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• Which is better?
Gravity Flooded System
Static
height
LIQUID CONTACT
BETTER IN PUMP
CIRCULATION
POINT-3
• TRIANGULAR PITCH OR SQUARE?-WHICH IS BETTER
Advantages-
1. Lower defrost Build up
2. Easy and quicker defrost
3. Lower Air resistance
4. Lower motor power
Disadvantages-
1. Lower air side heat Transfer
coefficient
2. Higher fin Temperature
3. Larger Air cooler compared to
Triangular fin
4. More expensive
1. Square Pattern: 21 Tubes
LMTD 4.93 which is 25.6% -More which means 25.92% smaller cooler
area selection
TD1
=Air on Temp.(Room Temp.)-Saturated Evaporating temp. at coil outlet
• Q= U * A * LMTD or A=Q÷(U*LMTD)
• TD1 is method is based on the difference between the air temperature
entering the evaporator coil ( room Temperature)and the corresponding
temperature of the saturated suction pressure of the refrigerant
measured at the outlet of the evaporator.
• -Selection by TD1 gives adequate and bigger air cooler compared to TM
and hence should always be used.
• High humidity requirements will require coils with large surface areas
and must be run at low TD’s.
• Low humidity requirements will require coils with smaller surface
• areas and greater TD’s.
POINT-5
• Air cooler Area-Which area to be considered?
• surface area which includes fin area or coil internal
volume/length of coil without headers?
Cross Section of Typical Fin
AO-EXTERNAL AREA
AI-INTERNAL AREA
Tube Volume and Tube external area more Effective & important than fin
area-IF-A0/AI LESS, MORE EEFFECTIVE IS THE COIL
POINT -7
+1 °C +1.2 °C -1 °C +1 °C -1.2 °C -1 °C
Air in +1 °C
Air out -1 °C
Evaporating temp. -6 °C
Surface 284 m2
K value 24
Air temperature °C
Air temperature °C
+1.2 +1
+1 TD air, motor side 0.2 °K 0
0 -1
-1 -1.2
-2 -3
-3 -4
-4 -5
-5 -6
-6 -7
-7 -8
-8 -9
-9 -10
0.3 m/s
Most sources recommend a theoretical air speed of 0.3 m/s at the end of
the room. This is pure theory, however, because any airflow of less than
0.5 m/s is dispersed and becomes impractical to measure.
Slide 42
AIR DISTRIBUTION BASICS
AIR THROW & AIR SPREAD
STANDARD POTATO COLD STORAGE-2000MT
• Chamber Size each -21m Lx16m Wx13.7m H
Volume 4603 m3, floor Area=226 m2
• (Refrigeration load -85.32kW)-NHB DOCUMENT
• In each room normally there would be three air
cooler units, each of 33kW, and air quantity of
each is approx.39000 CMH, for 3 coolers it
would be 1,17,000 CMH
Adequate Air Quantity Based on room Size
• If we consider the same room for storing frozen product which is frozen
elsewhere and brought to the cold rooms.
• All other parameters remaining constant as above except insulation which
would be 150mm thick, instead 100mm since it is low temperature room and
assuming that the product temperature while loading has increased to -15 deg.
C, which was frozen earlier elsewhere at -20 deg. C-Refrigeration Load 24.8 kW
• There would be 2 air coolers each of 13kW having air volume as having
Approx. 13000CMH each cooler, totaling to 26,000CMH as against positive
temperature storage would have 39000CMHx3=1,17,000 CMH
• Conclusion-Air quantity Inadequate for room size-Always Select based on room
Size-Considering -Throw-Spread-drop.-Velocity-0.5m/s at 85 to 90% distance
Air Spaces between packages
Air Spaces
INCORRECT USE OF SPACE
No Proper Air Circulation on Product
Air Circulation In The Coldroom
c. 90 cm
40 cm 40 cm
3-5 cm
GOOD AIR DISTRIBUTION
Figure 8 Batch-continuous air blast freezer with counterflow air circulation
Pa
Difference
Pressure
m3/h
Volume Flow
Frost layer causes less space between
Frost layer blocks heat transfer from the fins so that the pressure drop in air side
air to the fins. Cooling capacity of the is rising. Less air flows through the heat
air cooler is getting less. exchanger coils.
