Energy Conservation Refrigeration Systems

By J.ILANGUMARAN

REFRIGERATION SYSTEM

Vapour compression refrigeration systems (VCR) and Vapour

absorption refrigeration systems (VAR) find wide usage in the Indian industry. Although VCR's are dominating, over 1000 VAR's are in use in India. THE INDIAN SCENARIOSCENARIO-MAJOR ADVANCES

Widely used in industrial cooling, food retail and air

conditioning applications. Cost savings of 25 % are easily available. Efficient operation of refrigeration systems depends on the following factors : Design Selection Installation Use of the system

REFRIGERATION SYSTEM

The basic purpose of the refrigeration system is to control &

maintain specified temperature. The temperature maintained can be from 10C to 40C or even less. Types of Refrigeration Systems

Vapour Compression System Vapour Absorption System

Refrigerants

Ammonia and various halo carbon compounds R - 11, R - 12,

R - 22 and R - 502 for (VCR) Lithium Bromide, Ammonia (for VAR)

REFRIGERATION SYSTEM
Load or Source Evaporator Work

Compressor
Condenser Cooler Work

Expansion Device

TECHNICAL COMPARISON OF VAPOUR ABSORPTION CHILLER (VAC) & VAPOUR COMPRESSION CHILLER (VCR)
VAC Equipment : Absorber, Generator, Condenser & Evaporator Refrigerant : Water Absorbent : LiBr Input Required : Steam Equipment : Compressor, Condenser, Thermal Expansion Valve, Evaporator Refrigerant : CFC, Ammonia gases etc. Absorbent : Not Applicable Input Required : Power VCR

TECHNICAL COMPARISON OF VAC & VCR

VAC Cycle : 1. Take the latent heat from outside water (Chilled Water) in evaporator by absorbent. 2. Refrigerant water will be absorbed by absorbent. 3. These diluted absorbent is heated up and separate the refrigerant in the generator. 4. The refrigerant vapour is condensed in the condenser & the absorbent which is coming from generator is cooled down in the absorber. The total cycle is operated under vacuum condition i.e.6 mm Hg Cycle : 1. Take the latent heat from outside water (Chilled water) in evaporator by refrigerant. 2. These refrigerant at low temp. is compressed by compressor to high temp. and higher pressure. 3. These high temp. refrigerant gas will be cooled down in the condenser, refrigerant become a liquid. 4. This refrigerant will be expanded by thermal expansion valve which is connected to evaporator. VCR

VAPOUR COMPRESSION MACHINES

Types based on Compressors

Reciprocating Compressor Centrifugal Compressors Screw Compressors and Scroll Compressors VAPOUR ABSORPTION MACHINES

Types Steam Based Double Effect Steam Fired Machines Single Effect Steam Fired Oil / Gas Based Hot Water Based

STEAM BASED VAM

Double Effect Steam Fired Machines Steam pressure : 3.5 kg / cm2 to 10 kg / cm2 Capacity : 40 TR to 1400 TR Sp. Consumption : 4.5 kg / hr @ 8 kg / cm2 / TR

Single Effect Steam Fired Sp. Consumption : 4.5 kg / hr @ 8 kg / cm2 / TR Capacity : 70 TR to 1400 TR Sp. Consumption : 8.5 kg / hr @ 3 kg / cm2 / TR

VAPOUR ABSORPTION MACHINES Oil / Gas Based VAM Fuels : Kerosene, Diesel, LPG, LNG, Natural gas & Furnace Oil Capacity : 30 TR to 770 TR Hot Water Fired VAM Source : Hot Water (minimum of 85C) Capacity : 30 TR to 650 TR

DEVELOPMENTS IN THE FIELD OF VAM

Split Evaporator for Improved Output and

Coefficient of Performance (COP) Drain Heat Exchangers for improved oil consumption Cupro Cupro-nickel in Condenser and Absorber Maintenance Friendly Design for Heat Exchangers Leak Proof Service Valves Vacuum Pump Improvement

SPLIT EVAPORATOR FOR IMPROVED OUTPUT AND COP

Conventional System Lower Shell of VAM Split into two sections One each for Evaporator & Absorber Improved Design - Split into three sections - Evaporation section split into two - One each on side of the Absorber

