11

Types of Systems ....................................................... 163

Estimating Horsepower per Ton ............... 163
Horsepower and Condenser Duty for Specific
Refrigerants........................................................... 164
Refrigerant Replacements ........................................ 182
Ethyleneh'ropylene Cascaded System .......... 183
Steam Jet Type Utilities Requirements ...................183
Ammonia Absorption Type Utilities
Requirements ......................................................... 186

162
 Refrigeration 163

Types of Systems
The following table shows the three most used refrig- Source
eration systems and approximate temperature ranges.
Table 1
Ludwig, E. E., Applied Process Design for Chemical and
Types of Refrigeration Systems Petrochernical Plants, Vol. 3, 2nd Ed., Gulf Publishing
co., p. 201.
Approx. Temp.
Range, "F Refrigerant

1. Steam-Jet 35" to 70" Water

2. Absorption
Water-Lithium 40" to 70" Lithium Bromide
Bromide solution
Ammonia -40" to +30" Ammonia
3. Mechanical -200" to +40" Ammonia, halogen-
Compression ated hydrocarbons,
(Reciprocating or propane, ethylene,
centrifugal) and others
The most common light hydrocarbonrefrigerant cooling
temperature ranges are:
Methane -200 to -300°F
Ethane and ethylene -75 to -1 75°F
Propane and propylene +40 to -50°F

Estimating Horsepower per Ton

This quick but accurate graph shows the design engi- Example. A water-cooled unit with an evaporator tem-
neer how much horsepower is required for mechanical perature of -40°F will require 3 horsepower/ton of refrig-
refrigeration systems, using the most practical refrigerant eration. A ton of refrigeration is equal to 12,000BTUhr.
for the desired temperature range. Here are equations for these curves in the form:

y = A+BX+CX' + D X ~EX^

where

y = horsepower/ton refrigeration
)I = evaporator temperature, O F

Condenser
temperature
"F A B C D E
105 1.751 -2.686e-2 1.1 52e-4 3.460e-8 1.320e-9
120 2.21 8 -2.882e-2 1.036e-4 3.029e-7 3.961e-9

Equations were generated using FLEXCURV V.2, Gulf

I . Publishing Co.

?i40 -120 -100 -80 -SO -40 -20 o 20 40 Source

EVAPORATOR TEMPERATURE , 'F

Figure 1. Horsepower requirements per ton of Ballou, Lyons, and Tacquard, "Mechanical, Refrigeration
refrigeration. Systems," Hydrocarbon Processing, June 1967, p. 127.
164 Rules of Thumb for Chemical Engineers

Horsepower and Condenser Duty for Specific Refrigerants

Technical literature has graphs for a number of often where

used refrigerants. Here is a set of graphs (Figure 1-21)
for horsepower and condenser duty per 10'BTUh of x = evaporator temperature, O F
refrigeration duty. Parameters are evaporator and con- y = horsepower/106BTU/hr refrigeration duty
densing temperature. Single-stage, two-stage. and three-
stage systems are included for propane, propylene,
ethane, and ethylene. Condenser
temperature
Example. A 50 ton two-stage propane refrigeration "F A B C D E
system has a 40°F evaporator temperature and a 120°F -
60 87.8 -1.786 9.881e-3 -7.639e-5
refrigerant condensing temperature. Find the gas horse- 70 103.4 -1.91 6 1.101e-2 -6.944e-5 -
power requirement and condenser duty. 80 121.3 -2.121 1.2S3e-2 -6.250e-5 -
Using the two-stage propane graphs at 40°F evapora- 90 138.3 -2.294 1.S30e-2 -7.986e-5 -
tor temperature and 120°F condensing temperature, the 100 160.8 -2.545 1.570e-2 -6.34%-5 -
110 183.0 -2.81 6 1.741e-2 -6.376e-5 -
gas horsepower requirement is 100hp/106BTU/hr. A 50 120 208.4 -3.047 2.009e-2 -1 .Owe4 2.422e-7
ton unit is equivalent to 50 x 12,000 = 600,00OBTU/hr, 130 240.9 -3.447 2.285e-2 -1.220e-4 3.20%-7
so the gas horsepower is 100 x 0.6 = 60. The condenser 140 279.9 -3.939 2.657e-2 -1.390e-4 3.451e-7
duty read from the companion two-stage propane graph
is 1.25 x 0.6 = 0.75 MMBTU/hr.
If equations are desired, the curves can be fitted ac- Equations were generated using FLEXCURV V.2, Gulf
curately using polynomials. Here are the equations for the Publishing Co.
single-stage propane horsepower graphs, for example.

y = A + B X + CX' + D X EX^
~ (texf coritirzued on page 181I
VI

Evaporator temperature, "F

Figure 1. Gas horsepower for single-stage propane refrigeration system.

