CHEMICAL MANUFACTURING

Intelligent Jacket Cooling
Network for Chemical Processing

China • Chemical Manufacturing

≈60 kWCentral Process Cooling
7–25°CAdjustable Process Water
KAAir-Cooled Industrial Chiller
24/7Continuous Production
SYSTEM STATUS — OPERATIONAL
✓ Jacket Cooling System ✓ Multi-Tank Process Control ✓ Adjustable Water Temperature ✓ Closed-Loop Cooling Circuit
Lohabour China Jacket Cooling
≈60 kWCooling Capacity
7–25°CProcess Water
24/7Operation
KAChiller Model
PROJECT OVERVIEW

Engineering Brief

CustomerConfidential — NDA Protected
IndustryChemical Processing & Specialty Chemical Manufacturing
ApplicationReactor, Mixing & Emulsifying Tank Jacket Cooling
ENGINEERING OBJECTIVE

Design a reliable industrial cooling network capable of maintaining precise process temperatures between 7°C and 25°C while serving a reactor, mixing tank and emulsifying tank operating simultaneously — stable process temperatures, efficient removal of exothermic reaction heat, uniform cooling across every vessel, flexible temperature adjustment for different formulations, and continuous operation with minimal maintenance.

PROJECT SCOPE
  • ✓ Process cooling load analysis
  • ✓ Air-cooled chiller selection
  • ✓ Hydraulic distribution design
  • ✓ Closed-loop water circuit
  • ✓ Jacket cooling integration
  • ✓ Variable flow pump selection
  • ✓ PLC temperature monitoring
  • ✓ Commissioning & performance verification
View Full System Flow ↓
THERMAL NETWORK ARCHITECTURE

Factory Thermal Map

The full plant layout — heat rejection, generation, distribution, and return — with live flow direction. All three vessels are fed in parallel from the distribution manifold, so each receives chilled water at the same supply temperature.

Heat RejectionAmbient Air via Axial Condenser Fans
Thermal GenerationKA Air-Cooled Industrial Chiller
Hydraulic DistributionDistribution Manifold
Vessel 1Reactor Jacket
Vessel 2Mixing Tank Jacket
Vessel 3Emulsifying Tank Jacket
ConsolidationReturn Header
↺ Back to Chiller
THE PROCESS CHALLENGE

What Lohabour Was Called In To Fix

Heat generated during mixing and exothermic chemical reactions transfers through each vessel's jacket wall — three tanks running simultaneously, each with limited independent temperature regulation, made consistent process conditions difficult to hold.

BEFORE — INDEPENDENT COOLING CONTROL

  • Process temperature fluctuation during mixing and reaction
  • Uneven cooling distribution between tanks
  • No centralized system to equalize performance across vessels
  • Higher operating costs from multiple standalone cooling units

AFTER — ENGINEERED CENTRAL COOLING NETWORK

7–25°C
  • Stable chilled water supplied to all three vessels in parallel
  • Uniform jacket cooling across reactor, mixing and emulsifying tanks
  • Continuous circulation through a single closed-loop system
  • Automatic process temperature regulation, centralized maintenance
ENGINEERED SYSTEM MODULES

Not Equipment. Engineering.

01 Thermal Generation

KA Air-Cooled Industrial Chiller

Input

Variable thermal loads from the reactor, mixing tank and emulsifying equipment

Purpose

Produce adjustable chilled water for industrial process cooling

Result

Reliable chilled water supply with accurate control between 7°C and 25°C

02 Water Distribution

Closed-Loop Process Circuit

Input

Conditioned water supplied by the chiller

Purpose

Distribute chilled water evenly to all three tank jackets in parallel, with balanced hydraulic flow

Result

Consistent cooling performance across all production equipment

03 Jacket Heat Exchange

Reactor, Mixing & Emulsifying Tanks

Input

Heat generated during chemical reaction, blending and emulsification

Purpose

Remove excess heat through stainless-steel cooling jackets surrounding each vessel — each fitted with an agitator motor, feeding port and internal agitator

Result

Stable product temperatures and improved process repeatability

04 Intelligence Layer

PLC Temperature Monitoring

Input

Real-time temperature signals from every production vessel

Purpose

Automatically regulate chilled water temperature and circulation to match production requirements

Result

Reduced operator intervention, improved process consistency

HYDRAULIC DESIGN

Engineering Parameters

Chiller ModelKA Air-Cooled Industrial Chiller
Cooling Capacity≈60 kW
Process Water Temperature7–25°C Adjustable
Cooling MediumClosed-Loop Chilled Water
Compressor TypeHermetic Scroll Compressor
CondenserAir-Cooled Fin & Tube Condenser
Process EquipmentReactor, Mixing Tank & Emulsifying Tank
Heat TransferJacket Cooling
Pump SystemVariable-Speed Process Pump
Control SystemPLC + Digital Temperature Controller
Operation24/7 Continuous Industrial Duty
THERMAL CYCLE SIMULATION

