In my never ending (almost insane) quest to produce a better fog chiller, I began to question some of the concepts that I used in my own Scratch Built Fog Chiller
which has become known at the "Cube chiller". It's a GREAT Chiiler with Proven effective results.
I've been trying to read the entire "Vortex fog chiller thread" but it so long that I've had a hard time getting through the entire thing. It has some GREAT information so far And I'm looking forward to finishing the read. A few universal flaws of all Ice type fog chillers began to emerge as a theme. They all EAT a LOT of ice.
I run my (3) chillers a LOT during the Halloween season and racked up a $350 bill between Ice and Dry Ice over a few weeks. If you Just use your Cube (or similar) chiller for one night, than it's No big deal (Cheap).
Make a reasonably priced (Not Cheap) chiller that will do the job using a fraction of the Ice/ Dry Ice.
Make it in a size and shape that it can easily be incorporated as a monument base or other halloween related prop.
Make it easy to Load up with cooling materials.
Make a chiller that will work in colder climates where you have to UBER Chill the fog to get it be "Ground hugging"
Use "free" cold halloween air to assist in the cooling process.
Use "Stages" to cool the fog in a progression from warmer to colder.
Totally Contain the fog from entrance to exit.
Ice and Dry Ice can be added during fogger activity.
Self Feeding Ice/ Dry ice reserve for lower nightly maintenance.
Capture the negative calories of the melted ice (Still has cooling properties)
Chamber 1 -Expansion Chamber
Chamber 2- Active air cooling (fan Assist?)
Chamber 3- Ice bath (75% Ice and 25% Water)
Chamber 4- Dry Ice, or Dry Ice and water ice mix
THE PROJECT (In Progress and UNTESTED):
Here is what I came up with so far.
Hot fog will enter the expansion chamber (unfinished) in the foreground using 2"PVC and a 90 degree "Up Pipe".
The hot fog will expand. Via pressure it will be forced into the second "Air cooling" chamber through the 6 holes at the bottom of the panel in this view.
Again using the positive pressure from the fog machine, it will be forced up through the series of 1/2 cooper pipes that will be kept cool using a built in fan.
At the top of that chamber the fog will be forced into a "matrix" of copper tubes (Chamber 3) that submerge into an "Ice Bath".
Once the fog exits the ice bath, it will pass through a narrow transfer chamber to the Dry Ice chamber where it will recieve it's final cooling effect.
Add a plastic bag at the exit and there should be some very frigid fog carpeting the neighborhood.
Here's a good shot of the "Air cooling" chamber yet to be enclosed. A Fan will be mounted in a chamber on the right to force cold "ambient" air through the first set of copper pipes.
Partially enclosed. That thin slit is a transfer channel between the Ice bath and the dry ice chamber.
Here it is more or less complete, I still have to decide weather I want to put the air cooling fan on the Top (inside a monument), or on the side. The "Ice access lid isn't installed yet. I'm going to use that lid area as a "Hopper". There will be a "Cube" of Ice and dry ice (Separated) that will rise above the main body of the chiller inside a monument. THis will allow me to "Overload" the cooling areas and let the Ice melt down. My hope is that the "Ice chamber" will hold water so I can get really good contact with the small copper pipe matrix.
I just finished this stage of the chiller this evening. EVerything you see in this last picture is glued and sealed up. Nothing can be removed (except the ice hopper/lid, not shown). The entire thing is air/water tight (hopefully). The fog won't make direct contact with the Ice but will rely on trhe thermal properties of the copper to transfer the cold..
I'll let the PL Glue cure up and give it a trial run tomorrow or sunday. I want to test it while the weather is still cold, so I can get a good bearing on it's effectiveness. Of course if I lived in a warmer area, I wouldn't need to chill the fog to such an extreme to get it to stay on the ground.
WISH ME LUCK