Dry Cooler for Molding Industrial Processes Free Cooling System

Dry Cooler for Molding Industrial Processes Free Cooling System

Dry coolers (dry cooling towers) are highly suitable for free cooling systems in molding industrial processes, as they can efficiently reduce process fluid temperatures without consuming water, while aligning with the low-to-medium cooling demand characteristics of molding operations.

Core Advantages for Molding Process Free Cooling

Water-saving & Low Environmental DependenceMolding processes (e.g., injection molding, blow molding) often require cooling for molds or hydraulic oil. Dry coolers use air to exchange heat directly, eliminating the need for circulating water or spray systems. This avoids issues like water scaling, pipeline corrosion, and wastewater discharge, which is critical for regions with water shortages or strict environmental regulations.

Good Match with Free Cooling ConditionsFree cooling relies on low ambient temperatures (typically below 25°C) to replace mechanical refrigeration. Molding process cooling usually targets fluid temperatures of 30–50°C, and dry coolers can easily achieve this when ambient air temperature is low. This allows the system to switch to free cooling for long periods, significantly reducing energy consumption compared to traditional water-cooled chillers.

Adaptable to Harsh Workshop EnvironmentsMolding workshops may have dust, plastic fumes, or high temperatures. Dry coolers with corrosion-resistant coatings (e.g., epoxy) or stainless steel components can resist contamination. Additionally, their modular design allows flexible installation (e.g., outdoor rooftops, workshop exteriors) to avoid occupying production space.

Key Application Considerations

Cooling Capacity MatchingCalculate the total heat load of the molding process first (including mold heat, hydraulic system heat, and material preheating heat). Select a dry cooler with 10–15% excess cooling capacity to account for peak loads or high ambient temperature fluctuations.

System Switching ControlEquip the free cooling system with a smart controller to automatically switch between "dry cooler free cooling" and "mechanical refrigeration" based on ambient temperature and process fluid temperature. For example:

When ambient temperature ≤ 22°C: Use dry cooler alone for free cooling.

When 22°C < ambient temperature < 28°C: Use dry cooler + partial mechanical refrigeration.

When ambient temperature ≥ 28°C: Switch to full mechanical refrigeration.

Routine Maintenance Focus

Clean the finned coils monthly: Use compressed air or a low-pressure water gun to remove dust and plastic debris, preventing heat exchange efficiency degradation.

Inspect fans and motors quarterly: Check fan blade tightness and motor lubrication; replace worn bearings promptly (cost: ~$50–$100 per set).

Descaling annually (if using soft water for auxiliary circuits): Use weak acid cleaners to remove scale from pipelines, avoiding blockages.