Air vs. Water Cooled Chillers

Author: Mirabella

Oct. 28, 2024

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When it comes to choosing the ideal chiller for data centers, the decision often lies between air-cooled and water-cooled chillers. The right choice isn't straightforward, as various factors must be considered. HVAC system designers should evaluate unique project requirements such as available space, backup power plans, local regulations on energy and water usage, and the owner's environmental goals.

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It is crucial for data centers to collaborate with HVAC specialists early in the design process, ensuring the chosen solution aligns with both immediate and future goals. Familiarizing oneself with the benefits and drawbacks of each chiller type can help make informed decisions.

Capacity: Air-cooled chillers generally range from 7.5 to 500 tons [25 to 1,580 kW], while water-cooled chillers provide capacities from 10 to 4,000 tons [35 to 14,000 kW]. This indicates that water-cooled chillers can achieve higher cooling capacities with fewer units, ultimately needing less space.

Maintenance: One of the advantages of air-cooled chillers is that they eliminate the necessity for cooling towers. Conversely, water-cooled chillers come with cooling towers that require significant maintenance. This involves water treatment, cleaning of condenser tubes, mechanical upkeep of the towers, and freeze protection measures. Systems utilizing open cooling towers need a water treatment program to guard against bacteria and algae. Additionally, cooling towers evaporate water, necessitating access to ample amounts of make-up water to replace losses.

Location: The quest for affordable power and reduced taxes is reshaping the data center landscape, often leading to massive facilities being established in remote areas. In cold climates, air-cooled chillers can be more practical because they bypass the complications arising from operating cooling towers during extreme winter conditions, which may need special controls, heating solutions, or even indoor basins.

Energy Efficiency: Generally, water-cooled chillers demonstrate higher energy efficiency compared to their air-cooled counterparts. The refrigerant's condensing temperature in air-cooled chillers reacts to the ambient dry-bulb temperature, while in water-cooled chillers, it relies on the condenser-water temperature influenced by the ambient wet-bulb temperature. Given that the wet-bulb temperature is usually lower than the dry-bulb temperature, water-cooled chillers can operate at reduced condensing temperatures and pressures, demanding less energy from the compressor. However, this efficiency may fluctuate during night hours when the dry-bulb temperature decreases more swiftly than the wet-bulb temperature.

Delivery & Installation: Most air-cooled chillers come as 'packaged systems', meaning the entire system, including the condenser, compressor, and evaporator, is pre-configured at the factory. This streamlines design, delivery, and installation. Water-cooled chillers, however, introduce complexities relating to condenser-water piping, pumps, cooling towers, and controls.

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Longevity: Given the rapid advancements in technology and the growing demands for data processing, data center infrastructure must consistently deliver dependable performance. In general, air-cooled chillers have a lifespan of about 15-20 years, while water-cooled chillers can last 20-30 years. This difference is largely attributed to the installation environment: water-cooled chillers are typically housed indoors and operate at lower pressures, whereas air-cooled chillers function outdoors at higher pressures.

Water conservation: Choosing between air-cooled and water-cooled chillers should also factor in water availability, costs, treatment requirements, and potential construction inconveniences. Since air-cooled chillers do not rely on water, they are often favored in locations where water is scarce or costly.

In summary, air-cooled chillers offer benefits such as lower maintenance costs, easier design and installation due to their packaged nature, and superior performance in freezing conditions. In contrast, water-cooled chillers present advantages like improved energy efficiency, larger capacities, and longer lifespans. Ultimately, the best choice will depend on various specific decision criteria. It is vital for data centers and system designers to consider all relevant factors to ensure that the selected chiller meets long-term objectives.

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