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Choosing chiller technologies

Engineered Systems, Feb, 2003 by Evans J. Lizardos, John E.
Lizardos
With the variety of chiller options on the market today, it is imperative to determine which
approach will provide the lowest operating costs over the long term. Here, the author provides
a procedural method for factoring in the variables involved in the chilled water decision for a
given project.

Consulting engineers routinely recommend chiller technologies to clients who are seeking the
lowest annual energy operating costs to manage their facilities. Most often, evaluations are
made comparing gas/steam absorption machines vs. rotary/screw/centrifugal electric-driven
chillers. Naturally, first cost, reliability, maintenance, and equipment preferences are important
factors during their assessment. However, annual operating costs are most often the primary
consideration in their final decision.

The procedure that follows demonstrates a method to determine the magnitude of annual
operating cost differentials for gas and steam vs. electric.

1. Determine the tonnage and select the type of electric chiller and the type of absorption chiller
to be used in the comparison.

2. Calculate the operating cost factor (OCF) based on 1,000 annual hours of the equipment
running at full load:

OCF = 1,000 x (tonnage) x efficiency factor (EF) from Figure 1.

3. Once the OFC is known, multiply it by the energy cost ($/therm - $/kW $11,000 lb of steam)
to ascertain the annual operating energy cost (AOEC):

AOEC = (OCF) x (energy cost).

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Energy costs for central steam plants are usually in the range $6.00 to $8.00/1,000 lb of
steam. The method used to determine the energy costs can be best shown by the following
example:

Assume you are paying $0.70/gal for fuel oil or $0.5/therm for natural gas (142,500 Btu/gal at
$0.70 gal or 100,000 Btu at $0.5/therm.) The cost to generate 1,000 lb of steam would be:

High-pressure steam at 100 psig:

For fuel oil:

$0.70/gal x 1,000 lb x 880 Btu/lb/142,500 Btu/gal x 0.72 boiler efficiency = $6.00/l,000 lb

For gas:

$0.50/therm x 1,000 lbs x 880 Btu/lb/100,000 Btu/therm x 0.72 boiler efficiency =

$6.11/1,000 lb

Low-pressure steam at 12 psig:

For fuel oil:

$0.70/gal x 1,000 lb x 949 Btu/lb/142,500 Btu/gal x 0.72 boiler efficiency = $6.48/l,000 lb

For gas:

$0.50/therm x 1,000 lb x 949 Btu/lb/100,000 Btu/therm x 0.72 boiler efficiency =

$6.59/1,000 lb

Naturally, this approximate cost of $6.00/1,000 lb is just the fuel energy cost to produce the
1,000 lb of steam. Chemical treatment, operating personnel, and electrical power to equipment
are not included in these costs.

Energy costs for electric are computed from the monthly utility bills in which the total costs
(electric kWh consumption, demand charges, and fuel surcharges) are divided by the total
monthly kWh consumption:

$/kWh= Monthly kWh cost demand charges and fuel surcharges/Total monthly kWh consumed

Energy costs for gas are also computed from the monthly utility bill in which the total of all
monthly charges is divided by the number of therms consumed ($/therm).

The following example will illustrate the procedure outlined above:

1. Assume you have an existing boiler plant capable of generating 100 psig at an energy cost of
$6.00/1,000 lb or 12 psig steam at an energy cost of $6.48/1,000 lb.

2. Neglecting for this example first cost, equipment footprint size, maintenance, reliability, and
equipment preferences, determine the lowest operating cost for the following 300-ton water-
cooled chillers. The abbreviations are defined as: single-effect, low-pressure steam absorption
(SELPSA); double-effect, high-pressure steam absorption (DEHPSA); double-effect, gas

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absorption (DEGA); and electric-driven centrifugal (EDC).

3. Calculate the operating cost factors:

SELPSA - OCF = 1,000 hr x 300 tons x 18 lb/ton

= 5,400,000 lb of steam.

DEHPSA - OCF = 1,000 hr x 300 tons x 13.7 lb/ton

= 4,110,000 lb of steam.

DEGA - OCF = 1,000 hr x 300 tons x 0.12 therms/ton

= 36,000 therms.

EDC - OCF = 1,000 hr x 300 tons x 0.58 kW tons

= 174,000 kW.

