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 SCENARIO-

SCENARIO-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.
• 10°C to 40°
The temperature maintained can be from 10° 40°C 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 Expansion

Device

Condenser
Cooler

Work

TECHNICAL COMPARISON OF VAPOUR ABSORPTION CHILLER (VAC)

& VAPOUR COMPRESSION CHILLER (VCR)
VAC VCR
Equipment : Equipment :
Absorber, Generator, Condenser & Compressor, Condenser, Thermal Expansion
Evaporator Valve, Evaporator
Refrigerant : Water Refrigerant : CFC, Ammonia gases etc.
Absorbent : LiBr Absorbent : Not Applicable
Input Required : Steam Input Required : Power
 TECHNICAL COMPARISON OF
VAC & VCR
VAC VCR
Cycle : Cycle :
1. Take the latent heat from outside water 1. Take the latent heat from outside water
(Chilled Water) in evaporator by (Chilled water) in evaporator by
absorbent. refrigerant.
2. Refrigerant water will be absorbed by 2. These refrigerant at low temp. is
absorbent. compressed by compressor to high
3. These diluted absorbent is heated up temp. and higher pressure.
and separate the refrigerant in the 3. These high temp. refrigerant gas will be
generator. cooled down in the condenser,
4. The refrigerant vapour is condensed in refrigerant become a liquid.
the condenser & the absorbent which 4. This refrigerant will be expanded by
is coming from generator is cooled thermal expansion valve which is
down in the absorber. The total cycle connected to evaporator.
is operated under vacuum condition
i.e.6 mm Hg
 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
85°°C)
85
• 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
Non-
• Environmentally Clean & friendly
• Lesser Down Time
• Lower Noise Level
• Availability
• Continuous and Step-
Step-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 de-
de-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
30°°C uses more than twice
• A unit operating at - 30
10°°C.
energy required for operating at -10
• Reduction in condenser water temperature by
1°C or raising Chilled Water Temperature by
1°C leads to 1 to 1.5 % saving in power
consumption
 EFFECT OF EVAPORATION TEMPERATURE
Compressor Shaft
Evaporation Refrigeration kW / ton
Power kW

5 67.58 55.3 0.81

0 56.07 52.3 0.94

-5 45.98 49.8 1.08

- 10 37.20 46.6 1.25

- 20 23.12 38.7 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°
540 180° 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
Power Consumption Energy Input
Flow Hours Hours kW kWh
% % Run
1 2 1 2
30 5 438 23.33 4.73 10 219 2 072
40 5 438 23.56 6.08 10 319 2 663
50 10 876 24.03 8.01 21 050 7 017
60 10 876 24.71 10.61 21 646 9 294
70 10 876 25.62 14.04 22 443 12 299
80 20 1752 26.76 18.54 46 884 32 482
90 30 2628 28.17 24.28 74 031 63 808
100 10 876 30.22 31.48 26 473 27 576
100 8760 2 33 064 1 57 211

1 Two Way Valve Control 2 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 : Ref. SCREX 99
• Chiller Plant Capacity : 500 TR
• Power Consumption
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 Annual kWh
ECWT Annual
Poin Tons
°F hours Alt 1 Alt 2 Savings
ts
1 200 78 100 12 758 10 172 2 586
2 250 80 300 45 806 37 065 8 741
3 300 82 500 89 861 76 767 13 124
4 350 84 2 150 4 50 487 4 05 091 45 396
5 400 86 1 800 4 38420 4 12 744 25 676
6 450 88 200 56 709 55 754 955
7 500 90 100 32 438 33 851 -1 413
Total 5 150 11 26 479 10 31 414 95 065
•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
40°C
• Supply air @ 40°
25°C
• Design parameter is at 25°
• 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
• 17°C
Chilled water inlet / outlet temp. : 12 / 17°
• Hot water flow : 144 m3 / hr
• Hot water inlet / outlet temp 85°C
: 91 / 85°
• Cooling Water Flow : 300 m3 / hr
• 36.5°C
Cooling water inlet / outlet temp : 32 / 36.5°
• 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 : 0.56
• Evaporation temp : 30°°C
- 30
• Heating media temp : 172°C
172°
• Basis : 33°C
Cooling Water at 33°
 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
33°C
• Cooling Water at 33°
20°C
• Evaporation Temperature at 20°
• 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 : 1.75 kWh
• Operating Cost : Rs 7.0 / TR
• Difference in operating Cost : 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

Energy Input
Flow Hours Hours Power Consumption kW
kWh
Run
% % 1 2 1 2

40 5 438 12.80 2.67 5 606 1 169

50 15 1314 12.80 4.83 16 819 6 347

60 35 3066 12.80 7.85 39 245 24 068

70 20 1752 30.00 11.93 52 560 20 901

80 15 1314 30.00 17.27 39 420 22 693

90 10 876 30.00 24.16 26 280 21 164

100 0 0 0 0.00 0 0

100 8760 1 79 930 96 342

1 Two Way Valve Control 2 VSD 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