R

Refrecon Magic

FREE HOT WATER

from Air Conditioning Compressor
for Hospitality Industry
Vrajalal Kanetkar,
Director,
Refrecon Magic Systems Pvt. Ltd., Pune
ABSTRACT:
This presentation unfolds approach and opportunities for usable hot water from air
conditioning system without any operating energy cost. In conventional air conditioning
system heat from rooms is removed and rejected to atmosphere directly or through
cooling tower. Atmosphere acts as heat sink for system. For tropical atmosphere like
India comfort cooling has been of primary importance and need of hot water is met with
use of fossil fuel. Cooling and heating needs may vary in quantum and time of use.
However rejected air conditioning heat does provide very interesting opportunity to
recover and store this heat and use it as hot water. Preheated / hot water free of operating
energy cost reduces fuel used in boiler there by improving overall system efficiency.
Reduction in fossil / liquid fuel consumption also reduces CO 2 emission to atmosphere.
CO2 gas affects green house effect, resulting in global warming. A subject of importance
needs no overemphasis.
REFRECON heat recovery system has unique features that make it very effective, has
proven commercial viability even in most demanding situation, making it most suitable
for any system that has simultaneous use of heating and refrigeration.

Technical Paper presented at H&FS seminar

At World Trade Centre, Cuff Parade, Mumbai. 400 001
on 12th February 2003,

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INTRODUCTION:
Year 2001 was shock to the growing economies in world and we in India are victims of
happenings around us. Recession, slowdown in growth, severe reduction in revenue
earning, low risk business approach, all resulted in one outcome and that is diminished or
vanishing bottom-line for business. Business survival has been a key issue for all, may
be manufacturing, trading or service industry. Globalisation, ISO certification, Internet
access, IT developments has elevated standard of customer expectations and he is more
demanding than ever before. Product or service quality expectations from customer are
non-compromising. Competition has put limitations on passing higher costs to ultimate
customer. No wonder business margins are squeezing aggressively. If not actively
responded, good business activities have started showing red bottom-line. Cost reduction
and waste recycling are the BUZ WORDS for retaining high business standards.
Indirectly energy conservation is necessarily focused as key activity for survival in these
days.
Waste heat recovery to make hot water from air conditioning compressor (use of our
Desuperheater ) is one the major tools available for Hospitality industry in general.
Hospitality, Pharmaceutical, Dairies, and Process Industries will soon adopt this in days
to come. Techno-commercial advantages of this heat recovery are incredible and this is
why international institutes like ASHRAE, CADDET, AEE, DOE in USA are strongly
supporting this concept.
WASTE HEAT AVAILABILITY:
Air conditioning has been primary need of hospitality industry. At the same time fuel
fired (Diesel or Furnace oil) boilers are used to generate hot water for domestic use,
cleaning, or kitchen. Air conditioning rejects heat to atmosphere through air-cooled or
water-cooled condensers. Heat rejection and fresh hot water generation is done across the
wall at facility basement and seldom noticed for complimenting each other. While this
energy is of low-grade variety, it still represents waste energy. Combining these two,
(waste heat and fresh heat generation) make cleaver sense of energy conservation and
saves substantial money.
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Refrecon Magic

Air conditioning unit generally removes heat from interior spaces and this heat is rejected
to atmosphere. Rejected heat also contains heat of compression in addition to cooling
heat removed. However major part of this heat is available at lower or non-usable
condensing temperature. Taking this in to account it is important to assess the available /
recoverable heat in the system. It is also important to recover heated water as much as
required. Temptation to recover excess hot water should be avoided.
DYNAMICS OF HEAT RECOVERY:
It is important to know quantum and type of heat recovery and integration of use of
recovered heat. Low grade rejected condensing heat, say bellow 34 0 C is of least
importance to tropical countries as ours. If need of hot water is limited it is beneficial to
get higher temperature hot water and use as required. In the event that this temperature is
short of desired range, fuel can do further heating. It is important to note that waste heat
recovery does not necessarily replace conventional heating system but substantially
reduces fuel cost meeting facility hot water demand.
Add on heat recovery unit is connected between compressor and condenser known as
desuperheaters with requisite changes in refrigerant lines. These units effectively scalp
gas phase refrigerant heat. The water flow is controlled for these units to get desired out
put range of 500 to 550C. This type of installation is flexible in meeting facility hot water
needs.
USER CONCERN :
In the tropical country like India, cooling is a non-compromising need. Interruptions in
air conditioning or loss of efficiency of cooling, are normally not acceptable, as it directly
reflects quality and cost of facility service. Under this circumstance facility owners need
comfort from O & M staff as well as consultants to implement the change in the system.
Heat recovery is a secondary activity. Generally it has standby operating system to
provide required hot water. Any change made in the total comfort system must ensure no
alteration in the performance of refrigeration cycle. In fact present experience is that
cooling capacity of existing system has improved to a small extent.
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Exclusively crafted desuperheaters are different than conventional heat exchangers. They
are expected to withstand extreme demanding situation. The vented tube design provides
unmatched safety for facility owner, as cross-contamination of refrigerant and water is
avoided in the entire operating lifetime of equipment. Material of construction and
arrangement of tube matrix makes it convenient to clean tubes mechanically online i.e.
without any interruption of cooling process. These are designed to accept even untreated
water (with increased tube cleaning frequency) to maintain consistency in heat recovery
performance. Hot water tank can be an integral part of this heat recovery and correct
operating practice can help facility managers to extract maximum benefit from installed
system.
ECONOMICS
The economics of this heat recovery is attractive. It is important to ensure recovered hot
water displaces prime energy used by facility. The economics can be adversely affected
due to poor operating hours of compressor. The system evaluation and total integration
with facility hot water system is essential step to ensure favorable economics of project.
Though there are other advantages of heat recovery system, over empathising of these
benefits can create serious situation. While system is conceptualised use of hot water
should be properly estimated so that recovered heat is not wasted. Providing metering of
hot water flow and recording the operating temperature will help to monitor and compare
post implementation performance of system.
Following general norms may be useful for estimating hot water need by process
1. 1 liter of fuel oil delivers 270 liters of hot water at 550C
2. 1 kWh of electricity delivers 28 liters of hot water at 550C
3. Hotel uses 200 to 300 liters hot water per occupied room
4. Dairy needs 0.5 to 0.75 liter hot water at 700C for general sanitation per liter of milk
processed.

