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By J.ILANGUMARAN
REFRIGERATION SYSTEM
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
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
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
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
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
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
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
Automobile Engineering Petrochemicals Pharmaceutical Cement Soft Drinks Chemicals Fertilizers Refinery Commercial Establishments and more
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
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
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.
5 0 -5 - 10 - 20
MAINTENANCE ASPECTS IN REFRIGERATION Remove Excess Charge Clean the condenser periodically Add refrigeration to correct load Maintain oil temperature between 50 - 60 C
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
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
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
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
: :
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.
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
: : : :
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.
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
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