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SR.NO.
DESCRIPTION
1 ABSORBER
2 RECTIFYING COLUMN
3 DESORBER
4 SUB COOLER
7 SOLUTION HEAT EXCHANGER
SR.NO DESCRIPTION
1 ABSORBER
2 RECTIFYING COLUMN
3 DESORBER
4 SUB COOLER
5 CONDENSER
6 RECEIVER
7 SOLUTION HEAT EXCHANGER
Exclusive Features
Cold Storage
Freeze drying
Food Refrigeration
Brine Cooling
Vapor ammonia Recovery Chemical Processes.
Ammonia Recovery from Liquor Ammonia from Chemical Processes
Ice Making Plants
Ice Cream Plants
Meat Processing
Fish Processing Industries.
Dairies.
Refineries
Fertilizer plants
Bulk Drug Industries
Pesticide Plants
Ammonia Compression
Absorption Cycle
No Description
Refrigeration Refrigeration
plant Plant
1 Technical Specifications :
a) Refrigeration Load : TR 100 100 100 100
b) Ammonia Evaporation Temp. Deg.C -10 -30 -10 -30
c) Cooling Water Temp. (Deg.C) Summer 28 28 28 28
Monsoon 32 32 32 32
Winter 24 24 24 24
Average 28 28 28 28
d) Cooling Tower Load TR 288.7 356.4 131.4 154.6
Modern
Reciprocating
2 System configuration AARP Model
Compression
Cycle Plant
Modern
System
2 AARP Model Reciprocating
configuration
Compression Cycle
Plant
AMMONIA EVAPORATION TEMPERATURE = -10OC & -30OC
REQUIREMENT OF UTILITIES
Ammonia Absorption Compression Cycle
No. Description Unit
Refrigeration Plant Refrigeration Plant
Ammonia Evaporation
Deg.C -10 -30 -10 -30
Temp.
A] HEAT INPUT : kcal/hr 567254.15 770897.43 NA NA
STEAM
Steam Pressure kg/cm2(g) 1.7 5.18 NA NA
Steam Temperature Deg.C 130 160.1 NA NA
Steam required at Given
kg/hr 1092.60 1551.03 NA NA
Pressure
B] Boiler Fuel Data F.O Baggase Coal
Calorific value kcal/kg 9710.00 2200.00 4500.00
Boiler efficiency % 95.00 75.00 80.0
o
C] Fuel Consumption for above Steam Output. (f90 C) (Refer Note Below)
F.O lit/hr 69.69 100.62 NA NA
Bagasse kg/hr 370.15 534.41 NA NA
Coal kg/hr 169.65 244.94 NA NA
HOT WATER
Supply Temp. Deg.C 150 180 NA NA
Return Temp. Deg.C 120 150 NA NA
Rate of Circulation m3/hr 18.90 25.69 NA NA
D] Fuel Consumption for above Hot Water OutPut.
F.O lit/hr 64.73 87.96 NA NA
Bagasse kg/hr 343.80 467.21 NA NA
Coal kg/hr 157.57 214.13 NA NA
E] Fuel Prices Including C.Excise Duty, Sales Tax and Transport.