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Refrecon Magic

CASE STUDIES:
Refrecon Magic System has sufficient experience of successful installation and
commissioning of heat recovery hot water system. Overall results are highly encouraging.
Each installation has remarkable reported savings. Cooling tower load reduction is also
established.
Case I:
1. Reciprocating refrigeration system
2. Hot water temperature used
3. Operating hours for compressor
4. Water circulated
5. Earlier mode of hot water generation
6. Earlier fuel used
7. Reported fuel saving
8. Simple Pay back for System
Case II:
1 Reciprocating refrigeration system
2 Hot water temperature used
3 Operating hours for compressor
4 Water circulated
5 Earlier mode of hot water generation
6
7
8

Earlier fuel used

Reported fuel saving
Simple Pay back for System

Case II:
1 Reciprocating refrigeration system
2 Hot water temperature used
3 Operating hours for compressor
4 Water circulated
5 Earlier mode of hot water generation
6
7
8

Earlier fuel used

Reported power saving
Simple Pay back for System

50 TR
550 C
20 hrs. per day average
800 liters per hour
Hot water generator
Circulation through calorifier
250 liters per day (reported)
1100 liters per month ( reported )
17 months
75 TR
500 C
16 hrs. per day average
1200 liters per hour
Hot water generator
Circulation through calorifier
110 liters per day (reported)
1650 liters per month ( reported )
21 months
40 TR
480 C
16 hrs. per day average
600 liters per hour
Heat Pump
Continuous operation 24 hrs per day.
200 kWh per day (reported)
120 kWh per day ( reported )
18 months

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TEN GOOD REASONS TO INSTALL REFRIGERATION HEAT RECOVERY

FROM REFRECON MAGIC SYSTEM PVT. LTD. PUNE
1. Investment recovery guaranteed - two and half years or less
2. Life long cross contamination free heat recovery on guaranteed performance basis
due to unique design
3. Performance consistency assured due to ease and accessibility of cleaning of tubes
without any outage of refrigeration or cooling system
4. Increases air conditioning and refrigeration system performance
5. Reduces maintenance cost of air conditioning and refrigeration equipment
6. Conserves energy without personal discomfort or reducing equipment performance
7. Reduces 900 kg of CO2 gas emission to atmosphere per ton per year. Also reduces
heat discharged to atmosphere by burning fuel.
8. Increases standard water heater life and reduces expenses on annual maintenance.
Also reduced operating ours of heat generating equipments improves boiler room
operating condition.
9. Reduced operating hours of cooling tower fan and thereby reduced power cost
10. Tailor made system integration, design assistance, installation guidance to ensure
flawless commissioning and after sales service

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Refrecon Magic

CONCLUSION:
Heat recovery from refrigeration is effective and provides reliable source of heat to fulfill
major demand of hot water. Understanding total system and providing integrated solution
approach plays key role in successful implementation of project. System can preheat
water up to 600C without affecting refrigeration cycle. Simultaneous generation of chilled
water and usable hot water results in increased output of heating system, reduced fuel
consumption and enhanced overall system efficiency.
The organisation projects more eco-friendly as it physically reduces 900 kg / TR / year
of CO2 emission due to balanced use of energy. Ah! Men.

PSVP:
V. V. Kanetkar
Refrecon Magic Systems Pvt. Ltd.,
37/3, AIROTEC House,
Sinhgad Road, Pune 411041.
Phone: 95 20 439 2545 / 3418
Fax: 95 20 439 0551
e-mail: kvrajlal@vsnl.com

320430385.doc

Technology Solutions for Green Effect