166 Rules of Thumb for Chemical Engineers

Figure 2. Condenser duty for single-stage propane refrigeration system.

 Refrigeration 167

C
.-
1

I
.-m
c
L

!
a
t
c

Figure 3. Gas horsepower for two-stage propane refrigeration system.

168 Rules of Thumb for Chemical Engineers

2.0I
1
c
3
V
1.9

1.8

1.7

1.6

.
-2
(0

.
.c
3
m
1.5

z 1.4
E
1.3

1.2

1.1

1.o
-40 -20 0 20 40 60 80 100 120 140
Evaporator temperature, "F

Figure 4. Condenser duty for two-stage propane refrigeration system.

 Refrigeration 169

Figure 5. Gas horsepower for three-stage propane refrigeration system.

170 Rules of Thumb for Chemical Engineers

1.9

1.8

1.7

1.6

.
-
.
1.5

-
.c
2
m 1.4
E
z 1.3
3
L
3
U
L

I 1.2
01
0
1.1
-m8
I
0
I- 1.o
-40 -20 0 20 40 60 80 100 120 140
Evaporator temperature, ‘F

Figure 6. Condenser duty for three-stage propane refrigeration system.

 Evaporator temperature, 'F

Figure 7 . Gas horsepower for single-stage propylene refrigeration system.

172 Rules of Thumb for Chemical Engineers

2.4

2.2
z
.-
3
-0

2.0

-
f
3
*
m
1.8

€ 1.6
I
i
,d
3
D
L
I
al 1.4
-0
C

-sm
0
F
1.2

1.o
-50 -30 -10 0 10 30 50 70 90 110 130 140
Evaporator temperature, "F

Figure 8. Condenser duty for single-stage propylene refrigeration system.

 Refrigeration 173

Figure 9. Gas horsepower for two-stage propylene refrigeration system.

174 Rules of Thumb for Chemical Engineers

c
z
3
0
C
0
.-I
I
.-rn
.-
L

Evaporator temperature, "F

Figure 10. Condenser duty for two-stage propylene refrigeration system.

 Refrigeration 175

-50 -30 -10 0 10 30 50 70 90 110 130 140

Evaporator temperature, "F

Figure 11. Gas horsepower for three-stage propylene refrigeration system.

176 Rules of Thumb for Chemical Engineers

2.2

>
I
3
D
I:
.- 2 0
I
rn
L
UJ

-m
.-
L

L
-
-
-
r
I

3
1.8
I
m
w

.
2
.
I

IT
3
m 1.6
c

2:
c
3
U
L
0
1.4
E
U
C
u

1.2

1.o
-50 -30 -10 0 10 30 50 70 90 110 130 140
Evaporator temperature, "F

Figure 12. Condenser duty for three-stage propylene refrigeration system.

c
>
3
-0
C
.-c
m
L
W
.-cn
c
L.

--E
E
I

3
c
m

.
0

-2a
L
i
5
a
3
B
.K
v)
m
(3

-120 -100 -80 -60 -40 -20

Evaporator temperature, "F

Figure 13. Gas horsepower for single-stage ethane

refrigeration system.

Figure 15. Gas horsepower for two-stage ethane refrig-

eration system.

>
c
3
TI
1

Evaporator temperature, "F

Figure 14. Condenser duty for single-stage ethane Figure 16. Condenser duty for two-stage ethane refrig-
refrigeration system. eration system.
178 Rules of Thumb for Chemical Engineers

260

240

220

Evaporator temperature, "F

Figure 17. Gas horsepower for three-stage ethane Figure 18. Condenser duty for three-stage ethane refrig-
refrigeration system. eration system.
 Refrigeration 179

360

340

320

300

280

260
2.
c
3
U
240
-I
c
5?

F
c
220
2
-
r
=
c
200
m

-.180
W 1
"
3
13
3 C
L
.-c
160 E
$ .-m
L
Q
W L

$
L
140
Ln

d
120

100

E
80 2
i
4-
3
U
60
i
W
U
40 0
-
u
m
0
I-
20

0
-1 50 -130 -110 -90 -70 -50 -30
Evaporator temperature, "F

Figure 19. Single-stage ethylene refrigeration system.

