Size your process chiller correctly. Input your heat load source, flow rate, and temperatures to see required tonnage, air-cooled vs water-cooled comparison, and energy costs.
Select the type of heat source
Water returning from process
Water leaving chiller
Peak outdoor design temp
0% for pure water
Calculated Cooling Load
41.7 tons
Delta T: 20F, Glycol factor: 1
Required Capacity (with safety)
50 tons
Includes 20% safety margin
Recommended Type
Air-Cooled
Source Heat Load
28.4 tons
From process kw
| Metric | Air-Cooled | Water-Cooled |
|---|---|---|
| Equipment Cost Range | $60,000 – $100,000 | $50,000 – $95,000 |
| Efficiency | 1.2 kW/ton | 0.65 kW/ton |
| Annual Energy (kWh) | 360,000 | 195,000 |
| Annual Energy Cost | $36,000 | $19,500 |
| Annual Energy Savings | --- | $16,500/yr |
| Water Consumption | None | 1.5 GPM (540k gal/yr) |
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Proper chiller sizing requires accurate heat load data. Undersizing leads to process temperature instability; oversizing wastes capital and energy. The 20% safety margin accounts for ambient temperature spikes, fouled heat exchangers, and future capacity needs.
| Factor | Air-Cooled | Water-Cooled |
|---|---|---|
| Upfront cost | 30% higher | Lower |
| Efficiency (kW/ton) | 1.0 – 1.4 | 0.5 – 0.8 |
| Water consumption | None | 2–4 GPM per ton |
| Maintenance | Lower | Higher (water treatment) |
| Best for | <200 tons, water-scarce | >200 tons, efficiency critical |
Adding glycol reduces heat transfer capacity. A 30% propylene glycol solution reduces capacity by approximately 12-15% compared to pure water due to lower specific heat and higher viscosity.