Evaporator Coil Icing –Or-Excessive
Condensate removal-Reasons
• Coils running at too low a temperature
• Defrost system defective
• Storage RH is too high
• Inadequate air flow
• Coil design incorrect -high fin density, small tubing,
more than required depth leading to removal of
excess moisture than necessary
• Defective insulation-Air leakage through doors-holes
Defrost for 1Lb
1 Latent Heat Condensation 1076 Btu/lb
2 Sensible Heat to reduce Vapour Temp. From 500F to 320F 10 Btu/lb
3 Sensible Heat (320F to -150F) 23 Btu/lb
6 Latent heat of Frost 144 Btu/lb
7 Total BTU cost to produce frost 1253 Btu/lb
8 Raise temp. From -150F to 320F 24 Btu/lb
9 Latent Heat of Frost 144 Btu/lb
10 Sub total 576 Btu/lb
11 Raise water temperature from 320F to 420F 10 Btu/lb
12 Sub Total 754 Btu/lb
13 Sublimation (generally 16%)0.16x754= 121 Btu/lb
14 Evaporation (generally14%)0.14x754= 106 Btu/lb
15 Total defrost heat required(12+13 +14) 981Btu/lb
16 To produce frost 0.21KWH
17 To defrost frost 0.09KWH
18 Remove defrost heat 0.16KWH
19 Total KWH 0.46KWH
Defrost Loads-Latent Loads-Btu/0.7lb from coil
kWh
1 To produce Frost 0.21 kWh
2 To Defrost Frost 0.09 kWh
3 To remove Defrost Heat 0.16 kWh
4 Total power 0.46 kWh
6 Power required to remove 1 lb of Frost 0.46/0.7=0.66
kWh
Separate hot gas defrost line for defrost pans
As sensible Heat increases less defrost Frequency and closer fin spacing
Key Points for selecting right size evaporator
• Material of Construction
1. Stainless steel tubes, casing as well as drain pan & and Al fins
2. Entire construction in Aluminium
3. C.S. Tubes with hot deep galvanizing and aluminium fins
4. Any other material to suit surrounding conditions and refrigerant
Choice of Material
1. Hot Dip Galvanized Steel (Steel/Zn)- (SA179)
2. 304 S.S. Tubes with Aluminium Fins (SST/Al)- (SA249)
3. 3003 Gr. Aluminum Tubes with Aluminum Fins (Al/Al)- (SA210)
Material Properties
Metal Density Thermal Specific heat Tensile Allowable
Lbs/cft. conductivity Btu/lb. 0F strength Temperature
Btu/sq.ft0F/ft. kJ 0F
Q = U X A X T
Q = 4.5 X cfm X H
TD = TRM – TADP (Tevap)
SMALLER TD-LESS PRODUCT WEIGHT LOSS
Q = U X A X T
Q = 4.5 X cfm X H
TD = TRM – TADP (Tevap)
9
8
6
5
4
3
2
1
1200
1000
300
400
500
600
700
800
100
200
900
1100
0
3. HP-2/HP-1= (RPM2/RPM1)
3
9
8
7
6 BHP
FAN HP
5
4
3
2 COIL CAPACITY
1
8
7
CAPACITY
6
5 NET CAPACITY
4
3
2
1
1000
1200
1100
900
100
200
300
400
500
600
700
800
0
NET CAPACITY DECREASES WHEN FACE VELOCITY INCREASES AS LOSS OF FAN POWER IS
MORE THAN CAPACITY GAIN
•MORE COMPACT TUBE ARRANGEMENT
•LARGER TUBE DIAMETER
•LOWER SECONDARY TO PRIMARY AREA
•HIGHER PRESSURE DROP
•MORE FAN POWER
H1
H0
W1
W0
TS T0 T1
•DROP IN TEMPERATURE
•DROP IN MOISTURE
•DROP IN ENTHALPY
ENTERING AIR
LEAVING AIR
M0
M1
T2 T1 T0
COIL WITH SMALLER FACE AREA AND MORE ROWS DEEP WOULD REDUCE MOISTURE
CONTENT AND TEMPERATURE –M2 THAN MORE FACE AREA AND LESS ROS DEEP-M1
MORE ROW DEEP
(LOWER LEAVING TEMPERATURE)
M0
ORIGINAL
M1
MORE ROWS
OF TUBE
M2
MOISTURE CONTENT
AFTER 2 ROWS ENTERING AIR
AFTER 6 ROWS
AFTER 4 ROWS
AFTER 8 ROWS
TEMPERATURE
•EACH EXTRA ROW DOES LESS WORK
•CURVE STEEPER AS AIR PASSES
•RATIO OF MOISTURE REMOVAL TO TEMPERATURE DROP GREATER AT
OUTLET
CLOSER FIN
SPACING
T2 T1 T0
HIGHER AIR
FLOW RATE
T2 T1 T0
HIGHER
REFIGERANT
TEMPERATURE
T2 T1 T0
•REFRIGERATION CAPACITY DECREASES
•LEAVING AIR TEMPERATURE IS HIGH
• MOISTURE CONTENT IS HIGH
•RATIO OF MOISTURE REMOVAL TO TEMPERATURE DROP IS LESS
1. Efficient operation due to low discharge pressures. With 280C wet bulb temperatures,
it is possible to achieve and maintain 37 to 380C condensing temperatures and thus
lower discharge pressures.
