Chillers are indispensable systems in modern industrial and ...
Chillers are indispensable systems in modern industrial and commercial applications, playing a vital role in temperature control for various processes and environments. From achieving precision in semiconductor manufacturing to supporting large-scale HVAC systems, chillers help the whole system to uplevel its performance and reliability.
But what exactly is a chiller, and how does it work? In this blog, we’ll explore the fundamentals of chillers, their types, and industrial chiller working principle. This blog will help you understand why chiller is an essential part of temperature control systems in factories and industries.
A chiller is a mechanical system used to remove heat from a liquid (typically water or a water-glycol mix) and circulate it through a cooling system. It is commonly used in industrial, commercial, and HVAC applications to maintain desired temperatures in processes or spaces. In semiconductor manufacturing, for example, chillers are used to cool equipment and maintain optimal temperatures for precision processes. They can be air-cooled or water-cooled, depending on the application.
In the semiconductor sector and other ICT manufacturing industries, the chillers in the fluid can reach a precision of ±0.01℃.
This level of temperature control is essential for processes that require extreme accuracy and stability, such as:
Photolithography: Precise temperature management ensures the stability of chemicals and the quality of patterns on wafers.
Etching and Deposition: Temperature fluctuations can lead to inconsistencies in layer thickness or etching depth.
Wafer Bonding and Cleaning: Consistent fluid temperatures are critical to avoid thermal stress and ensure uniform cleaning or bonding results.
High-precision chillers achieve this accuracy through advanced control systems, efficient heat exchange mechanisms, and high-quality sensors to monitor and adjust temperatures in real time.
Generally, types of industrial chillers can be divided into 2 kinds: Air-cooled chiller and water-cooled chiller.
Air-Cooled Chillers: These chillers use air to cool the refrigerant in the condenser. The heat is transferred from the refrigerant to the surrounding air via fans.
Water-Cooled Chillers: These use water (often from a cooling tower) to absorb the heat from the refrigerant in the condenser. This method is more efficient for larger systems because water can carry away more heat than air.
An industrial chiller works by removing heat from a liquid (usually water) and transferring it to another medium, typically air or water, depending on the type of chiller. The process involves a refrigeration cycle, similar to the operation of a refrigerator, which consists of several key steps:
Process: The refrigerant gas is compressed by the compressor, which increases its pressure and temperature. This makes the refrigerant hot and in a gaseous state.
Outcome: The refrigerant becomes a high-pressure, high-temperature gas that is ready to release its heat in the next stage.
Process: The hot, pressurized refrigerant gas flows through a condenser (either air-cooled or water-cooled). As the gas cools down, it releases its heat to the surrounding air or water.
Outcome: The refrigerant condenses into a high-pressure liquid. The heat extracted from the refrigerant is either released to the outside air (in air-cooled chillers) or to a water system (in water-cooled chillers).
Process: The high-pressure liquid refrigerant flows through an expansion valve, which reduces its pressure and temperature. The refrigerant is now in a low-pressure, cold liquid state.
Outcome: The refrigerant is ready to absorb heat once again, which is crucial for the cooling process.
Process: The low-pressure, cold refrigerant enters the evaporator, where it absorbs heat from the chilled water or liquid circulating through the system. This heat exchange causes the refrigerant to evaporate into a gas.
Outcome: The refrigerant evaporates and absorbs heat from the liquid that is being cooled, lowering its temperature. The cooled liquid is then sent to the system that requires cooling (e.g., machinery, air conditioning systems, or manufacturing processes).
Process: The cooled liquid is pumped through the system or to the equipment that needs cooling (e.g., semiconductor machines, manufacturing equipment, or air-conditioning units).
Outcome: The chilled liquid removes heat from the equipment, and the cycle repeats.
1. The compressor compresses the refrigerant into a high-pressure, hot gas.
2. The condenser cools the gas, causing it to condense into a high-pressure liquid.
3. The expansion valve reduces the pressure, making the liquid cold.
4. The evaporator absorbs heat from the water being cooled, turning the liquid refrigerant back into a gas.
5. The chilled liquid is pumped to the system, and the cycle repeats.
This continuous cycle ensures that the process or environment being cooled remains at the required temperature.
In conclusion, an industrial chiller operates through a continuous refrigeration cycle that efficiently removes heat from a liquid, typically water, to maintain aiming temperature in various applications. The process involves compression, condensation, expansion, and evaporation stages, in which the cooling material absorbs and transfers heat.
Depending on the system type, air-cooled or water-cooled chillers are frequently used in industries such as semiconductor manufacturing, HVAC, and large-scale cooling processes. Their ability to maintain precise temperatures makes them play an important role in ensuring the accuracy and efficiency of temperature control.
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