SPLIT EVAPORATOR FOR IMPROVEMENT OUTPUT

How ? Improved Design Allows uniform flow of the evaporated vapours Optimal Absorption of refrigerant vapours by LiBr in the Absorber Results in Improvement in Evaporation rate Enhanced Output

BENEFITS OF VAM

Non-dependence on Electrical Power NonEnvironmentally Clean & friendly Lesser Down Time Lower Noise Level Availability Continuous and StepStep-less Modulation and 100 % Depreciation LIMITATIONS OF VAM Minimum chilled water Temperature possible : + 4.5 C Only water cooled condensers are available commercially. High initial investment

APPLICATIONS OF VAM IN INDUSTRIES

Automobile Engineering Petrochemicals Pharmaceutical Cement Soft Drinks Chemicals Fertilizers Refinery Commercial Establishments and more

REFRIGERATION SYSTEM ENERGYCONSERVATION OPPORTUNITIES

Replace Chiller (Usually Smaller) Reduce Refrigeration Loads Minimize Chiller Operation Isolate Special Loads Lower Condenser Water Temperature Reasons to replace a chiller Future Refrigerant Cost / Availability Future Maintenance Repair Cost Efficiency Improvements

REDUCTION IN REFRIGERATION LOAD

The refrigeration load itself can be reduced by

the following methods : Reduction in the use of Refrigeration Improved Insulation Reduction in Auxiliary Loads
REDUCTION IN USE OF REFRIGERATION

Whether it is necessary? If required, how much and what temperature?

IMPROVED INSULATION

Insulation of Pipe Lines, Valves, Flanges etc. Better Design of Building and enclosures Provision of Films, Curtains, Venetian Blinds Orientation of Windows Provision of Natural Cooling and Lighting Planting of Trees

ENERGY CONSERVATION OPPORTUNIES ISOLATE SPECIAL LOADS

Computer Room Control Rooms Office Administrative Building

ENERGY CONSERVATION OPPORTUNIES

Optimize Cooling Tower Fan Energy Raise Chilled Water Temperature Optimize staging of Multiple Chillers Eliminate bypass through dede-energized Chillers Enhance Heat Transfer Surfaces for Efficiency Gains Minimize Pump Operation Optimize Use of Cheap Rate Non Peak Hour Power Using Cooling Tower Water if possible Use Variable Speed for part load operation Avoid Hot Gas bypass Availability of Waster heat, low cost steam vapour absorption refrigeration.

ENERGY CONSERVATION OPPORTUNIES

Temperature Drop between condensing and

evaporator temperatures leads to power saving doubly A unit operating at - 30C uses more than twice energy required for operating at -10C. Reduction in condenser water temperature by 1C or raising Chilled Water Temperature by 1C leads to 1 to 1.5 % saving in power consumption

EFFECT OF EVAPORATION TEMPERATURE

Evaporation Refrigeration Compressor Shaft Power kW kW / ton

5 0 -5 - 10 - 20

67.58 56.07 45.98 37.20 23.12

55.3 52.3 49.8 46.6 38.7

0.81 0.94 1.08 1.25 1.67

MAINTENANCE ASPECTS IN REFRIGERATION Remove Excess Charge Clean the condenser periodically Add refrigeration to correct load Maintain oil temperature between 50 - 60 C

ENERGY SAVINGS OPPORTUNITIES DISCUSSED IN DETAIL

Efficient Scroll Compressors Secondary Chilled Water Pump Opportunities VSD used in Centrifugal Compressor VAR based on Heat Recovery Ammonia VAR System Cooling Tower Energy Optimization

SCROLL COMPRESSORS
The scroll compressor is the heart of the new
generation premium, high efficiency heat pumps and air conditioners. Range Available : 5 TR - 15 TR Scroll Compressors are finding acceptance in packaged chillers of leading brands Principle of Working Two identical spirals or scrolls One scroll remains stationery while the other orbits around the first As this motion occurs, gas is drawn into the scrolls and Moved in increasingly smaller pockets towards the center

WORKING OF SCROLL COMPRESSORS

At this point, the gas now compressed to a

high pressure is discharged from a part in the fixed scroll. During each orbit, several pockets of gas are compressed simultaneously, creating smooth, nearly continuous operation.

