Compact Heat Exchangers

Compact Heat Exchangers

Compact Heat Exchangers

Compact heat exchangers are used in a great variety of applications. They allow for an increased heat transfer rate, require less volume and weigh less compared to other heat exchanger types. The disadvantage is the higher pressure drop.

 Compact heat exchangers  in Specifications : –

    • To be eligible for inclusion on the Energy Technology Product List, products must meet the eligibility criteria as set  out below.

Compact heat exchangers  Applications : –

Compact heat exchangers are very flexible in the various fields of possible applications. They are available with standard connections in various diameters and in different lengths. Compact heat exchangers can be designed in horizontal and vertical orientation and can be used for a wide variety of applications including, among others

  • Compressed Gas / Water coolers
  • Water / water coolers
  • Oil / water coolers
  • Preheaters, CiP-Preheaters
  • Condensers and evaporators for chemical and technical processes of all kinds.
  • Machine coolers
  • Oil coolers for hydraulic systems
  • Oil and water coolers for power machines
  • Refrigeration and air-conditioning units

Possible variations of our proven standard are suitable for other applications e.g. Engine-Water cooling with seawater made in titanium partially. Especially in welding the tube to tube sheet connection we have a wide range of experience. Investments in CHEs can only qualify for Enhanced Capital Allowances if the specific product is named on the Energy Technology Product List.

Advantages as Compact heat exchangers : –

Three types of compact heat exchanger are covered by the ECA Scheme. These are : –

  • 1. Plate heat exchangers.
  • 2. Plate-fin heat exchangers.
  • 3. Compact heat exchangers with precision formed surfaces.

Stainless steel compact heat exchangers are divided into two different basic types : –

  • KF type with fixed tube bundle
  • KM type with retractable tube bundle

High Efficiency Level : –
Thanks to special welding know-how, we are in a position to achieve a 20% higher level of efficiency with compact heat exchangers versus conventional shell-and-tube heat exchangers. For this reason, compact heat exchangers are small in size.

 

Brazed Plate Heat Exchanger

Brazed-Plate-Heat-Exchangers

Brazed Plate Heat Exchanger

Compact brazed heat exchangers provide the all the advantages and efficiencies of a plate heat exchanger while providing capabilities of a large duty in a small footprint. The compact brazed heat exchangers are typically used for a wide array of both industrial and commercial/domestic applications. Brazed plate heat exchangers are also used in refrigeration cycles and are widely used as evaporators and condensers.

Major Advantages of brazed Plate Heat Exchangers:

  • Compact, light weight brazed heat exchanger allows for the unit to be installed in very restrictive and tight mechanical rooms
  • Low initial costs for the heat exchanger
  • Close temperature approach will enable a greater heat loads than other type of heat exchangers like shell & tube heat exchangers
  • Typically all connections are on a single plane so heat exchanger can be removed for service without disturbing any hard piping
  • Compact brazed plate heat exchanger are always in stock for immediate delivery

Brazed Plate Heat Exchangers – Product Range:

Brazed Plate Heat Exchangers - Product Range

Brazed plate heat exchangers are manufactured using stainless steel 316 plates and copper brazed in a furnace to provide a strong bond resulting in an extremely high pressure rating for this type of heat exchanger. The flow pattern in a brazed plate heat exchanger is very turbulent allowing for an extremely high heat transfer coefficient. This in turn allows for a smaller footprint because the surface area required to perform a similar duty will be much less. This is reflected in the economical pricing of the brazed plate heat exchanger.

Another common usage for brazed plate heat exchangers permits the end user to maximize the heat recovery as very close temperature approaches are attainable. It is very common to have 2°F temperature approaches between the hot and cold sides. This allows the end user to maximize the efficiency of the boiler by reducing the set temperature to a lower level.

