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
- Chiller = 2.4 Gallons per Minute / ton
- 1 ChillerTon = 12,000 BTU / hr
- Chiller Ton = GPM x ΔT / 24
- 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, Profile, 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 Polyolefins = 1 ton (minimun Flow is 4.8 GPM / ton)
- MACHINE
- Hydraulics = .1 ton / Horsepower
- 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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