Hydraulic Cooling Cycle

Heat rejected to ambient air ↑ Axial Condenser Fans
🧊
KA Air-Cooled Industrial Chiller
Scroll CompressorAir-Cooled Fin & Tube CondenserExpansion ValveEvaporator
🔀
Distribution Manifold
⚗
Reactor · Mixing · Emulsifying Jackets (Parallel)
↩
Return Header
🧊
Back to Chiller
7–25°CChilled Water Supply
AdjustablePer Formulation
SYSTEM ARCHITECTURE

Layered Automation Stack

INTELLIGENCE

Temperature Sensors · PLC Monitoring · Alarm Protection

CONTROL

Temperature Regulation · Variable Flow Control

HYDRAULICS

Distribution Manifold · Variable-Speed Pump · Piping

THERMAL CORE

KA Chiller · Axial Condenser Fans

DESIGN PERFORMANCE

Thermal Performance Dashboard

Design parameters, not live telemetry — figures reflect engineered targets for this system.

≈60 kW
Cooling Capacity
7–25°C
Process Water Range
3
Vessels Served in Parallel
100%
Closed-Loop Circuit
24/7
Operating Schedule
ENGINEERING RATIONALE

Engineering Decisions

Why an Air-Cooled Chiller?

Challenge

The project required an independent cooling solution without cooling tower infrastructure.

Decision

Select the KA air-cooled industrial chiller.

Benefit

Reduced installation cost, simplified maintenance, reliable performance for medium-temperature process cooling.

Why Jacket Cooling?

Challenge

The chemical process generates heat directly inside the production vessels.

Decision

Cooling jackets remove thermal energy uniformly around each tank wall, with no direct contact between cooling water and product.

Benefit

Precise temperature regulation while maintaining product purity.

Why a Closed-Loop Water Circuit?

Challenge

An open system risks contamination, higher water consumption, and unstable hydraulic conditions.

Decision

Implement a fully closed-loop water circuit.

Benefit

Improved reliability, lower operating costs, consistent cooling performance.

Why Centralized Cooling?

Challenge

Independent chillers per vessel duplicate equipment and maintenance effort.

Decision

One centralized cooling plant serves all three tanks through a common, parallel-fed distribution network.

Benefit

Lower maintenance requirements, better energy utilization, simplified future expansion.

PROJECT RESULTS

What This System Delivers

✓
Stable process water between 7°C and 25°CHeld continuously across all formulations
✓
Uniform cooling across reactor, mixing and emulsifying tanksBalanced parallel flow, equal supply temperature to every vessel
✓
Improved batch consistency and product qualityMore repeatable reactions, mixing and emulsification
✓
Reduced temperature fluctuations during productionAutomatic regulation replaces manual adjustment
✓
Simplified maintenance through centralized coolingOne system replaces multiple standalone units
✓
Reliable 24/7 industrial operationContinuous production with no cooling downtime
✓
Energy-efficient closed-loop architectureLower water consumption, stable hydraulics
ENGINEERING DNA PROFILE

What Defines This System

Ratings below are a qualitative engineering assessment, not a measured benchmark — shown as a segmented meter rather than star icons to keep the framing technical.

THERMAL
CORE
Thermal Stability
Reliability
Automation
Scalability
Maintainability
Energy Optimization
PROJECT EVIDENCE

Documented On Site

KA Chiller Unit
KA Chiller Unit
Production site
Production site
Cooling Tank
Cooling Tank
ENGINEERING PRINCIPLES

Engineering Principles Applied

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SPECIFICATION PLATE

Project At A Glance

EquipmentKA Air-Cooled Industrial Chiller
IndustryChemical Processing
LocationChina
ApplicationReactor, Mixing & Emulsifying Tank Jacket Cooling
Cooling Capacity≈60 kW
Process Water Temperature7–25°C Adjustable
Cooling MediumClosed-Loop Chilled Water
Heat RejectionAir-Cooled Condenser
Process TanksReactor, Mixing Tank & Emulsifying Tank
Control SystemPLC Process Temperature Control
Operation24/7 Continuous Industrial Production
ENGINEERING SCOPE
NEXT ENGINEERING MISSION

Design Your Process
Cooling Architecture

Every chemical process has a unique thermal profile. Lohabour engineers analyze heat load, vessel count, hydraulic requirements and future expansion plans to develop complete jacket cooling architectures engineered for consistent, repeatable production.

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