F.O Rs/lit 9.25
Bagasse Rs/Kg 0.50
Coal Rs/Kg 2.50
F] Fuel Cost for Steam
F.O Rs/hr 644.63 930.73 NA NA
Bagasse Rs/hr 185.07 267.20 NA NA
Coal Rs/hr 424.12 612.35 NA NA
Fuel cost for Hot Water
F.O Rs/hr 598.75 813.63 NA NA
Bagasse Rs/hr 171.90 233.60 NA NA
Coal Rs/hr 393.92 535.32 NA NA
G] ELECTRIC POWER :
Power requirement for Compressor :
At Compressor Shaft KW - - 110 191
Belt losses (8%) KW - - 8.8 15.28
Power required at Motor
KW - - 118.8 206.28
shaft
Power for Solution Pumps
KW 7.5 15 - -
Motor
Power for Cooling water
KW 12.3 12.3 5.6 5.3
Pumps
Total Power at Motor
KW 19.8 27.3 124.4 211.6
Shaft
Add Motor Losses (Motor
KW 1.5 2.1 9.4 15.9
Efficiency assumed 93%)
Total Power at Motor
KW 21.3 29.4 133.8 227.50
Terminals
Add HT metering losses
(Transformer efficiency KW 1.1 1.5 6.7 11.40
assumed 95%)
Total Power Metered at
Incoming of HT KW 22.4 30.9 140.5 238.9
Transformer
H] Make-up-Water
Make-up-water M3/hr 1.50 1.85 0.68 0.80
Cost of make up water
Rs. 15 18.50 6.80 8.00
(@ Rs.10.00 per m3/hr)
2 Construction : 2 Construction :
Refrigerant - Ammonia (NH3) Refrigerant - Water
Absorbent - Water Absorbent - Lithium Bromide (LiBr)
4 Functioning 4 Functioning
- Fully automatic continuous - Fully automatic continuous
Modulation Modulation
- Part load efficiency is good - Part load efficiency is good
Heat Heat
Heat (Steam/
(Steam / (Steam / Heat (Hot Heat
Hot Water /
Hot Hot Water) (Steam
Hot Oil)
2 Energy Input Electricity Electricity Electricity Water / Water / /Hot
Hot Hot Oil/ Oil /Direct
Oil/Direct Direct Fired )
Fired) Fired)
Heat Input
Temp. Range Minimum Minimum Minimum Minimum
3 - - - Minimum 85oC
-Maximum 85oC 130oC 55oC 190oC
-Minimum
Typical Energy
to TR Ratio
-Air 0.7-0.9 kw/TR 0.65 kw/TR 5000 2575 7500 2000
0.63kw/TR 4615 kcal/TR
Conditioning kcal/TR kcal/TR kcal/TR kcal/TR
4
Temp. Range 1.25 to 2.5 1.25 to 2.5
----- 6666 kcal/hr
kw/TR kw/TR ------ ----- ----- -----
-Subzero Temp.
Range
R11,R123,R134a R22, R134a Pure
5 Refrigerant R22, R12 Pure Water Pure Water Pure Water Pure Ammonia
Ammonia Ammonia Water
Water-
Water-LiBr Water-LiBr Water-LiBr Ammonia-LiBr
6 Absorbent ------ ------ ------ LiBr
solution solution solution solution
solution
Typical single
unit capacity
range -Air 300 TR & 30 TR & 30 TR & 30 TR & 50 TR &
1-150 TR 50-200 TR 30 TR & above
Condition above above above above above
7
temperature
range 10-50 TR 50-200 TR 30 TR & above
------ ----- ----- ----- -----
-Subzero temp.
range
5-6 mm Hg
2.5-3.5 bar a 5-6 mm Hg 5-6 mm 1.2kg/cm2(a)
5-6 mm Hg (abs)
Typical Internal 0.15-0.40 bar a (abs) Hg (abs)
2-5.5 bar (abs)
Pressure Levels 11-12 bar 18 kg/cm2(a)
-Low -High 370-390
60-70 mm 2 kg/cm2
9 1.20-1.50 bar a 18-20 bar 60-70 mm mm Hg
Hg (abs) (a)
-5 to 50oC Hg (abs) (abs) -25 to +150oC
Typical Internal
Temp. Levels -25 to 50 C
o
-25 to 50oC
+4 to +4 to
+4 to 75oC +4 to
130oC 160oC
+130oC
Typical Cooling
tower capacity
range per 100
TR of chillers
-Air conditioning 130 120 120 260 200 370 170 290
Temperature
10
Range
- Subzero temp. 190 ----- 160 --- --- --- --- 290
range
Typical Make-up
water quantity
range in Ltrs/Hr. 672 620 620 1345 1035 1914 880 1500
-Air Conditioning
11
temperature
range 983 --- 830 --- --- --- --- 1500
-Subzero temp.