Aluminium Heat Exchanger

Aluminium Heat Exchangers

Aluminium Heat Exchanger

Aluminum Tube and Fin Heat Exchangers
(Mechanically Expanded)

The most common design of a Heat Exchanger today is the fin and tube heat exchanger. Pole Star recommends a solution using aluminium fins and specific aluminium tubes, as an obvious alternative over the copper tube. As illustrated, the aluminium tubes are first inserted into a stack of fins. The tubes are pre-bended in hair-pin shape. After insertion, the tubes are expanded. The expansion secures the thermal contact between tube and fin. Afterwards, U-bends are brazed to the tubes.

This all aluminum fin and tube heat condensing coil does not only maximize the heat transfer rate, but will also prolonged the life of the condensing coil. The condenssing coil can also be made using hydrophili.

Compared to a traditional HVACR copper tube/aluminium fin heat exchanger, this provides:

  • A lighter heat exchanger
  • Better corrosion resistance, due to a better galvanic balance of the materials
  • More cost-effective heat exchanger

Why Aluminum: Aluminium as a material has major benefits.

  • Cost
  • Weight
  • Corrosion
  • Heattransfer
  • Aluminium as a material has major benefits that we can’t keep secret any longer. 
  • Price Aluminium remains one of the most cost-effective materials you can use, with outstanding properties which enable considerable savings – it is two-to-three times cheaper than copper – and significant technological improvements.
  • Performance Using aluminium in HVACR applications improves system weight significantly. You save space and, also, in the case of a brazed heat exchanger, refrigerants. Further, you will gain a highly corrosion-resistant material with suitable alloys.
  • Sustainability Due to its material properties, aluminium lasts longer than other materials when used in an appropriate way. More than that, we view the increased recycling of aluminium as important for resource preservation.
  • Manufacturing Aluminium keeps adding benefits at the manufacturing stage by presenting easy forming abilities.

To know more please see the Comparison tables of aluminum to copper tubes used in HVAC heat exchangers.

Air Fin Cooler

Gireesh Air Fin Cooler

Air Fin Cooler

The Air Cooled Heat Exchangers are also known as Fin fan Coolers. Fin Fan Cooler is nothing but traditional name of Air Cooled Heat Exchanger. Since Fins are used in the Cooler it is called as Fin fan Cooler. Please refer Air cooled Heat Exchanger for all the details. In the Fin fan coolers, the ambient air is used as the cooling media to cool.

Refurbishment
Serck undertake complete refurbishment of fin fan air coolers on site. From complete Re-tubing, partial re-tubing, coating of fins, water jetting of tubes, fitting of liners in leaking tubes, combing of fins, fixing of fin supports to pressure testing as site.
Clients
We serve our clients in Power Generation and all traditional areas of process industries such as chemical, Petrochemical plants, Oil Rigs and Refineries.

Air Cooler Applications

Gireesh  air coolers, also called air fin coolers, are typically used in refineries, often operated together with our shell & tube heat exchangers and distillation columns. Other areas of application include the steel industry and power stations, as long as the outlet temperature is higher than the ambient air temperature.

Simple and Elegant Design

Process fluid passes through one or more tubing bundles. Heat is transferred away from the fluid through means of large fans that are either installed below (forced draft) or above (induced draft) the tubing. Aluminum fins attached to each tube enlarge the surface area of the air cooler bundle, significantly increasing the effectiveness of the heat transfer.

Benefits of Forced Draft Air Coolers

  • Lower energy consumption
  • Suitable for higher inlet temperatures
Benefits of Induced Draft Air Coolers

  • More even air flow across the tube bundles
  • No recirculation of hot air

This simple and elegant design makes Gireesh air coolers very easy to maintain and ensures a long service life.

We Build Great Air Coolers

Refinery equipment is what we are good, and with many years of experience, we able to design and build every component of your refinery system, including shell and tube heat exchangers and distillation towers.

We know what is important and where the pitfalls are. This enables us to tailor each air cooled heat exchanger to your specific requirements and make sure it is delivered in full compliance with the specifications.

 

Multi Compressor Chiller

Multi Compressor Chiller - 1

Multi Compressor Chiller

Multi Compressor Chiller contains number of compressors & variable speed drive for smooth functioning. It is used in various industries for chilling purposes like pharmaceutical, chemical, soap, food processing, beverage and many more. This Multi Compressor Chiller is manufactured by our experts by making use of the finest quality components and modern technology at our high-end production unit.