ENERGY EFFICIENCY OF SCROLL COMPRESSOR

10 % more energy efficient than reciprocating
Compressors Near 100 % volumetric efficiency The scroll compression process occurs during a full 540 of rotation where 180 of rotation in reciprocating compressors Results in : Smoother Compression & discharge The scroll design does not require a dynamic valve where piston Compressor needs. Suction & discharge process in a scroll compressor is physically separated. Results in : Lesser heat transfer, which improves overall efficiency.

OPERATING PERFORMANCE

Reliability - Fewer Moving Parts Durability - Axial and radial compliance make
the scroll compressor more tolerant to liquid refrigerant and debris. Lower Sound Flooded starts normally will not harm scroll compressor

SECONDARY CHILLLED WATER SYSTEM ENERGY CONSERVATION OPPORTUNITIES

Application - used for distribution of chilled

water to the loads from the primary production loop. Present System - Two Way Control Valve Proposed System - VSD for Sec. Chilled Water Pump

Case Study SECONDARY CHILLED WATER SYSTEM ECO

Flow % 30 40 50 60 70 80 90 100 Hours % 5 5 10 10 10 20 30 10 100
1

Hours Run 438 438 876 876 876 1752 2628 876 8760

Power Consumption kW 1 23.33 23.56 24.03 24.71 25.62 26.76 28.17 30.22 2 4.73 6.08 8.01 10.61 14.04 18.54 24.28 31.48

Energy Input kWh 1 10 219 10 319 21 050 21 646 22 443 46 884 74 031 26 473 2 33 064 2 2 072 2 663 7 017 9 294 12 299 32 482 63 808 27 576 1 57 211

Two Way Valve Control

VSD Control

SECONDARY CHILLED WATER SYSTEM ENERGY CONSERVATION OPPORTUNITIES Basis : 30 kW Pump Comparison with Two Way Valve Savings : 75 840 kWh
VARIABLE SPEED DRIVE FOR CENTRIFUGAL COMPRESSOR

Model Case Study Chiller Plant Capacity Power Consumption

: :

Ref. SCREX 99 500 TR

at Full Load : 250 kW ( 0.5 kW / TR ) 82 % of total power consumption is by Chiller Motor in Chilled Water System. Constant speed chillers handle lower loads by gradually closing at set of guide vanes on the Compressor inlet while keeping the motor turning at full speed Closing the vanes create friction losses in Refrigerant flow, producting

RECOMMENDATION
Single stage compressors are especially well suited for
Variable Speed Drive. Power consumption can be reduced upto 30 % by installing VFD. Annual saving : 95065 kWh

LIMITATIONS Multistage compressors have the added complexity of maintaining the appropriate inter stage pressure, hence varying the speed will upset this balance and this will penalise the performance of the compressor.

OTHER BENEFITS OF VSD

Ideal soft starter (Inrush amp for VSD never

exceeds the 100 % FLA of the motor where solid state starter of Star Delta starter have 300 - 400 % FLA). Addition of VSD enhances the unloading capability of a Centrifugal chiller by varying the speed prior to closing the guide vanes. Quite Operation VSD also come with automatic power factor correction

VSD Vs CONSTANT SPEED OPERATING COST COMPARISON

Load ECWT Poin Tons F ts 1 200 78 2 250 80 3 300 82 4 350 84 5 400 86 6 450 88 7 500 90 Total Annual hours Annual kWh Alt 1 Alt 2 10 172 37 065 76 767 4 05 091 4 12 744 55 754 33 851 10 31 414 Savings 2 586 8 741 13 124 45 396 25 676 955 -1 413 95 065

100 12 758 300 45 806 500 89 861 2 150 4 50 487 1 800 4 38420 200 56 709 100 32 438 5 150 11 26 479

Alt 1 is for the chiller with constant speed unit Alt 2 is for VSD chiller.