range
Material of
12 construction --- --- --- Cu-Ni or Stainless Steel Carbon Steel
-Generator
-Absorber --- --- --- Cu-Ni Carbon Steel
Copper / Carbon copper / Copper/
-Evaporator Cu-Ni Carbon Steel
steel Carbon steel Carbon steel
Cu-Ni
Copper / Carbon Copper / Copper /
-Condenser Carbon Steel
steel Carbon steel Carbon steel
-Solution Heat
--- --- --- Carbon Steel Carbon Steel
Exchange
Cast Iron Cast Iron with
-Solution Pump --- --- ---
Hermatically Sealed (Canned motor type) Meh.Seal
-Refrigerant --- --- --- Cast Iron Not needed
pump Hermatically Sealed (Canned motor type)
Normally
Expected Periodic Compressor Overhaul Tube Replacement Practically no
14
Repairs / Tube Replacement after 1-12 years due to Corrosion repairs
Maintenance
Factory
Factory
Assembled
Assembled
15 Factory Assembled upto 230 TR in
packaged Or
A/C & subzero
Site Assembled
range
Sudden Power
failure for 45-
a) Vacuum in Chiller 60 min. or
-Lubrication b) Purge System for Vacuum more can
disturb the
System c) Corrosion Inhibitors in distillation
-Compressor
Absorbent column for
Critical -Electricity Operation &
17 ---- continuous
Parameters supply Maintenance d) Surfactants in Absorbent operation.
-Electrical
Needs D.G.set
Power Panel e) Cooling Water Treatment if there is
Maintenance
f) Cooling Water Temperature frequent power
failure for
g) Heat Source Temperature periods longer
than 30 min.
SMALL AMMONIA REFRIGERATOR
Anhydrous Ammonia (Nh3) has been used for many years to perform all
types of refrigeration and air conditioning chores. Anhydrous Ammonia means
ammonia without water, Aqua Ammonia is a solution of ammonia and water
which is used in refrigeration and air conditioners that are not a vapor
compression type. Vapor compression systems use compressors to compress
the ammonia vapor. Absorption type systems do not use a compressor but
instead use a generator. These systems shall be the main topic of the
following chapters. It is assumed by the Author that you have some
knowledge of refrigeration and are aware of the cycles and pressures of
refrigeration in general. Please refer to our available Browser Books on the
subject if you are not. Ammonia Refrigeration Basics is a good source of
basic information should you require a better understanding on the subject.
Example:# 101A
The Intermittent absorption system uses a generator charged with water and
ammonia. A heat source, usually a kerosene flame, heats this solution in the
generator. The ammonia is vaporized and driven off.
A condenser, at the top of the system, condenses the ammonia vapor into a
liquid. The liquid flows by gravity into the liquid receiver shown above and
then into the evaporator. During the generating cycle, little or no refrigerating
effect is taking place. As the system cools, the pressure drops, causing the
liquid ammonia in the evaporator to boil (flash off) and absorb heat. The cycle
is completed when vaporized ammonia is re-absorbed in the Aqua ammonia
solution in the generator.
When the kerosene has all been burned (usually from 20 to 40 minutes), the
generating cycle ends.
Example:#101B
The pressure in the system drops as the water cools and absorbs ammonia
vapor. Liquid ammonia (Light Blue) flows into the evaporator, begins to
evaporate, and cools it. Evaporated ammonia (Aqua Blue) flows back through
the tube (B). It is again absorbed by the water in the generator. Refrigeration
continues, usually until the next firing of the kerosene burner. The small
restrictor perform two functions, it allows the liquid to enter the evaporator at
a controlled level. This protects the evaporator from getting flooded. The
restrictor also acts as a expansion valve which greats a pressure differential.
A pressure differential is essential to the refrigeration cycle as it causes the
liquid ammonia to change it's boiling point from a high pressure flash of
temperature to a lower pressure flash off temperature. Without this change in
pressures the refrigeration would not be performed and the system would
simply act as an ammonia container.
This type of refrigerating system is quite simple. The piping is welded steel
because the pressures on the generating cycle are quite high. The
refrigerating ability is quite good. Kerosene flame heated absorption
refrigerators are popular in areas where electric power is not available.
