mm apart from one another complemented by 0.5/0.4 mm thick fluid layers transitionally descending downwards – this product ensures successful thermal energy transfer without fail! The FALLING FILM CHILLER, a widely-employed technological solution for businesses in both the food and beverage industry as well as chemical and pharmaceutical sectors abroad, relies on optimized film layer thickness to achieve better exchange coefficients. A thinner falling film is associated with higher levels of efficiency while increased plate numbers will result in thicker layers that reduce overall performance.?
The simplicity of a Falling film chiller with open design to produce water at 0,5°C
In direct contrast to the Plate Heat Exchanger:
In conclusion, plate-heat-exchangers require temperature control, hot gas-defrost and flow control on the water side. The costs for the controllers and temperature sensors do not depend on the capacity while control valves, pilot valves as well as solenoid valves and shut valves are dependent on capacity. Having said that it should be taken into account that there could be enormous additional cost incurred due to the planning, piping, mounting of valves and electric wiring as well as setting and programming of the controller. Plate-Heat-Exchangers have gaskets between plates likely needing cleaning depending on various water qualities causing massive lose of power if overlooked.
Industrial Applications for Industrial Falling Film Water Chillers
What’s the Process?
The water-cooling system with falling film chillers is becoming increasingly established as an efficient and cost-effective solution for heat dissipation in industrial applications. The use of falling film chillers is suitable wherever different consumers such as processes or individual machine parts such as spindles, motors, or hydraulic devices need to be economically supplied with a cooling system. In addition, a customized water-cooling system is an optimal solution for demanding conditions such as high ambient temperatures and heavy dirt.
In the Falling Film Chiller,?the homogeneous falling film allows to chill water down to 0,5 °C. Within industrial processes it can function as pre-chiller for industrial ice bank systems or is connected to the ice water side of a Plate Heat Exchanger. Or will be pumped directly to various food cooling processes. From the water collecting tank under the Falling Film Chiller pumps to bring the chilled water to the desired consumption locations. An industrial cold water-cooling system with falling film chillers is a type of water cooling that extracts heat from a heat source while ensuring constant temperatures, pressures, and flows through a cooling system. Simply put, an industrial cold water-cooling system works by circulating a cooling fluid from a reservoir to the devices that need to be cooled. This differs from other cooling systems, such as air-based systems, which use fans for heat dissipation.
Industrial Ice water chiller in dairy processes
A?Falling Film Chiller?or?ice water chiller?continuously generates ice water at 0.5 ° C without ice formation. Ice water is the ideal cooling medium for milk-processing plants because it is non-toxic, has excellent heat transfer and transport properties, is inexpensive and available everywhere. To meet high global quality standards, fast and smooth cooling processes must be guaranteed from processing to storage of?sensitive dairy products such as milk, milk powder, yoghurt, milk desserts, butter and cheese, mostly at the expense of high energy costs.
Low-specific and thermodynamic parameters from an industrial water chiller of ice water near freezing point
As zero point is approached, the problems in ice water production with the attendant risk of ice formation increase. The known anomaly of water (lowest specific volume at 4°C) results in the water volume expanding when it freezes, and under certain circumstances this can cause destruction of the equipment used. Furthermore, ice formation in ice water systems with their thick layers of ice always involves considerable performance losses because the ice layer acts like insulation and greatly reduces the thermal transmission output.
The flow-specific and thermodynamic parameters of water are favorable, so that high heat transfer rates can be achieved. However, the freezing point of the water itself (zero point) sets crucial physical boundaries for ice water production and cooling with ice water.?
Above all, temperatures achievable in the water are made to approach the zero point as closely as possible in order to exploit maximum temperature differences for the products to be chilled with ice water and to keep the temperature of the cooled product as low as possible.
Process water chiller with discontinuous inlet water flow
This?Falling Film Chiller?or ice water cooler?is designed to be robust to unexpected fluctuations in operation.?For this purpose, we use a?split-tank-design is the optimal solution for cooling water with inconsistent flow rates or temperatures, ensuring that your refrigeration machine operates continuously and efficiently. The Falling Film Chiller or ice water cooler achieves this by incorporating a custom-designed water reservoir and flow path that caters to the specific flow profile and temperature variations of your application. This unique design ensures the chiller is resilient to unforeseen operational shifts while maintaining high-performance levels. Additionally, by employing food-grade stainless steel in its construction, the Ice Water Falling Film Chiller meets all necessary standards for use in the food and beverage industry, ensuring a hygienic and reliable cooling solution for your business.
?Falling Film Chiller versa Ice Bank
Ice storage adapts quickly to changing cold demand. This applies to energy consumption, energy costs, investment costs, as well as availability of space and electricity. Most often, our customers are faced with the choice of a storage system or a spray cooler, a falling film chiller. By using storage, high peak cold consumption can also be managed with cooling systems that are only designed for the daily average value. There is no doubt that an ice storage system can be operated more efficiently by taking advantage of the favorable off-peak hours.
De-oiling device of an industrial water chiller
If the Falling Film Chiller is used with NH3, a de-oiling device for the system is provided as a small suction pipe at the liquid bottom header of the system for gravity or pump operation. This is standard for NH3 and done on request for CO2. With refrigerant NH3, and depending on the oil, probably as well for CO2, there are severe miscibility gaps or solubility gaps with different oils, even if helpful additives are used. Prior to the de-oiling procedure the evaporator system must be out of operation for some time, to allow the oil to separate to the bottom of the system.
In case of using oil with a lower density compared to the liquid refrigerant CO2, the refrigerant must be evaporated completely for this de-oiling function. A regular de-oiling is needed, according to the properties of the refrigerant compressor and the oil. Experienced engineers with academic advice are responsible for the design. Individual channel design and construction for each project due to the high inside film coefficient and low pressure drop.
Why mainly NH3?
The?natural refrigerant ammonia, which is not only climate-neutral, but also highly energy-efficient, is normally used. Due to its very good thermodynamic properties, ammonia requires the least amount of energy to generate a certain cooling capacity.
This advantage is particularly important in dairies with their large plants, so that refrigeration plants using ammonia have proven their worth in the milk processing industry. At the same time the ammonia volume in this system is low. Gravity-driven evaporators with separators are used. In this way, the efficiency of the system is increased compared to plants with direct expansion and energy costs are reduced. For heat recovery, effective systems use an evaporative condenser, a heater and oil cooler. All in all, this increases the efficiency of the entire system and reduces operating costs.
Simple Falling-Film Chiller maintenance
Falling Film Chiller construction and dimensions example
Typical dimensions without tank L (m) / B (m) / H (m)
Compact system: 1.2 / 0.5 / 1.8 System type A: 2.0 / 2.1 / 2.0 System type B: 3.8 / 2.5 / 2.0
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