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Process Cooling System Chiller and Tower Sizing Formuals

This document provides formulas and guidelines for sizing chillers, cooling towers, and determining cooling loads for various industrial applications including injection molding, extrusion, blow molding, and die casting. It includes formulas for calculating tower tons and chiller tons based on GPM and temperature difference. It also lists common material throughput rates that equal 1 ton of cooling load for different plastics and manufacturing processes. Additional guidelines cover load sizing for equipment like air compressors, vacuum pumps, machine tools, and more.

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Chuen Hau Tan
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225 views2 pages

Process Cooling System Chiller and Tower Sizing Formuals

This document provides formulas and guidelines for sizing chillers, cooling towers, and determining cooling loads for various industrial applications including injection molding, extrusion, blow molding, and die casting. It includes formulas for calculating tower tons and chiller tons based on GPM and temperature difference. It also lists common material throughput rates that equal 1 ton of cooling load for different plastics and manufacturing processes. Additional guidelines cover load sizing for equipment like air compressors, vacuum pumps, machine tools, and more.

Uploaded by

Chuen Hau Tan
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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CHILLER AND TOWER SIZING FORMULAS


TOWER SYSTEM DESIGN FORMULAS Cooling Tower = 3 GPM per ton 1 Tower Ton = 15,000 BTU/hr Tower Ton = GPM x T/30

CHILLER SYSTEM DESIGN Download Now


1 P age doc ument with full c olor. A c robat P D F file. Size: 3 7 KB.

Chiller Tower = 2.4 GPM / ton 1 ChillerTon = 12,000 BTU / hr Chiller Ton = GPM x T / 24

LOAD SIZING FOR INJECTION MOLDING APPLICATIONS MATERIAL 30# / hr H.D. Polyethylene = 1 ton 35# / hr L.D. Polyethylene = 1 ton 35# / hr Polypropylene = 1 ton 45# / hr PVC = 1 ton 50# / hr ABS = 1 ton 50# / hr Polystyrene = 1 ton 40# / hr Nylon = 1 ton 35# / hr Acrylic = 1 ton 40# / hr Polyurethane = 1 ton 50# / hr Acetal = 1 ton 40# / hr PPO = 1 ton 40# / hr PET = 1 ton 50# / hr Polycarb = 1 ton MACHINE 3Hydraulics = .1 ton / HP Feed Throat = 1/2 ton each

LOAD SIZING FOR EXTRUSION APPLICATIONS : Pipe, Profile, and Sheet MATERIAL 50# / hr H.D. Polyethylene = 1 ton 50# / hr L.D. Polyethylene = 1 ton 50# / hr Polypropylene = 1 ton 75# / hr Polystyrene = 1 ton 70# / hr PVC = 1 ton MACHINE Extruder Barrel = .1 ton / inch Gear Box = 1 ton / 100 HP Feed Throat : diameter is < 3" = 1 ton Feed Throat : diameter is > 3" = 1 ton Air Ring Cooling @ 105 CFM = 1 ton (50F air @ 78F WBT)

LOAD SIZING FOR BLOW MOLDING APPLICATIONS MATERIAL 40# / hr Polyolefins = 1 ton Minimun Flow is 4.8 GPM / ton MACHINE Hydraulics = .1 ton / inch Feed Throat = 1/2 ton

LOAD SIZING FOR OTHER EQUIPMENT Air Compressors with no after cooler = .1 ton / HP Air Compressor with after cooler = .2 ton / HP Vacuum Pump = .1 ton / HP Machine Tools = .1 ton / HP Water-Cooled Chillers = 1 ton tower for 1 ton chiller Mold Temperature Controllers = 1.2 ton per zone (heating) Mold Temperature Controllers = use PPH chart (cooling) Barrel Cooling = Heat removal (BTU / hr) = 1 ton / inch screw diameter Spot Welders = 1/4 ton per tip (for chilled water) Plating Baths = Heat removal (BTU / hr) = DC amps x DC volts x 2.56 Mold Room Heating = 25 BTU / sq.ft. with 16' ceiling

Non Mold Room Heating = 50 BTU / sq.ft. with 16' ceiling Mold Room Air Conditioning = 80 sq.ft / ton with 16' ceiling

LOAD SIZING FOR DIE CASTING Zinc = Heat removal (BTU / hr) = M x 35 BTU / lb M = throughput rate (lbs / hr) Pour at 800F Remove at 300F Aluminum = Heat removal (BTU / hr) = M x 35 BTU / lb M = throughput rate (lbs / hr) Pour at 1200F Remove at 900F

CHILLER CAPACITY LOSS For each 1F below 50F LWT = 2% of rated chiller capacity

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