Other means of firing the burner can be propane or natural gas. Many RV unit
refrigerators use a combination of propane fired burners and add a small 12
volt fan assembly to improve cooling within the evaporator section of the
refrigerator (Ice Box).. Many types of absorption systems are on the market
these days and are not limited to small appliances. The theory can and has
been applied to very large commercial systems and perform in much the
same manner.
Most small RV type refrigerators are not field repairable due to the critical
charge ( The right amount of Aqua Ammonia ) and the nature of the system
construction. If a small unit develops a leak, the best thing to do is replace it
with a new one. Most manufacturers design the units to last for a very long
time, but a damaged unit should be replaced (Leaking). Maintenance can and
should be performed on the burner assembly and the piping that feed the
propane or kerosene. Most Aqua Ammonia leaks are easy to find as are
Anhydrous Ammonia leaks the smell is very strong and aids in detecting even
the smallest of leaks.
DALTON'S LAW
The law further explains that each gas behaves as if it occupies the
space alone. To illustrate, the absorption refrigerator uses two gases,
ammonia and hydrogen. The ammonia, at room temperature, is
absorbed by the water in the closed sustem.
Heating this solution drives out the ammonia. (The hydrogen is not
absorbed by the water and remains as a gas.) Due to the pressure it is
under, the ammonia condenses into a liquid in the condenser. The
pressure is uniform throughout the system. Total pressure in the
system is the sum of the vapor pressure of the ammonia plus the
hydrogen pressure. When the pressure of the ammonia vapor is below
the pressure corresponding to the vapor pressure for ammonia alone,
the ammonia continues to evaporate. It tries to reach a vapor pressure
corresponding to the temperature in the absorber.
This refrigeration device is widely used in domestic refrigerators, and
recreational vehicles. It is also used in year-around air conditioning of both
homes and larger buildings. The unit consists of four main parts the boiler,
condenser, evaporator and the absorber. When the unit operates on
kerosene or gas, the heat is supplied by a burner. This element is fitted
underneath the central tube (A). When operating on electricity, the heat is
supplied by an element inserted in the pocket (B).
The evaporator is supplied with hydrogen. The hydrogen passes across the
surface of the ammonia. It lowers the ammonia vapor pressure enough to
allow the liquid ammonia to evaporate. The evaporation of the ammonia
extracts heat from the evaporator. This, in turn, extracts heat from the food
storage space, lowering the temperature inside the refrigerator.
The mixture of ammonia and hydrogen vapor passes from the evaporator to
the absorber. A continuous trickle of weak ammonia solution enters the upper
portion of the absorber. It is fed by gravity from the tube (D). This weak
solution flows down through the absorber. It comes into contact with the
mixed ammonia and hydrogen gases. This readily absorbs the ammonia from
the mixture. The hydrogen is free to rise through the absorber coil and to
return to the evaporator. The hydrogen circulates continuously between the
absorber and the evaporator.
The strong ammonia solution produced in the absorber flows down to the
absorber vessel. It passes on to the boiler system, thus completing the full
cycle of operation.
This cycle operates continuously as long as the boiler is heated. A thermostat
which controls the heat source regulates the temperature of the refrigerated
space.
Since the refrigerant is ammonia, it can produce quite low temperatures. Most
systems require electrical devices, so both gas and electricity must be
supplied. Except for the thermostatic controls and (in some cases) fans, there
are no moving parts.
Service is usually quite simple. The burner and stack must be kept clean. The
refrigerator should be carefully leveled before being placed in operation.
2. Features
Single-Effect Absorption Heat Pump Schematic (Source: Ammonia-Sodium Thiocyanate Double-Effect Abs
M. J. Moran and H. N. Shapiro, Fundamentals of Engineering Heat Pump (Source: Columbia Gas System Service
Thermodynamics, 4th edition, Wiley) Corporation)
A simple, single-effect absorption heat pump is shown above. The principle of operation is as
follows: thermal energy is used to boil a refrigerant from a concentrated refrigerant-absorbent
solution in a generator at high pressure. The refrigerant is condensed using ambient air as the
heat sink, and expanded to a low pressure across a valve. At this low pressure, the refrigerant
is cold enough to effect space-conditioning as it evaporates in the evaporator, thus cooling
room air. The evaporated refrigerant is combined with the dilute solution in an absorber (while
releasing the heat of absorption), from where it is pumped back in liquid form to the generator,
which requires orders of magnitude less electrical energy than the compression of the
refrigerant vapor in conventional systems. This thermodynamic cycle can also be run in the
heating mode in winter, with the evaporator coupled to the outdoor air to withdraw heat from
the ambient, and the condenser and absorber coupled to the indoor air to provide space
heating. Thus, these thermodynamically attractive absorption systems have been implemented
in large commercial applications.