2. The efficiency is better since both sensible and latent heat transfer takes place when
water comes in contact with hot tubes carrying ammonia gas.(Heat and Mass Transfer)
3. These condensers are generally site fabricated and thus reduces other incidental costs.
4. Can be attended /repaired while the plant is in operation by isolating particular bank.
5. Additional banks can be added when more capacity is required.
6. Coil surface visible, hence external cleaning can be done in case fouling is observed
7. Requires low head, water circulation pump and no fans are involved, thus saving in
power.
8. Do not require additional fan power, as these do not use fans and depend only on
natural air movement.
Disadvantages:
1. Occupies large floor space area. However, this drawback is generally overcome by
installing the condenser banks on the roof slab of the machine room.
2. Needs to be kept nearer to machine room to ensure shorter high-pressure ammonia gas
pipelines.
3. Spray water losses are high due to wind velocities as water is carried by winds.
4. Due to constantly varying wind velocities and direction, it is always not possible that all
spray water will wet the tube surface and hence capacity of condenser may not remain at
100% all the times.
5. Higher pressure drops on discharge side due to longer discharge pipe lengths.
Shell and Tube Condenser
Advantages:
1.Compact construction, can be used in skid mounted factory
assembled condensing unit
2.The condenser is installed generally in the plant room
3.The discharge pipe line is small
4.Water consumption is less compared to Atmospheric
condenser
Disadvantages:
1. Requires additional cooling tower and water pump sets with its water piping, valves and
controls
2. Cleaning of tubes requires stopping of compressors & dismantling water heads
3. Manufacturing in factory requires special skills and machinery for handling, rolling,
welding, tube expansion, testing etc.
4. Cooling tower fans and water pump sets requires extra power.
5. Cleaning of tubes require long wire brushes or chemical cleaning facility
6. Additional space for tube cleaning equal to at least the length of tubes needs to be
provided in the machine room.
7. With 280C-wet bulb, the water inlet temperature is around 320C, water out let
temperature is 360C and condensing temperature is around 400C, which is higher than
evaporative or atmospheric condensers.
PHE Semi Welded Condenser
1. Extremely compact, enabling factory produced condensing units, especially using screw
compressors.
2. High heat transfer coefficients on water as well as ammonia side due to turbulent flow
and higher velocities.
3. Capacity can be increased/decreased easily by adding/removing plates
4. Reduces total ammonia charge in the system
5. Reliable product since plates manufactured on automatic machines
6. Longer life due to S.S. construction of plates
7. Chances of ammonia leaking in to water do not exist. If ammonia leaks, it would be to
atmosphere and not in the water. This is important since many times cooling towers are
common for the entire utilities and other heat exchanger materials may not be
compatible with ammonia.
Disadvantages;
1. Requires chemical cleaning equipment
2. Water quality needs to be monitored and treated water is preferred
3. Ammonia gas has high discharge temperatures and hence proper material for gaskets need
to be selected. These may need frequent replacements and are expensive.
4. Higher pressure drops on water and ammonia side due to narrow passages
5. If condensing temperatures lower than 400C are required, it is possible with PHE, since PHE
can work with very small temperature differences between water temperature and
condensing temperature, however initial costs are of PHE are higher compared to other
designs.
6. The software available does not recognize two phase conditions i.e. first removal of
superheat, then latent heat for condensing and if required sub-cooling. The flow rates for
the same capacity indicated are different in condenser than evaporator. The mass flow in
system should remain constant, the PHE works out different mass flow rates for condenser
and evaporator
2nd August 2015 107
Evaporative Condensers
EVAPORATIVE CONDENSR OPERATION
Evaporative condenser Tube Arrangement
Advantages:
Condensing Temperature-0C 38 40