180 Rules of Thumb for Chemical Engineers

320

300

280

260

240

220

200 2.0

180
-
U
z
3

C
.-c0
160 1.8
.-m
L
L

E
140

120

100

E
80 1.4 2
i -
3
U
60 W
L

C
W
U

-$m
40 1.2
w
0
k
20

n
1.o
-150 -130 -1 10 -90 -70 -50 -30
Evaporator temperature, "F

Figure 20. Two-stage ethylene refrigeration system.

 Refrigeration 181

2.
L
3
U
t
.-
L
E
.-0)
c
L

-.
f
I
m
H
I

Evaporator temperature, "F

Figure 21. Three-stage ethylene refrigeration system.

Source

Mehra, Y. R., "Hydrocarbon Refrigerants series," parts 1,

2, 3, and 4, Chernicnl Engineering, December 18,
1978, January 15, 1979, February 12, 1979, and March
26, 1979.
182 Rules of Thumb for Chemical Engineers

Refrigerant Replacements

As you know, most countries are phasing out certain See the "Properties" section for a description of
refrigerants to lessen damage to the ozone layer. The physical data available.
chemicals being phased out are chlorofluorocarbons
(CFCs) and hydrochlorofluorocarbons (HCFCs).
Source
Replacements are hydrofluorocarbons (HFCs) and certain
blends. The DuPont web site (www.dupont.com) gives
E. I. DuPont de Nemours and Company web site
the handy Table 1 of recommended replacement refriger-
(www.dupont.com), "Selection of DuPont Refriger-
ants for various applications.
ants," reprinted by permission.
DuPont also provides a computer program to simulate
performance of different refrigerants in your system. It is
called the "DuPont Refrigeration Expert" (DUPREX).

Table 1 Table 1 (Continued)

DuPont Refrigerants
CFCIHCFC New
CFCIHCFC New Application Refrigerants Retrofit System
Application Refrigerants Retrofit System
Frozen Food R-502 SUVA@ SUVA@
Air conditioning in R-11 SUVA@123 SUVA@123 storage below -18°C HP80 HP62
buildings and industrial .SUVA@'
temperature control HP81
R-12 SUVAB SUVA@ Refrigerated R-12 SUVA3 SUVA@
134a 134a TransDort MP66 134a
SUVAB
Low R-502 SUVA@ SUVA@
MP39
Temperature Transport HP80 HP62
R-22 SUVA"' SUVA"
9000 9000 Medium R-12, SUVA@ SUVA@
SUVA@ Temperature R-500 MP39 134a
9100 commercial refrigeration
SUVA"
Split and window N C R-22 SUVA@ SUVAB
MP66
systems 9000 9000
SUVAB Low to Medium R-22 .SUVA@ SUVAa
9100 Temperature commercial HP62 HP62
refrigeration
Air and marine R-114, SUVA@l24 SUVA@l24
A/C svstems R-12B1 Very low temperature R-1361 SUVA@ SUVA"9100
9100
Automobile R-12 SUVA@l34a SUVAal 34a
R-13 HFC-23 HFC-23
air conditioning
R-503 SUVAB95 SUVA@95
SUVA"
MP52 *The choice of a SUVA@refrigerant will depend on the application as
Fresh food R-12 SUVA@ SUVA@ well as on the type of CFC to replace.
storage, above O'C MP39 134a This table is intended as a guide, to cover the situations most likely to
be encountered. The equipment owner may request the use of the per-
Domestic refrigerators, R-12 SUVA@ SUVAE'
manent or "New System" refrigerant in a retrofit, usually to ensure the
drink cooler, commercial MP39 134a
lowest ODP
and restaurant non-frozen Retrofitting directly to a SUVAo HFC Refrigerant can of course be done,
chilled foods storaae but takes longer and costs more than the simple change to a SUVA@
Light commercial R-22 SUVAa SUVA@ Blend.
refrigeration HP62 HP62
SUVA@
HP62
 Refrigeration 183

Ethylene/Propylene Cascaded System

The following information was used in olefin plant Propylene alone at 110°F condensing temperature
case studies to determine if the ethylene/propylene cas-
A B C Range, "F
caded refrigeration systems had enough horsepower for
various plant operations. The propylene was condensed 1.98 -1.991 e-2 1.691e-5 -40 to 110
against cooling water at 110°F and the ethylene was con- Ethylene alone at -20°F condensing temperature
densed against propylene at -20°F. For comparison, the
horsepower requirements for each refrigerant alone are A B C Range, "F
also shown. 4.67 -1.256e-2 7.77ae-5 -1 50 to -60
The data is presented in the following equation form:
Cascade with ethylene condensing at -20°F and propylene
at 110°F

A B C Range, "F

where 3.47 -2.289e-2 4.444e-5 -1 50 to -60

y = horsepower/ton refrigeration Equations were generated using FLEXCURV V.2, Gulf

x = evaporator temperature, "F Publishing Co.