The coefficient of performance of absorption heat pumps can be improved by using increasingly
complex thermodynamic cycles. One example is a double-effect cycle, as shown in the
adjacent figure. In such a cycle, the heat of condensation of the refrigerant generated in the
gas-fired generator is used to generation a "second effect" refrigerant stream, thus improving
the COP over the corresponding single-effect values. In the 1980s, Dr. Garimella developed a
double-effect residential heat pump (Garimella et al. 1992) using an ammonia-sodium
thiocyanate fluid pair as the working fluid, in collaboration with Prof. Richard N. Christensen of
The Ohio State University and Steven Petty, Bert Cook and others at the Columbia Gas System
Service Corporation. A prototype system with a nominal cooling mode COP of 0.8 and a
heating mode COP of about 1.6-1.8 was developed.
Triple-Effect Absorption Heat Pump Duhring Diagram Dual-Cycle Absorption Heat Pump (Source: Batte
(Garimella et al. 1997) Institute, Columbus, OH)
Triple-effect cycles offer further increases in COP through additional internal recuperation.
Several cycle layouts are possible for the development of a triple-effect cycle, one of which is
shown above as a Duhring diagram. Here, the heat of condensation, absorption and
rectification from the high pressure cycle are used as the heat source for the desorber of the
low pressure cycle. Systems with this cycle configuration employing ammonia-water as the
working fluid for the high pressure cycle, and ammonia-water or ammonia-sodium thiocyanate
for the low pressure cycle were investigated by Dr. Garimella (Garimella et al. 1997), and
yielded high COPs. Performance variation over a range of postulated ambients was also
documented.
Another approach to improve the COP of an absorption cycle without the corresponding
increase in system pressures typically required for multiple-effect cycles is the use of a dual
cycle, as shown above. A dual-cycle using LiBr/H2O as the working fluid for the high
temperature cycle and ammonia-water for the low-temperature cycle was investigated in the
mid-eighties by Dr. Garimella and his colleagues at Battelle Memorial Institute, Columbus, OH
with funding from the Gas Research Institute, Chicago, IL. Here, the heat of condensation from
the LiBr/H2O cycle is used as the heat source for the ammonia-water portion of the cycle.
Considerable advantage was taken in this system of the numerous internal recuperation
possibilities. Multiple heat exchange functions were performed in individual components. Two
notable examples are the Absorption Power Module (which combines the desorption of water,
condensation of water, and the desorption of ammonia-water) and the Quad Heat Exchanger
(which combines the solution-solution heat exchange, water condensate subcooling, and the
rectification of ammonia). Schematics of these components are shown below.
Dual-Cycle Absorption Heat Pump Multi-Function Components (Source: Battelle Memorial Institute, Columbus, OH
Generator-Absorber Heat Exchange heat pumps offer another means of obtaining extremely
high COPs with the pressures representative of a single-effect cycle. Essentially, the cycle is
operated over a large absorbent-refrigerant concentration range, which offers possibilities for
considerable overlap in the temperature ranges of the absorption and desorption processes.
Therefore, the external (e.g., gas-fired) heat input can be minimized. A portion of the
desorption is done using the high-temperature dilute solution exiting the desorber as the heat
source. Similarly, yet another portion of the desorption is conducted using the solution near
the hot end of the absorber, which over this wide concentration range, is hotter than the cold
end of the generator. Detailed investigations of the performance of the cycle as a heat pump
in the heating and cooling modes were conducted by Garimella et al. (1996).