REFRIGERATION & AIR-CONDITIONING

Refrigeration systems account for about 5% electricity consumption in the industrial sector
Air-conditioning Refrigeration

Industrial refrigeration Cooling and Heating including food dehumidifying humidifying preservation, operations in and control of chemical and air conditioning air quality process industries

Relationship of the refrigeration and airconditioning fields

Heat sink (High temperature level) Cooling Tower

Condenser

Evaporator
Motor Compressor

AHU Heat Source (Low temperature level)

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Energy efficiency Ratios

The cooling effect of refrigeration systems is measured in Tonnes of Refrigeration (TR) A ton of refrigeration is defined as quantity of heat to be removed in order to form 1 ton of ice in 24 hours when the initial temperature of water is 0C. 1 TR = 3024 kcal/hour

=
=

3.51 kW
12,000 BTU/hour
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The commonly used figures of merit for comparison of refrigeration systems are COP (coefficient of performance) EER (energy efficiency ratio) KW/TR (specific power consumption)

The performance of refrigeration cycle is usually described by the COP. It is defined as the ratio of amount of heat removed divided by the required energy input to operate the cycle.
Useful refrigerating effects ______________________________________ Net energy supply from the external sources

COP =

In the air-conditioning industry, the EER is generally

used measuring the refrigeration effect in BTU/hour

and the work done in watts.

EER

Refrigeration effect (BTU/hour)

Work done (W)

Power consumption (kW) Specific power consumption = Refrigeration effect (TR)

A lower value of specific power consumption implies that the system has better efficiency

Most commonly used refrigeration systems Vapour compression system Vapour absorption system Type of compressed used Reciprocating compressors (up to 120 TR) Screw compressors (about 150 TR - 750 TR) Centrifugal compressors (150 TR - very large size) Scroll compressors (up to 30 TR)

The vapour compression system has the following features

Absorbing heat by the evaporation of a liquid refrigeration in the evaporator at a controlled lower pressure

Raising the pressure (to raise the condensing temperature)

Removing heat from the high-pressure vapour in the condenser so as to liquefy or condense the vapour Reducing pressure of the high-pressure liquid to the level needed in the evaporator by using the throttling device (from the condenser)
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The vapour compression cycle

Condenser

Comp.

Evaporator

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Vapour absorption machine

Basic principle

Boiling point of water is a function of pressure. At atmospheric pressure it boils at 100 C. At lower pressure water boils at lower temperature. The boiling point of water at 6 mm of mercury absolute is only 3.7 C. Lithium Bromide (LiBr) salt has the property to absorb water due to its chemical affinity. As the concentration of LiBr increases, its affinity towards water increases. As the temperature of LiBr increases, the affinity decreases.
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Comparison of the absorption and vapour compressor systems

In the absorption system, except for two small electrically operated centrifugal pumps, there are no moving parts. Hence, the absorption system has no vibration and does not need heavy foundation as required in vapour compression system. For the absorption machine, the capacity control is stepless whereas in the vapour compression system, the capacity control operates in certain steps

The vapour absorption system can be operated on waste heat.

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 The COP of the absorption system is very low (around 1.1 for 2-stage lithium bromide machines) compared to the vapour compression system (4 to 5) for air-conditioning applications. The absorption system becomes competitive only if the electricity to fuel price ratio is greater than four
The heat rejection factor for the vapour absorption system is high (2.5 as compared to the vapour compression (around 1.2). The cooling tower and pump condenser circulating pump capacity have to be proportionally higher. The life span for the absorption system is less compared to vapour compression because of the corrosive nature of the lithium bromide solution.
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Comparison of different types of vapour compression refrigeration plants

Parameters 1.Refrigeration temp. Range (Brine/water) 2.Sp. Power consumption Air conditioning Sub zero temp. 3.Refrigerant Reciprocating +7 to -30C Centrifugal +7 to 0C Screw +7 to -25C

0.70.9 kW/TR 0.590.63 kW/TR 1.22.5 kW/TR R11, R123, R134A R22, R12 Ammonia

0.650.7 kW/TR 1.252.5 kW/TR R22, R134A Ammonia

4.Typical single unit capacity Air conditioning Upto 150 TR Sub zero temp. 10-50 TR

250 TR & above -

50-250 TR 50-200 TR

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Vapour compression system (for chilled water at 8 C, Condenser water 20 C)

Capacity Power COP EER Specific power (kW) (BTU/hr/W) (kW/TR) Open-type reciprocation compressors 7.65 4.95 16.9 0.71 19.26 5.24 17.9 0.67 21.38 5.32 18.2 0.66 32.06 5.32 18.2 0.66 38.52 5.24 17.9 0.67 42.75 5.32 18.2 0.66 Semi-hermetic reciprocation compressor 6.25 4.94 16.9 0.71 7.00 4.62 15.8 0.76

10.78 28.90 32.20 48.30 57.80 64.40 8.77 9.26 13.90 42.00 563.67

Open-type centrifugal compressor 329.94 6.00 20.5 0.59

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COP- coefficient of performance; EER energy efficiency ratio; kW/TR specific power consumption