Scroll compressors perform at higher efficiency levels than reciprocating compressors. The compressors operate without cylinders, pistons or valves so it offers:

Inside the scroll compressor, two spiral-shaped members fit together forming crescent shaped gas pockets. One member remains stationary while the other orbits relative to first. This movement draws gas into the outer pocket and seals off an open passage. As the spiral movement continues, gas is forced toward the center of the scroll design, creating increasingly higher gas pressures.

With several pockets of gas simultaneously compressing, you receive a nearly continuous compression cycle. Gas discharges from a port at the center of the fixed scroll member. With both radial and axial compliance, the scroll members wear in rather than wear out.

 FEATURES :

  • Cooling Capacity from 11 to 96 tons (50 Hz).
  • Hermetic scroll type operating at 2950 RPM(50Hz).
  • Proven high efficiency ,low noise and high reliability compressor.
  • Two or multiples scroll compressors with minimum two independent refrigerant circuits.
  • A  large surface area copper tubes- aluminum fins condenser coil for efficient heat transfer.
  • Weatherproof  casing constructed from heavy gauge galvanized steel coated with epoxy polyester paint.
  • A compact braze plate heat exchange used as cooler.
  • Two or multiple axial propeller fan with direct drive induction motor.
  • Factory packaged  and pre-wired power and control panel.
  • A microprocessor based controller for capacity steps modulation and safety precautions.
  • Compressor and Condenser Fan motor protection as a safety controls.
  • Suitable for outdoor installations with free and un-ducted condenser fans air discharge.

 

Salient Features :

• Robust construction
• High durability
• Superior performance
• Energy efficiency
• Low maintenance and high reliability
• Low noise and vibration levels
• Low space requirements
• Relatively low weight

Cold Room Chiller

Gireesh Cold Room Chillers

Cold Room Chiller

A cold room is a walk-in storage facility. Safe operation of cold rooms in restaurants, hotel, food shops and supermarkets is crucial for preserving the quality of the stored foods. The application of cold rooms are numerous, including packaging of foods and beverages, short and long term food storage as well as freezing. For each application you need a customized solution to meet the exact demands for refrigeration.

In the Danfoss product range, you will find a wide range of compressors, mechanical controls and electric controls to suit the varying capacities, temperatures and processes of different cold room applications – for plugin or remote installation. Our solutions in general are energy efficient, low-noise and low-maintenance.

Cold Room Chiller For specific purposes you will find the following components in the Danfoss portfolio : –

  • MCX and OPTYMA™ range controllers, suitable to automate the process of ripening, defrosting and cooling
  • Expansion valves, filter driers, ball valves, sight glass, pressure switches and pressure regulators maintain the desired temperature in the cold room
  • Solenoid valves enable efficient hot-gas defrost
  • Micro-channel heat exchangers save energy and refrigerant of condensing units
  • Fan-speed controllers save energy at varying ambient temperatures and inside loads
  • Fixed speed and inverter compressors to optimize the core of your system

Panels for Cold Room Chiller : –

Pre-fabricated, insulated, metal laminated panels best suited for freezing and chilling

  • Rigid polyurethene Foam (RPUF) insulation
  • Pre-painted Galvanised Steel (PPGS) or Stainless Steel (SS) metal laminate
  • Insulation thickness from 60mm up to 200mm
  • Panel width of 1200mm
  • Panel length up to 12500mm
  • Joinery through camlock and finished with a silicone sealant

 

State-of-the-art refrigeration in Cold Room Chiller : –

  • Hermetic or semi-hermetic compressors
  • Air-coled or water-cooled condensation systems
  • High efficiency evaporators equipped with auto defrost features
  • Hot gas defrost
  • All metallic casings are in galvanised steel with powder-coating finishes. This enables them to withstand H500 SS test
  • Safety systems like high and low pressure cutouts, microprocessor-based thermo controls
  • Drain-tray and drain-pipe heaters
  • Vibration eliminators in refrigerant piping
  • Temperature controllers
  • Humidification systems with indicators and controllers

Lab Chillers

LAB CHILLER

Lab Chillers

Identis designs chiller manufacturers in India . We are sourcing the chillers for the purpose to keep chillers cools in the heaters. We are focused design the innovative ideas and design with suitable adjustable mechanical devices.The chillers are the mechanism which is used to remove heat from a liquid via a vapor-compression. This products are majorily used in the laboratories, scientific research, etc.