4. Determine the annual operating energy cost (AOEC) for the SELPSA and DELPSA.

SELPSA: AOEC = (OCF) x (energy cost)

AOEC = (5,400,000) x ($6.48/1,000 lb)

AOEC = $34,992

DEHPSA: AOEC = (4,110,000) x ($6.00/1,000 lb)

AOEC = $24,660

5. Determine the energy cost for gas and electric that would equal the annual operating cost of
the DEHPSA.

Electrical energy cost: AOEC/OCF = $24,660/174,000 kW = $ 0.14/kW

Gas energy cost: AOEC/OCF = $24,660/36,000 therms = $0.68/therm

FIGURE 1

An abridged table taken from the ASHRAE Standard 90.1-2003 "Energy

Standard for Buildings Except Low-Rise Residential Buildings, Table
6.2.1C," which is the energy code for minimum equipment efficiencies.

Energy standard for buildings except low-rise residential buildings

(Table 6.2.1C)

Water chilling packages

Minimum efficiency requirements

Equipment type Size category

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Air cooled without condenser, <150 tons

electrically operated [greater than or equal to] 150 tons

Air cooled without condenser, All capacities

electrically operated

Water cooled, electrically All capacities

operated, positive displacement
(reciprocating)

Water cooled, <150 tons

electrically operaed,
positive displacement,
rotary screw and scroll

150 tons and <300 tons

[greater than or equal to]300 tons

Water cooled, <150 tons

electrically operated
centrifugal

[greater than or equal to]150 tons

and [greater than or equal to]300
tons

[greater than or equal to]300 tons

Air cooled, absorption All capacities

single effect

Water-cooled, absorption All capacities

single effect

Absorption double effect All capacities

indirect-fired

Absorption, double effect All capacities

direct-fired

Water Conversion calculation to

chilling determine the
packages
Minimum efficiency factor (EF)
efficiency
requirements

Equipment type Minimum COP = Output/Input

efficiency

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Air cooled without condenser, 2.8 COP 2.8 =

electrically operated 12,000 Btu/4,286 Btu
3.51 kW/1.25 kW

Air cooled without condenser, 3.10 COP 3.10 =

electrically operated 12,000 Btu/3,871 Btu
3.51 kW/1.13 kW

Water cooled, electrically 4.20 COP 4.2 =

operated, positive displacement 12,000 Btu/2,857
(reciprocating) 3.51 kW/0.84 kW

Water cooled, 4.45 COP 4.45 =

electrically operaed, 12,000 Btu/2,857
positive displacement, kW/0.79 kW
rotary screw and scroll

4.90 COP 4.9 =

12,000 Btu/2,449 Btu
3.51 kW/0.72 kW

5.50 COP 5.5 =

12,000 Btu/2,400 Btu
3.51 kW/0.70 kW

Water cooled, 5.00 COP 5.00 =

electrically operated 12,000 Btu/2,400 Btu
centrifugal 3.51 kW/0.70 kW

5.55 COP 5.55 =

12,000 Btu/2,162 Btu
3.51 kW/0.58 kW

6.10 COP 6.10 =

12,000 Btu/1,967 Btu
3.51 kW/0.63 kW

Air cooled, absorption 0.60 COP .6 =

single effect 12,000 Btu/
20,000 Btu

Water-cooled, absorption 0.7 COP .7 =

single effect 12,000 Btu/
17.143 Btu

Absorption double effect 1.00 COP 1.00 =

indirect-fired 12,000 Btu/
12,000 Btu

Absorption, double effect 1.00 COP 12,000 Btu/100,000

direct-fired Btu/therm

Conversion calculation to
determine the
efficiency factor (EF)

Equipment type COP = Effiency

Output/Input
Factor (EF)

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Air cooled without condenser,

electrically operated 1.25 kW/ton

Air cooled without condenser,

electrically operated 1.13 kW/ton

Water cooled, electrically

operated, positive displacement 0.84 kW/ton
(reciprocating)

Water cooled, 0.79 kW/ton

electrically operaed,
positive displacement,
rotary screw and scroll

0.72 kW/ton

0.64 kW/ton

Water cooled, 0.70 kW/ton

electrically operated
centrifugal

0.63 kW/ton

0.58 kW/ton

Air cooled, absorption 20,000 Btu/ 21 lb

single effect 949 Bu/lb * stm/ton

Water-cooled, absorption 17,143 Btu/ 18 lb

single effect 950.02 Btu/lb * stm/ton

Absorption double effect 12,000 Btu/ 13.7 lb

indirect-fired 880 Btu/lb ** stm/ton

Absorption, double effect .12

direct-fired therms/ton

* The enthalpy value for 12 psig steam is 949 Btu/lb

** The enthalpy value for 12 psig steam is 800 Btu/lb

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