Steam consumption for vapour absorption system (for chilled water at 8C)
Capacity (TR) Steam Steam COP EER Specific pressure consumpti (BTU/hr steam (kg/cm2) on (kg/hr) /W) consumption (kg/hr/TR) Single effect chiller 3.0 2101.0 0.61 2.10 8.75 Double-effect chiller 8.5 415.2 1.10 3.76 4.88 8.0 490.2 1.10 3.76 4.90 8.0 736.5 1.13 3.86 4.76 8.5 1284.0 1.13 3.86 4.76 8.5 1904.1 1.13 3.86 4.76 8.0 2296.0 1.17 4.00 4.59
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240 85 100 155 270 400 500

Effect of variation in condenser temperature on compressor power consumption

Condensing Refrigeration Specific power Increase in temperature capacity (tonnes) consumption kW/tonne (%) 26.7 31.5 1.17 35.0 21.4 1.27 8.5 40.0 20.0 1.41 20.5
Evaporator temperature at 10 C

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Effect of variation in evaporator temperature on compressor power consumption

Evaporator temp. ( C) 5.0 0.0 -5.0 -10.0 -20.0 Refrigeration Specific power capacity consumption (tonnes) (kW/tonne) 67.58 0.81 56.07 0.94 45.98 1.08 37.20 1.25 23.12 1.67 Increase in kW/tonne) 16.0 33.0 54.0 106.0

Condenser temperature at 40 C

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Different Types of Capacity Control (Vapour compression chillers)

Parameters Capacity controls Reciprocating Centrifugal Screw Slide valve

on/off (small) Inlet guide vane (IGV) Unloading of cylinders

Typical COP at part load upto 50%

Variable Variable speed speed drive drive with IGV Suction throttling Reduces at part Reduces at Improves by 15 load part load 20%
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Measurements/field testing
The parameters needed to be looked into are:
Inside and outside design conditions, measured flows and capacities of all the equipment used in the system, comparison of the measured and design capacities, and

comparison of energy consumption with the design values

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Water flow
The water flow in a piping system is measured by: Taking the pumping head at the pump discharge and then referring the pump characteristic curves, Measuring the pressure drop across a fixed length of piping and then using equations,

Taking the pressure drop across the heat exchangers and then comparing with the design pressure drop across the heat exchanger, and Measuring the flow with a portable non-intrusive ultrasonic flow meter

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Air Flow
This is calculated by measuring velocity across a fixed opening having a definite area. The velocity is

determined by either measuring the pressure drop

across the opening with the help of a pilot tube and manometer/hot-wire aenmometer.

Rotation/speed
Rotation/speed can be measured with the help of: Stroboscope Non-contact type electronic techometer,

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Temperature/humidity Two types of temperatures, DB (dry bulb) and wet bulb, are measured by:

Sling psychourometers
Electronic thermohygrometers Electrical parameters Electrical measurements are taken with the help of the

clamp-current, power, power factor, and frequency

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Performance evaluation
Compressor
From the operating suction and the discharge pressure, the capacity may be evaluated from the rating charts. The operating kW input can give the value of input power. This can be then compared with the rated input.

Condenser
Water or air flow rate and temperature rise across the condenser gives the heat rejection. The flow rates and temperature rise should be compared with the design parameters. TR :
(Flow (kg/h) X sp .heat (k.cal/kg0C) x diff. temp C )/3024

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Chiller Water or brine flow rate and temperature drop across the chiller gives the cooling load. The flow rates and temperatures drop should be compared with the design parameters. Any variation must be analyzed
TR = (flow rate (kg/h) x specific heat (kcal/kg0C) x diff. Temp C)/3024 Cooling coil
Air flow rate and enthalpy drop across the cooling coil will give the cooling load. The flow rates and enthalpy drop should be compared with the design parameters and any variation analyzed TR= ( air flow (m3/h) X density (kg/m3) X diff. H (k.cal x kg))/3024
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Cooling tower The heat rejected at the condenser must match the heat rejected at the cooling tower. The equation for cooling tower is the same as that of the water-cooled condenser. For the cooling tower, the approach must also be evaluated
The efficiency of cooling tower is: Water in - water out temp. Water in - ambient WBT (wet bulb temp.)

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Air washer An air washer can be used for air-conditioning, evaporative cooling, or for the heating-humidifying

process. The efficiency of an air washer depends upon

the face velocity and spray arrangement or, in case of pad-type units, on the air/water surface contact area.

The efficiency of an evaporating cooling air washer is:

Entering temp. DB - leaving temp. DB Entering temp. - ambient WBT

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Sample calculation for refrigeration capacity

Screw chiller
Chilled water flow rate Inlet water temperature Outlet water temperature Refrigeration capacity

: 250 TR
: 42 lps : 12.2C : 7.2C : 42 x3600x1x(12.2 7.2) 3024

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Sample calculation for AHU

(Design 26 TR Capacity)
Inlet air flow Entering air Entering air enthalpy Leaving air : 21665 m/h (6.02 m/s) : 24.2DBT, 17.2 C WBT, 51.5% RH : 52 kJ/kg : 24.2DBT, 12.5 C WBT, 85% RH

Leaving air enthalpy

Entering air density

: 38 kJ/kg
: 1.05 kg/m

Tons of refrigeration

: 21665x1.05 x (52-58)/(3024x4.18)
: 25.2 TR
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