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Process Cooling System Chiller and Tower Sizing Formulas
TOWER SYSTEM DESIGN FORMULAS
Cooling Tower = 3 Gallons per Minute per ton
1 Tower Ton = 15,000 BTU/hr
Tower Ton = GPM x ΔT/30
CHILLER SYSTEM DESIGN
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Chiller = 2.4 Gallons per Minute / ton
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1 ChillerTon = 12,000 BTU / hr in full color.
Chiller Ton = GPM x ΔT / 24 Acrobat PDF
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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
LOAD SIZING FOR INJECTION MOLDING APPLICATIONS : MACHINE
Hydraulics = .1 ton/Horsepower
Feed Throat = 1/2 ton each
LOAD SIZING FOR EXTRUSION APPLICATIONS : Pipe, Pro le, 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 of screw diameter
Gear Box = 1 ton / 100 HP
Feed Throat : diameter is < 3" = 1 ton
Feed Throat : diameter is > 3" = 2 ton
Air Ring Cooling @ 105 CFM = 1 ton (50°F air @ 78°F WBT)
LOAD SIZING FOR BLOW MOLDING APPLICATIONS
MATERIAL
40# / hr Polyole ns = 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 = .2 ton / HP
Machine Tools = .2 ton / HP
Water-Cooled Chiller = Each ton of chiller requires 1 ton of cooling tower
Mold Temperature Controllers = 1.2 ton per zone + .2 ton/horsepower (heating)
Mold Temperature Controllers = use PPH chart + .2 ton/horsepower (cooling)
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 95 BTU / lb
M = throughput rate (lbs / hr)
Pour at 800°F
Remove at 300°F
Aluminum = Heat removal (BTU / hr) = M x 325 BTU / lb
M = throughput rate (lbs / hr)
Pour at 1200°F
Remove at 900°F
CHILLER CAPACITY LOSS
For each 1°F below 50°F LWT = 2% loss of rated chiller capacity
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