The advantage of the Chiller Manufacturers

  • Effective turbulent cool
  • Efficient methodology used
  • Controls heating before reaching max heat flow
  • Easy to use
  • Adjustable easily to rotavapor
  • Safety
  • Cost effective.
  • Freezes at lesser time
  • Saves power consumption

    This range of National Lab recirculating chillers is especially designed for use in laboratories or pilot plants with laboratory-type conditions.

    Apart from catering to the space constraints and pump performance requirements, they also take account of the demands for lowest possible noise emission.

    These recirculating chillers are also supplied as compact, ready-to-install appliances for cooling liquids within a circuit.
    As is the case with recirculating chillers, they use water or water with additives as the liquid (cooling medium).

    Laboratory recirculating chillers have a similar construction and function to recirculating chillers for cooling water. Depending on their design, they can be used as both atmospherically open and closed versions. They are therefore also suitable for cooling open baths as are frequently used in laboratories.
    Wherever small cooling capacities of 300 W to approx. 2 kW are required, laboratory recirculating chillers are used for cooling laboratory apparatus, distillation and extraction systems, but also in spectroscopes, X-ray equipment and many other applications.

    Due to their compact design and ease of use, our laboratory recirculating chillers are now also found in numerous industrial applications where suitable conditions prevail.

Schematic diagram of recirculating chillers

Single-circuit system including tank

 

single-circuit system with tank

Food Processing Chillers

 

Food Processing Chillers

 

In the food and beverage industry, industrial sized food processing chillers are used every day to cool food and liquids like dairy products to a specific temperature. These temperatures are necessary to keep products fresh and prevent health risks, but they are also important for businesses like bakeries that need key ingredients to be kept cool. Any restaurant that sells soft serve ice cream, for example, needs a chiller to keep the ice cream at a constant temperature to maintain its consistency. Unlike a refrigeration unit which wastes the heat that its motor produces while cooling the inside; a chiller uses a heat exchanger to cool equipment by circulating liquid.

 

Water chillers are the most common type of chilling equipment found in most food and beverage businesses. These units circulate water through a heat exchanger to cool whatever is contained in them and maintain a constant temperature. An exterior control system allows operators to manage the unit and set the desired temperature. This kind of technology is used to cool soft drinks, baking mixes, wine, sauces, soups and more. Large food processing chillers can be found in factories where food is being prepared for packaging and shipment to grocery stores and distribution centers. A chiller is important during the wine making process to develop a consistent taste and create the best possible product. Too much variation in temperature during fermentation could lead to a ruined batch, particularly if the temperature becomes too warm.

 

A food processing chiller is usually made using stainless steel so that it can be easily wiped down and kept clean to ensure that food and safety standards for cleanliness are maintained at all times. In food manufacturing facilities, a chiller only represents a small fraction of the necessary processing equipment, but it is essential to the reliability and precision of the final product. Dairy processing facilities use large chillers to keep milk from spoiling before it is bottled, and any cafeteria that has milk on tap will store the milk in a chilling machine that keeps it at a steady temperature before it is consumed.

Industrial Chillers

Chiller

Industrial chillers

Industrial chillers are classified as a refrigeration system that cools a process fluid or dehumidifies air in commercial and industrial facilities.  A chiller will use either a vapor compression or absorption cycle to cool.  Chilled water has a variety of applications from space cooling to process uses.

