Chiller Fluid Options for Year-Round Operations

Maintaining an optimal cooling throughout the year requires a chiller fluid that can withstand extreme working conditions – from cold to high heat rejection requirements.

The fluid should handle varying cooling loads, offer superior heat transfer, prevent biological fouling or even pipe bursts.

In case you are wondering which chiller fluid can fit your systems, our engineers will share various options you should consider.

What is a Chiller Fluid?

Every chiller has a specialized fluid flowing through its systems’ channels or tubes allowing for efficient heat transfer. That is, it absorbs and dissipates heat to maintain the desired working temperature.

Factors Determining Chiller Fluid Suitability for Year-round Operations

• An all-year-round chiller’s freezing temperature should be lower, with the typical freezing point falling between 10 and 20 °F.
• Chiller fluids should maintain relatively low viscosity when exposed to cooler temperatures for consistently good circulation and heat transfer.
• These fluids should have the right balance of water, which is an excellent conductor of heat. It also requires a precise amount of glycol that prevents freezing without impacting heat transfer efficiency
• Given its permanence and utilization all year round, the chiller fluid you choose should be compatible with the material used to construct the chiller. Corrosion inhibitors are also incorporated into the mixture to prevent the fuel from reacting with the surfaces.
• Consider your specific application requirements and consult local regulations to ensure your operations are up to standard. For example, for consumable products such as food, pharmaceutical products, and beverages, you will require chiller fluid that is food-grade.
• A suitable chiller fluid designed for year-round use should be chemically stable under a wide range of operating temperatures. It should be able to withstand breakdown and have a balanced inhibitor level and PH.

Types of Chiller Fluid Suitable for All Year-round Operations

Glycol–Water Mixtures

· Ethylene Glycol/Water

Ethylene glycol is typically incorporated in water and offers you elevated heat transfer and a lower viscosity, making it highly efficient when it comes to power consumption. These properties allow the chiller fluid to cool more efficiently while utilizing less power to circulate the fluid.

Ethylene glycol has a higher inhibition capacity when it comes to freezing, allowing you to utilize minimal quantities effectively. The fluid is, however, very toxic and, as such, is only suitable for industrial applications that do not involve consumed products. The system used should also have no leaks.

You can also explore our Glycol vs water chillers.

· Propylene Glycol/Water

For consumed products, propylene glycol and water are the best combination for chiller fluid, as it is available in food-grade variations. This fluid features a higher viscosity, which impedes flow and heat transfer, and consumes a lot more energy to pump it. You will need to incorporate a larger amount of 2-4% propylene glycol to attain the same freezing capability Ethylene affords you.

Selecting Glycol Concentration

When determining the right percentage of glycol concentration to incorporate into your chiller water, the aim is to utilize the least amount of glycol while maintaining optimal functionality.

Specialty and Alternative Year-Round Fluids

· Engineered Heat Transfer Fluids

These refer to specially engineered fluids composed of synthetic or semi-synthetic liquids. Engineered heat transfer fluids are designed to give set results under a specific range of temperature. Unlike other year-round chiller fluids, this variation is formulated for applications and manufacturing processes that operate at a specified temperature, and therefore, accuracy is vital.

The liquid features elevated thermal stability as well as controlled viscosity, which makes them ideal for industrial applications. It also has elevated corrosion resistance, which allows it to be used all year round.

· Salt Solutions

Inorganic salts such as calcium chloride or sodium chloride brines can be incorporated in water to form a salt solution chiller fluid. The inorganic salts added lower the freezing temperature of water, allowing it to be used for external application in areas that experience lower temperatures.

The salt nature of this chiller makes it corrosive to various materials typically incorporated in systems requiring chillers. As such, it requires the use of stronger materials and more intense use of inhibitors. Careful maintenance is required to prevent the system from rapidly deteriorating.

· Oils for High-Temperature Process Chillers

Oils, both synthetic and mineral, can be used as chiller fluids for applications involving extreme temperatures that cannot be handled by water or glycol. Oils used as a chiller fluid have the ability to remain liquid and stable despite exposure to high temperatures. They are more viscous but have limited heat transfer compared to water.

Their elevated viscosity requires more power as it requires more energy to keep the fluid circulating in the system. It also requires specialized equipment to optimally function.

· Low-Temperature Specialty Fluids

This type of chiller fluid can be obtained from various materials, but is typically designed using synthetic fluids, organic fluids, silicone-based fluids, or specialty glycols. Low – temperature specialty fluids are specifically designed to handle heat loads in low temperature operating conditions.  They are used in situations where the liquid is exposed to temperatures below the freezing point of both water and glycol.

Application-Specific Chemical Fluids

There are chemical sensitive application that require a very specific type of chiller for optimal functionality. Parameters such as compatibility, toxicity, purity, and flammability are typically considered when selecting the most suitable variation.

In such instance, the chiller fluid to be used is considered in the initial design of the system it is to be used in to ensure safety of the system and its users, as well as efficiency and accuracy.

· Dielectric (Non-Conductive) Fluids

For an electrical application involving the chiller fluid directly coming into contact with electrical components, high voltage parts, or even power equipment, this type of fluid is the most suitable. Dielectric fluids are non-conductive and, as such, will not react with the system or affect its operations. This type of fluid features great thermal stability as well as compatibility with a wide range of materials.

Water and Water-Based Fluids

· Treated water

Treated water is a common choice for chiller fluid used for a broad range of applications. There are different types of treatment the water is subjected to, depending on its intended application, such as filtering, softening, or deionizing. This type of chiller fluid has an elevated capacity, which, when combined with superior thermal conductivity, makes the fluid very efficient in heat transfer and energy consumption.

Treated water is cost-effective and easily available, but it has a relatively low freezing point and is therefore best suited for mild climates or indoor applications. Chemical treatments are also done to inhibit corrosion, the growth of microorganisms, and scaling.

· Proprietary Water-Based Heat Transfer Fluids

This is a chiller fluid that is primarily composed of water, but with an additional optimized blend of treatments that make it suitable for specific applications. The additives incorporated in this type of chiller fluid include trace amounts of glycol, pH buffers, biocides, and corrosion inhibitors.

Unlike treated water, this variation offers elevated resistance against corrosion for a longer period, longer service life, and a more enhanced stability during exposure to chemicals. It is best suited for applications that require elevated electrical resistivity.

FAQs

How do I choose between ethylene glycol and propylene glycol?

For industrial applications and a cost-friendly option, ethylene glycol is a suitable option. For consumable products such as food, drinks, and pharmaceutical products, the food-grade propylene glycol is best suited.

Can I use plain water in a year‑round chiller?

Plain Water is not a good choice for a year-round chiller, as it will freeze when subjected to low temperatures, which can damage the whole system.

How to determine the compatibility of a chiller fluid with your system?

Consult both the machine’s material specifications and compatibility as well as the fluid’s specifications to ensure that it is suitable for you.

Is chiller fluid for year-round operations sustainable?

Year-round chiller fluid can be considered sustainable as it is designed for prolonged use and, if well maintained, helps cut energy costs.

How often should chiller fluid be tested or replaced?

Basic tests should be conducted weekly or monthly, and lab tests can be carried out 2 to 4 times a year.

Partner with Chillerone Today

Choosing the right fluid for your chiller systems can be an overwhelming task. The good news is that Chillerone engineers are here to help you get the right chiller design, accessories and fluids.

We have supplied chillers in many regions across the globe – from the U.S.A., Europe, Asia and Africa. Our chillers guarantee all year round operations, even with varying temperature and cooling loads.

Tell us more about your project cooling requirements and our engineers will help size the chiller design – talk to Chillerone engineers now.