Air Cooled Screw Chillers
Air Cooled Screw Chiller – Smart Cooling for Reliable, Cost-Effective Performance
When cooling demand is high but water availability is limited, an air cooled screw chiller becomes the most practical and reliable choice. Built to handle large cooling loads, long operating hours, and harsh outdoor conditions, air cooled screw chillers are widely used in industries that need strong performance without the complexity of cooling towers.
If your plant requires heavy-duty cooling with simple installation and predictable operating cost, an air cooled screw chiller is a solution worth serious consideration
What Is a Air Cooled Screw Chiller?
An air cooled screw chiller is a refrigeration system that removes heat from a process or HVAC system and rejects that heat directly into the atmosphere using air-cooled condensers and axial fans. The system uses screw compressors, which are specifically designed for high capacity, continuous operation, and smooth load control.
Unlike water cooled chillers, air cooled screw chillers:
- Do not require cooling towers
- Do not need condenser water pumps
- Do not consume water
This makes them ideal for locations where water is scarce, water treatment is difficult, or plant infrastructure needs to remain simple.
Why Customers Choose Air Cooled Screw Chillers
Customers who invest in air cooled screw chillers usually have one clear priority:
“We need powerful cooling, but we don’t want water-related headaches.”
Key Customer Advantages
- High cooling capacity with simple installation
- No water consumption or water treatment cost
- Reliable 24/7 performance
- Strong efficiency at medium to high loads
- Suitable for outdoor installation
For many industries, air cooled screw chillers strike the perfect balance between performance, reliability, and operational simplicity.
Advantages of Air Cooled Screw Chillers
Air Cooled Screw Chillers provide high-capacity, reliable cooling without water dependency, offering easy installation, stable 24/7 performance, and lower system complexity for industrial applications.
One
No Water Dependency: Ideal for regions facing water shortages or strict water regulations.
Two
High Capacity Performance: Suitable for applications above 40 TR, where scroll chillers become inefficient.
Three
Easy Installation: No cooling tower or complex piping reduces installation time and cost.
Four
Reliable Outdoor Operation: Designed to operate in high ambient temperatures.
Fifth
Lower Overall System Complexity: Fewer auxiliary components mean fewer failure points.
Process of Air cooled Screw Chiller
An air cooled screw chiller operates on the vapour compression refrigeration cycle, with air acting as the heat rejection medium.
Working Process Explained Simply
1. Heat Absorption (Evaporator)
Chilled water absorbs heat from the process or air-handling units. The refrigerant inside the evaporator absorbs this heat and evaporates.
2. Compression (Screw Compressor)
Low-pressure refrigerant gas enters the screw compressor. Two intermeshing rotors compress the gas smoothly and continuously, producing high-pressure, high-temperature refrigerant vapour.
3. Heat Rejection (Air-Cooled Condenser)
The hot refrigerant flows through condenser coils. Large axial fans pull ambient air across the coils, releasing heat into the atmosphere.
4. Expansion
The refrigerant passes through an expansion valve, reducing pressure and temperature before returning to the evaporator.
This cycle repeats continuously to maintain a stable chilled water temperature.
How to Calculate Air cooled Screw chiller
How to Calculate TR for an Air Cooled Screw Chiller
Correct TR calculation is critical to ensure:
Stable performance
Energy efficiency
Long equipment life
Industry-Standard Formula
TR = (Flow Rate × 4.187 × ΔT) / 3024
Where:
Flow Rate = Water flow in m³/hr
ΔT = Temperature difference (°C)
Easy Customer Example (High-Load Application)
Application
Central cooling for plastic extrusion plant.
Given Data
Water flow rate: 80 m³/hr
Chilled water inlet temperature: 12°C
Chilled water outlet temperature: 7°C
Temperature difference (ΔT): 5°C
TR Calculation
TR = (80 × 4.187 × 5) / 3024
TR = 1674.8 / 3024
TR ≈ 55 TR
Recommended Chiller
A 60–65 TR Air Cooled Screw Chiller is recommended to:
Handle peak summer conditions
Allow future expansion
Maintain stable cooling
Typical Capacity Range
Air cooled scroll chillers are most suitable for:
5 TR to 60 TR
Stable or moderately varying loads
Medium operating hours
For higher capacities or 24/7 heavy-duty operations, screw chillers may be more suitable.
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Key Components & Applications
Key Components of an Air Cooled Screw Chiller
Screw Compressor
The heart of the system, designed for:
High efficiency at large capacities
Long operational life
Smooth and reliable performance
Air-Cooled Condenser
Equipped with heavy-duty coils and fans to handle high ambient temperatures.
Evaporator
Usually a shell & tube or plate heat exchanger for efficient heat transfer.
Capacity Control System
Slide valve or VFD control allows smooth load matching and energy savings.
Control Panel
Advanced microprocessor or PLC-based control system for:
Temperature accuracy
Safety protection
Energy monitoring
Typical Applications of Air Cooled Screw Chillers
Air cooled screw chillers are widely used across industries:
Plastic & Injection Molding Plants
Maintains stable mold and oil temperatures even during continuous operation.
Pharmaceutical & Chemical Industry
Provides dependable cooling for reactors and process lines.
Food & Beverage Industry
Used in breweries, dairies, cold processing, and packaging plants.
HVAC Systems
Suitable for malls, hospitals, data centers, and airports.
Textile, Rubber & Tyre Industries
Handles heavy thermal loads efficiently.