Example. With the example cascaded system at an Source

evaporator temperature of - 100°F. the horsepower
requirement is 6.2 hp/ta8nrefrigeration. A ton of refriger- The horsepower per ton raw data is from a private
ation is equal to 12,000BTU/hr. source.

Steam Jet Type Utilities Requirements

Steam and cooling water requirements for barometric water. If one has 140gpm of 85°F cooling water the y-
steam jet refrigeration units are shown in the following axis is 7 g p d t o n of refrigeration. The steam consumption
graphs for given available cooling water temperature and on the x-axis is about 17 lb/hr steam per ton of refrigera-
delivered chilled water temperature. The graphs are for tion. A ton of refrigeration is equal to 12.000BTU/hr.
IOOPSIG motivating steam. For 30-50 PSIG steam. the
quantity required will increase by a factor of about 2 for
Source
40°F chilled water and a factor of 1.5 for 55°F chilled
water.
Ludwig, E. E., Applied Process Design for Cizeniical rid
Petrocizenzical Plarzts, Vol. 3 , 2nd Ed.. Gulf Publishing
Example. To produce 20 tons of refrigeration while
Co., pp. 208, 209.
delivering 50°F chilled water, the steam consumption
depends upon the quantity and temperature of the cooling
184 Rules of Thumb for Chemical Engineers

Ib./hr. Steom per Ton o f Refrigerotion(for 1OOpsig Steom)

Figure 1. Ib/hr steam per ton of refrigeration (for 1OOpsig steam) for 40°F chilled water.

Coolina Water TemDerature .*F.

Ib./hr. Steam per Ton o f Rcfrigcration(for 100 psig Steam)

Figure 2. Ib/hr steam per ton of refrigeration (for 1OOpsig steam) for 45°F chilled water.
 Refrigeration 185

Figure 3. Ib/hr steam per ton of refrigeration (for 1OOpsig steam) for 50°F chilled water.

Coolinq Water Temperature ,OF.

Ib.lhr. Steam per Ton of R e f r i q e r a t i o n l f o r 100 psiq Steam1

Figure 4. Ib/hr steam per ton of refrigeration (for 1OOpsig steam) for 60°F chilled water.
186 Rules of Thumb for Chemical Engineers

(te.\-r coritiniiedjl-otii page 183)

Ammonia Absorption Type Utilities Requirements

Steam and cooling water requirements for ammonia Table 1

absorption refrigeration systems are shown in Table 1 for Steam and Cooling Water Required for Ammonia
single-stage and two-stage units. The tables are based Absorption Refrigeration Systems
upon cooling water to the condenser of 85°F with 100°F Single-stage
condensing temperature. Water from the condenser is Btu Per Min.
used in the absorbers. Req. In Water Rate
Steam Sat. Generator Per Thru Cond.
Temp., "F. Ton Refrig. Steam Rate (75°F.
Example. For an evaporator temperature of -lO°F, a Evap. Req. In (200 BTU/ Lb/Hr/Ton Temp. Rise),
steam rate (300°F saturated temperature in the generators) Temp., "F Generators Min.) Refrig. GPMITon
of 33.6 lb/hr/ton refrigeration is required. Also, 5.4gpm 21 0 325 20.1 3.9
50
cooling waterlton refrigeration, assuming a 7.5"F rise 40 225 353 22.0 4.0
through the condenser, are required in this system. 30 240 377 23.7 4.1
20 255 405 25.7 4.3
10 270 435 28.0 4.6
Source 0 285 467 30.6 4.9
-1 0 300 507 33.6 5.4
-20 315 555 37.3 5.9
Ludwig, E. E., Applied Process Desigrz for- Chenzical and -30 330 621 42.5 6.6
Petrochemical Plarzts, Vol. 3, 2nd Ed., Gulf Publishing -40 350 701 48.5 7.7
-50 370 820 57.8 9.5
Co., p. 214, Table 11-2.
Two-stage
Btu Per Min. Water Rate
Steam Sat. Req. In Steam Rate, Thru Cond.
Temp., OF., Req. Generator Per LbIHrlTon (75°F. Temp.
In Generators Ton Refrig. Refrig. Rise), GPMlTon
175 595 35.9 4.3
180 625 37.8 4.5
190 655 40.0 4.6
195 690 42.3 4.9
205 725 44.7 5.3
210 770 47.5 5.7
220 815 50.6 6.3
230 865 54.0 6.9
240 920 58.0 7.8
250 980 62.3 9.0
265 1050 67.5 11.0