Types of Industrial Chillers : –

A chiller is rated between one to 1000 tons of cooling energy.  There are three different types of chillers :-

(1) Air,

(2) Water,

(3) Evaporative condensed chiller.

There are four subcategories in each of the above categories for industrial chillers:  –

(1) Reciprocating,

(2) Centrifugal,

(3) Screw driven

(4)  Absorption chillers.

The first three types are mechanical chillers which are powered by electric motors, steam, or gas turbines.  An absorption chiller is powered by a heat source such as steam and uses no moving parts.

Components of an Industrial Chiller
The mechanical compression cycle has four basic components through which the refrigerant passes: – 

(1) The evaporator

(2) The compressor

(3) The condenser

(4) The expansion valve.

The evaporator in the chiller will operate at a lower pressure and lower temperature than the condenser.

Prominent features

  • Highly reliable reciprocating  : –  Compressor packages from Europe, Japan and US
  • Environment friendly  : –  Very stable and operation friendly refrigerant R-404A
  • Factory assembled  : – And tested equipment with the option to dismantle and re-commission at site, in case of very large sizes
  • Customized as per  : – The extreme and sensitive environmental conditions, factory inspected and certified
  • Electronic expansion  : – Valves for increased efficiency and precise temperature control
  • Factory made and tested  : – DX and Flooded evaporators, made as per highest international standards of manufacturing
  • High fouling factors : –  Increased condensing area, extra tube thickness and high-flow design, for highest energy efficiency, higher operational reliability and easier maintenance
  • Low FPI count and high : –  Condensing area together with low noise, high flow, pressure-controlled axial fans, ensuring best possible energy efficiency while being operable within the harshest ambient conditions
  • Stepped capacity : – Control from 25% to 100% adapting precisely to varying process loads
  • Fully automatic PLC : – Based units with remote operation and data logging facilities
  • Customized turnkey  : – Cooling solutions available

 

Aluminium Heat Exchangers

Aluminium Heat Exchangers

Aluminum Tube and Fin Heat Exchangers

The most common design of a Heat Exchanger today is the fin and tube heat exchanger. Pole Star recommends a solution using aluminium fins and specific aluminium tubes, as an obvious alternative over the copper tube. As illustrated, the aluminium tubes are first inserted into a stack of fins. The tubes are pre-bended in hair-pin shape. After insertion, the tubes are expanded. The expansion secures the thermal contact between tube and fin. Afterwards, U-bends are brazed to the tubes.

Features

  • for applications including storage, process, comfort cooling, steam distrubiting, preheat, boosters, reheat, duct heaters, process air and gas heaters, fluid process heat, glycol heating, hot water application and more
  • avaliable in all sizes shapes, capacities, circuit patterns, mainfolds, thread fittings on manifolds, fin / tube configurations
  • avaliable from 1 to 12 rows deep and from 6 to 21 fins per inch
  • for use with steam / hot water / chill water / hfc’s and non hfc’s
  • manifold / connection ends of copper for easy installation / copper to copper brazing  in the system.

 

Compared to a traditional HVACR copper tube/aluminium fin heat exchanger, this provides:

  • A lighter heat exchanger
  • Better corrosion resistance, due to a better galvanic balance of the materials
  • More cost-effective heat exchanger

Aluminium as a material has major benefits.

  • Cost
  • Weight
  • Corrosion
  • Heattransfer

Aluminium as a material has major benefits that we can’t keep secret any longer. 

  • Price Aluminium remains one of the most cost-effective materials you can use, with outstanding properties which enable considerable savings – it is two-to-three times cheaper than copper – and significant technological improvements.
  • Performance Using aluminium in HVACR applications improves system weight significantly. You save space and, also, in the case of a brazed heat exchanger, refrigerants. Further, you will gain a highly corrosion-resistant material with suitable alloys.
  • Sustainability Due to its material properties, aluminium lasts longer than other materials when used in an appropriate way. More than that, we view the increased recycling of aluminium as important for resource preservation.
  • Manufacturing Aluminium keeps adding benefits at the manufacturing stage by presenting easy forming abilities.