THERMAL TECH EQUIPMENTCo. Inc. 
   "SOLUTIONS FOR THE PLASTICS INDUSTRY"

Advantage Engineering
Engineering Formulas

Nominal Design Parameters

Chillers: 2.4GPM/Ton @ 10° F ∆T Flow Rate

  • 12,000 BTU/HR/Ton
  • 20° F - 60° F Standard Supply Range
  • Rating at 50° F Supply Temperature
  • 85° F Water Cooled Condenser
  • 95° F Air Cooled Condenser

Cooling Tower = 15,000 BTU/HR/Ton 

  • 3 GPM per Ton
  • 85° F Leaving Water Temperature
  • 95° F Entering Water Temperature
  • 78° F Wet Bulb
Tower water make-up requirements:  Untreated 2% of flow rate   Treated 1.5% of flow rate
Weighted Water Test
Chiller Ton = GPMx∆T (Delta Temp)
                 24                  		Tower Ton =GPMx∆T (Delta Temp)
        30         
Chiller Sizing
Injection Molding

Blow Molding

Extrusion
30#/hr H.D. Polyethlene = 1ton

40#/hr Polyolefins= 1 ton

50#/hr H.D. Polyethlene  = 1 ton
35#/hr L.D. Polyethlene = 1ton 40#/hr PET= 1 ton 50#/hr L.D. Polyethlene  = 1 ton
35#/hr Polypropylene   = 1ton Minimum Flow 04.8 gpm/ton

50#/hr Polypropylene = 1 ton         

45#/hr PVC = 1 ton   75#/hr Polystyrene = 1 ton                 
50#/hr ABS= 1 ton   75#/hr PVC = 1 ton
50#/hr Polystyrene= 1 ton

Blown Film Air Ring Cooling
105 CFM (50 ° F @ 78°  F WBT)= 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

Chiller Capacity Loss/Gain

  • Decrease nominal tonnage by approximately 2% per degree below a 50 ° F leaving water temperature.
  • Increase nominal tonnage approximately 2% per degree above 50 ° F leaving water temperature up to 55 ° F

Other Equipment

Air Compressor w/no after cooler =.1 ton/Hp
Air Compressor w/after cooler =.2 Ton/Hp
Vacuum Pump =.1 ton/Hp
Hydraulic Cooling =.1 ton/Hp
Barrel Cooling =.1 ton/in screw Dia.
Hot Runner Mold = 1 ton/10.5KW
Water Pump in Circuit =.2 Ton/Hr
Feed Throat 400Ton Machine or above 1 Ton
Below 400 Ton - 1/2 Ton

Extrusion Equipment

Gear Box Cooling =1 Ton/100Hp
Feed Throat 3" Screw or Less =1 Ton
Above 3" Screw =2 Tons
Barrel or Screw Cooling =1 Ton/Inch of Screw Diameter

Pipe Sizing Guide 
 (Based on 5' - 7' feet/second velocity)
1/8”  = .75 GPM    3/4" = 10 GPM   2" = 70 GPM    6" = 600 GPM
¼” = 1.5 GPM    1" = 15 GPM    2 1/2" = 100 GPM 8" = 1,000 GPM
3/8” =  3 GPM    1 1/4" = 30 GPM  3" = 150 GPM 10" = 3000 GPM
1/2" =  6 GPM     1 1/2" = 40 GPM    4"= 275 GPM 12" = 5000 GPM

Metric Conversion Chart

To Convert   

 To Convert
Unit Volume

Power

US GPM Liters/Min 3.785 FT/Lb/SEC Watts 1.356
US GPM Cum/Hr .2271 KW BTUH 342
CFM Liters/Min 28.317 Boiler HP BTUH 33475
CFM Cum/hr 1.6992 HP BTUH 2545
Unit Weight HP KW .7457
Lb/Ft Kg/m 1.4881
Lbs/Sq in gr/sq cm 70.31 Heat
Lbs/Sq in kPA 6.894 BTU Kg-cal .252
Lbs/Sq in Kg/Sq Cm .07031 BTU/LB Kg-cal .5556
Lbs/Sq in gr/cu cm 27.68 BTU/SQ FT gr-cal/sq cm .2713
Length BTU/CU FT Kg-cal/Cum 8.899
Inches cm 2.540 Weight
Feet meters .3048 Grains grams .0648
Yards meters .9144 Ounces* grams 28.350
Miles km 1.609 LBS kg .4536
Volume US tons kg 907.2
Cu. Inches cu cm 16.387 US Tons Tonnes .9072
Cu. Inches liters .01639 Long Tons kg 1016
Cu Feet cu meter .02832

Area

Cu Feet liters 28.317 SQ Inches sq cm 6.452
Cu Years cu meters .7646 SQ Years sq meters .8361
Fl Ounces cu cm 29.57 SQ Miles sq km 2.590
US Gallon cu meters .003785      
US Gallon liters 3.785      

*Auoirdupois pounds and ounces

Temperature
°F °C °F °C °F °C °F °C
0 -17.8 35 1.7   15 -9.4 50 10.0
5 -15 40 4.4   20 -6.7 55 12.8
10 -12.2 45 7.2   30 1.1 60 15.6
°F  to °C = (°F - 32) x .55 =°C   °C  to °F = (°C x 1.8) + 32 =°F

Flow Rate Vs. Temp Differences Per Ton

 % Ethylene Glycol by Volume vs Freeze Protection
1.2 GPM =   20 °F T 10%            25°F 
2.4 GPM =   10 °F T 20%            15°F 
4.8 GPM =     5 °F T 30%              0°F 
9.6 GPM =  2.5 °F T 40%           -15°F 
  50%           -40°F 

Abbreviations, Equivalents & Formulas

T = Delta Temperature = Temperature Differential
PSI = Pounds per square inch 1 Cooling Tower Ton= 15,000BTU/HR
GPM = Gallons per Minute 1 Refrigerant Ton = 12,000 BTU/HR
EWT = Entering Water Temperature 1 Gallon = 8.33 lbs (water)
LWT = Leaving Water Temperature 1 Cubic Foot = 7.48 gallons
BTU = British Thermal Unit 1 Mil = .001"
BTU/HR = GMP x 500 x . T (water) 1 Bar = 14.7 PSI
1 HP = 2544 BTU/HR 1 KW = 3413 BTU/HR
Ft. H.D. = PSI x 2.31 1 KW = 1.34 HP
Q=4.5 x CFM x H = BTUH (Air Cooling) PSI= Ft of head/2.31
Pump HP=  .          GPM x P (Ft.H.D)        .
                  3960 x (0.65 to 0.75) (Pump Eff)		 KW = Amps x Volts x 0.85 x 1.73
                           1,000

Head in Feet to PSI Conversions calculator

Filtration Chart

Mesh

Micron

Inches

  

Mesh

Micron

Inches

4

5205

0.2030

80

177

0.0070

8

2487

0.0970

100

149

0.0059

10

1923

0.0750

120

125

0.0049

14

1307

0.0510

140

105

0.0041

18

1000

0.0394

170

88

0.0035

20

840

0.0331

200

74

0.0029

25

710

0.0280

230

62

0.0024

30

590

0.0232

270

53

0.0021

35

500

0.0197

325

44

0.0017

40

420

0.0165

400

37

0.0015

45

350

0.0138

550

25

0.0009

50

297

0.0117

800

15

0.0006

60

250

0.0098

1250

10

0.0004

70

210

0.0083

 

5

0.0002
 

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Rick White
 2704 NE 78th Street, Kansas City,  MO  64119
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