Canadian Finishing & Coatings Manufacturing Magazine Jan/Feb 2023 - 60

PLATING AND ANODIZING: CHILLERS
Are there other ways to reduce
costs in process cooling
systems?
TS: I've already mentioned a couple
ways, but there are quite a few.
Using a variable speed compressor
design avoids wasting energy while
the system is not operating at full
load. The other is dividing your
cooling loads based on the required
temperature from the chiller
system. Another solution that can
often be neglected is preventive
maintenance for the chillers. Many
chillers are air-cooled which means
the heat is rejected from the system using forced air through
a condenser. If that condenser coil is dirty, the whole system
operates less efficiently.
Has there been a recent demand in specific systems?
If so, why?
TS: More and more systems are being installed outside of the
facility. This is primarily driven by availability of space inside.
Installing a chiller system outside is a great solution, but you
need to ensure the system is properly designed for the climate
and geographic considerations, such as proximity to a coastline
or elevation.
What are the benefits of having an external heat
exchanger?
TS: An external heat exchanger is easier to service for
maintenance issues. Thermal Care has designs that utilize a
three-way modulating valve to bypass the heat exchanger based
on the acid temperature leaving the heat exchanger. This can
control a system well within +/- one deg. F (-17 deg. C). The
heat exchanger's primary purpose is to isolate the bath from the
coolant. These two fluids cannot mix.
How important is it to regulate the temperature of
rectifiers and tanks throughout the process?
TS: This is extremely important. Ultimately, if energy imparted
to a system is not removed, it will overheat. The parts produced
during this time would likely not conform to spec or worse the
entire process could be shut down.
In terms of pump technology, how do these pumps stand
up to corrosive materials over time?
TS: Thermal Care's primary responsibility in the system is the
coolant pump which is handling the circulation of the water or
water/glycol mixture. These are stainless steel pumps usually
with totally enclosed, fan-cooled (TEFC) motors. These are
robust pumps designed to withstand harsh industrial
environments. Thermal Care works directly with its pump
suppliers to specify the type and concentration of the acid to
ensure the design is able to handle the fluid without damage.
Lastly, do you have any process tips for maintaining these
systems?
TS: I mentioned that, preventative maintenance is very
important for the chiller systems. The air-cooled systems can get
dusty or dirty and require cleaning to keep the system operating
efficiently. Additionally, there are strainers integral to the
chillers that should be check and cleaned regularly. Maintaining
good water or water/glycol quality is extremely important for the
operation and longevity of the chiller system's equipment.
60
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Canadian Finishing & Coatings Manufacturing Magazine Jan/Feb 2023

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