I once had an employer who always said there were no problems, only challenges. You might say that this month’s issue of Process Cooling follows that same optimistic and motivational approach. This month’s authors provide you with solutions and guidance for more than one cooling process challenge.

Challenge No. 1: Debris in Cooling Towers.Water-cooling towers often use fixed-sump screens to protect circulation pumps and downstream exchangers from leaves, pollen, dirt and any number of other contaminants, yet debris continues to vex maintenance personnel by causing pump failure and loss of heat exchanger efficiency. Traveling sump screens may be the solution, according to “A Traveling Solution to Cooling Tower Debris” by Michael D. Moreaux, vice president of Industrial Cooling Tower Services Inc., Baton Rouge, La.

Challenge No. 2: Moisture Damage to Insulation.Water is the most notorious enemy of any insulation system. For example, just four percent moisture in a below-ambient environment can reduce the insulation’s thermal efficiency by 70 percent and cause other difficulties that interfere with a smooth-running process. In “8 Tips for Choosing the Right Insulation,” sales manager Michael J. Irlbacher Jr., at Extol of Ohio Inc., Norwalk, Ohio, tells readers how to evaluate and choose an insulation system.

Challenge No. 3: Saving Energy but Losing Control.Cutting back on energy consumption is virtually every business’s concern, both for the environment and the bottom line. But two managers in Italy know that some operations such as food processing cannot be compromised in the effort.

Raffaele Calcagni, marketing manager at Ascon SpA in Baranzate, and Gianni Lenoci, R&D manager for Otiz srl in Bari, note in “Improved Control for High-Efficiency Cooling” that manufacturers of food storage refrigeration equipment have developed solutions that combine energy savings with the ability to obtain the highest quality products.

Challenge No. 4: Moving Large Amounts of Air.Oversized ceiling fans are relatively energy efficient, move large volumes of air, and are effective in some work environments for comfort and space cooling. However, Jim Whittle, director of marketing at Patterson Fan, Blythewood, S.C., explains in “Hybrid Equipment Cooling,” that these fans may not meet the stringent demands of equipment and process cooling. For those, a hybrid fan that incorporates a “gill” might provide a better solution.

Challenge No. 5: Pipe Corrosion in Ammonia Systems.Jim Young, an application technology leader for at Dow Chemical Co., Midland, Mich., looks at insulation for ammonia refrigeration systems. In “High-Performance Insulation for Ammonia Refrigeration, he explains how to protect the cold surfaces inherent in ammonia refrigeration systems, which will naturally attract water vapor from the warmer and moister surroundings, before they lead to corrosion.

Challenge No. 6: Condensation in Food Processing Rooms.Just about all food processors are familiar with the risk and food safety dangers associated with having moisture droplets form over products that are being processed for human consumption. It’s essential to prevent this condensation. In “Controlling Condensation,” sales manager Kevin Smith at Concepts and Designs Inc., Wixom, Mich., presents the basics needed to understand why condensation occurs in food processing rooms and describes different control technologies.

Challenge No. 7: Getting What You Pay For. According to Phil Gatto in “Reliable Refrigeration,” budget-priced chillers need to be looked at carefully. The sales and marketing director at Standard Refrigeration in Melrose, Ill., says that the evaporator is a crucial component of any industrial refrigeration system. A low-price chiller system sometimes ends up costing substantially more over its life in operating and maintenance costs. Gatto describes three key areas to evaluate: efficiency, durability and serviceability.

Anne Armel
Group Publisher