CASE STUDY ON HOT WATER FIRED VAPOUR ABSORPTION MACHINE A continuous process industry in TN. DG set details Capacity : 2 Nos of 4 MW Fuel : LSHS Supply air @ 40C Design parameter is at 25C Average Units generation (per DG set) : 3400 kW / hr

RECOMMENDATIONS
One number of Vapour Absorption Machine (VAM)
connected to one DG set hot water circuit with a provision to link the second DG set, in case the first is under maintenance. Capacity of VAM : 173 TR Chilled water flow : 104.6 m3 / hr Chilled water inlet / outlet temp. : 12 / 17C Hot water flow : 144 m3 / hr Hot water inlet / outlet temp : 91 / 85C Cooling Water Flow : 300 m3 / hr Cooling water inlet / outlet temp : 32 / 36.5C Power consumption for VAHP : 3.7 kW Charge air cooling requirement : 73 TR

SAVINGS IN FUEL CONSUMPTION BY VAM

Savings in specific fuel consumption / kW

6.5 gm / kW Savings in fuel cost / year : Rs. 39 lakhs Savings due to additional loading in DG :Rs. 50 lakhs. Total savings : Rs. 89 lakhs Other benefit : 100 TR of chilled water for plant use (OR) 173 TR of Chilled Water Investment of Rs. 44 lakhs

AMMONIA VAPOUR ABSORPTION REFRIGERATION (AVAR) - FEATURES

Ability to operate at rates higher than

nameplate capacitors without negative consequences. Inertial storage at low loads to meet transient with sizable spikes. Putting up with interrupted heat supply while maintaining cold supply on continuous mode. Low pressure steam and available waste heat sources can be utilized.

FACTORS IN FAVOUR OF AVAR

Increase in cost of electricity and low cost steam

generation through various available resources. Improvement in COP (COP has gone up from 0.4 to 0.56, in latest machines)

Example COP Evaporation temp Heating media temp Basis

: : : :

0.56 - 30C 172C Cooling Water at 33C

BARRIERS IN AVAR

Premium first cost Lack of familiarity Perceived (rather than real) reliability and
maintenance problem Poorer COP (even though heat energy price compared to electricity is low) Ineffective or nonexistent sales structure for commercial implementation after R & D.

BENEFITS OF AVAR OVER VCR

Basis Cooling Water at 33C Evaporation Temperature at 20C Unit TR Requirement Power Cost : Rs 4.0 / kWh Steam Cost : Rs 500 / MT AVAR System Requirements Steam Quantity Requirement : 9 kg Power Consumption : 0.25 kWh Total Cost : Rs 5.5 / TR

AVAR OPERATING BENEFITS

Compression Refrigeration Requirements : Power Consumption : Operating Cost : Difference in operating Cost : 1.75 kWh Rs 7.0 / TR Rs 1.5 / TR

COOLING TOWER - FANS APPLICATION Cooling Towers are used to cool condenser water in water cooled Chiller Systems. Water cooled chiller systems provide 20 % more efficient cooling system than air cooled chiller systems. Conventional Control Systems ON / OFF Control Two Speed Motors Adjustable Pitch Blade Fans

COOLING TOWER - CASE STUDY

Case Study on Cooling Tower fan with VSD Drive. Basis : 30 kW fan Comparison with two speed motor is made Savings : 83 588 kWh BENEFITS OF VSD CONTROL OVER TWO SPEED MOTOR CONTROL Flow % 40 50 60 70 80 90 100 % 5 15 35 20 15 10 0 100 1 Hours Hours Run 438 1314 3066 1752 1314 876 0 8760 2 Power Consumption kW 1 12.80 12.80 12.80 30.00 30.00 30.00 0 2 2.67 4.83 7.85 11.93 17.27 24.16 0.00 Energy Input kWh 1 5 606 16 819 39 245 52 560 39 420 26 280 0 1 79 930 VSD Control
2 1 169 6 347 24 068 20 901 22 693 21 164 0 96 342

Two Way Valve Control

SUM UP
Several Energy Saving Opportunities exist Selection of the VCR & VAR Systems depend
upon cost of Energy Input New technologies give sizable Energy Savings Retrofits for Evaporator give good scope for savings Savings in Auxiliaries system improvement Fit case to implement