Lowtemperatureprocessdesign Module06 Lecture35

Module05
Lecture35:Lowtemperatureprocessdesign
Keywords:Refrigerationsystem

RefrigerationSystem

A refrigerator is simply a heat pump where heat is rejected to atmosphere( the sink).
Fig.41.3(lecture41) shows closed cycle system and Fig.41.5(lecture41) shows the absorption
refrigeration system. Since, absorption refrigeration system is more complex and expensive, it
isgenerally,notintegratedwithprocesses.

The grand composite curve, once again, can give the clue as to when the absorption system
mightbefavoredoverthecompressionsystem.Theabsorptionsystemrequiresalargeabove
ambient heat input. If there is sufficient waste heat from the process below the pinch at a
sufficientlyhightemperatureisavailable,thentheabsorptionsystemcouldberuncompletely
on free energy, whereas the competing compression refrigeration system has to run on
expensive imported power. Conversely, compression refrigeration will be favoured if there is
little waste heat available, or the pinch temperature is close to ambient, or the refrigeration
load is required well below ambient, or a CHP system can be installed above the pinch.
Refrigeration systems tend to be the most expensive of all site utilities per unit of heat load.
ThereasonforthiscaneasilybeunderstoodfromtheCarnotefficiency.

Theworkrequiredtoabsorbheatfromthebelowambientheatsourceisgiven
byarearrangementofEq.35.8.

w =

2
C0P
R
=

2
(I
1
-I
2
)

mcch
I
2
(SS.1)

Theuppertemperature,T
1
isusuallyambienttemperature,butasthelowertemperatureT
2
is
below ambient, the value of W rises exponentially and becomes infinite as T
2
approaches to
absolute zero. Hence, the power consumed in refrigeration rises sharply as the required
refrigeration temperature falls. Further, for running a refrigeration system the T
1
has to be
more than ambient temperature to reject heat in to it and similarly the Temperature of
evaporatorshouldbelowerbyanamountT(about5C)toabsorbheatatT
2
temperature.For
a typical refrigeration system with a mechanical efficiency of 50% (most losses occur in the
compressor), to remove 2 kW of heat from a process at 0C already requires 0.44 kW power.
For refrigeration system, the energy and cost penalty increase sharply as temperature falls.
Thus, any possibility to increase the energy efficiency of a refrigeration system are worth
investigation.

Sinceprocesscoolingiscarriedoutbyevaporatingtheliquidrefrigerant,theserepresenton
theGCCasaseriesofconstanttemperaturecoldutilitylevels(formultilevelrefrigeration
system),andloadsandlevelsarematchedintheusualway.

Lowtemperatureprocessdesign Module06 Lecture35

OnewayofreducingthepowerrequiredbythesimplecycleinFig.35.1(a)istoincorporatean
economiser, as shown in the figure. The compression and flash expansion are split into two
stages,withflashvapourfromthefirstexpansionstageisreturnedtothesuctionofthehighest
pressure compressor( Comp.H). In this way, the quantity of vapour flowing through the low
pressurecompressor(Comp.L)ofthesystemisreduced,savingpower.

Matching of refrigeration cycles against the grand composite curve is illustrated in Fig.35.1(b).
TheGCChasapinchtemperaturelittlebelowthecoolingwatertemperaturemarkedbyBon
theGCC.Thusthecoolingdutybelowthecoolingwaterinlettemperatureshouldbehandledby
therefrigerationsystem.TheGCCprofilebelowthepinchisshownbyBCDEFandtherequired
coolingloadoftheGCCisH
R
whichisservicedbyasinglelevelrefrigerationsystem.Aclose
analysis of the system shows that for EG section this arrangement is good. For section BC of
GCCthesupplieddrivingforceismuchhigherthanrequired.Thussubstantialpowersavingcan
be achieved if the single level refrigeration system is converted into a two level refrigeration
systemwhichaddsarefrigerationlevelforBCsectionofGCCseparatelyasshowninFig.35.2.

(b)
(a)
1
2
Coolingwater
2
H
R
1
G
D
F
E
B
S
h
i
f
t
e
d

T
e
m
p
.
,

T
AMBIENT

Processstream
liquid
Vapor
Vapor+Liquid
Vapor Vapor+Liquid
Comp.H
Comp.L
H
R

Fig.35.1(a)schematicoftherefrigerationsystemand(b)GCCofprocess
Pinchpoint
C
H
Lowtemperatureprocessdesign Module06 Lecture35

Shiftingloadupwards(loadofBCsection)intemperaturelevelreducesvapourflowtothe
compressor(Comp.L)servicingthelowpressurepartoftherefrigerationcycle.Thenetresult,
however,isasubstantialreductioninpowerconsumption.Nowisitpossibletofurtherreduce
thepowercostoftherefrigerationsystembyincreasingthelevelofrefrigerationinthepresent
system.AcloseexaminationofprocessGCCshowsthatthiscanbedonebyexploitingthe
pocket(representedbyhatcharea)intheGCC.TheconceptisshowninFig.35.3.

(b)
(a)
1
2
Coolingwater
2
H
R
1
G
D
F
E
B
S
h
i
f
t
e
d

T
e
m
p
.
,

T
AMBIENT

Processstream
liquid
Vapor
Vapor+Liquid
Vapor Vapor+Liquid
Comp.H
Comp.L
H
R

Fig.35.2(a)Twolevelrefrigerationsystemand(b)GCCofprocess
Pinchpoint
C
H
Processstream
3
4
3
4
Lowtemperatureprocessdesign Module06 Lecture35

Afurtherpowersavingcanbeobtainedifsomepartoftheheatabsorbedin12isrejectedat7
8.Thiswillsaveenergyasthetemperaturelevelof78isbelowambient.Therestpartof12
canberejectedatambienttemperature.Thesavingsaremorethanmaintainingalow
temperaturelevelloadat56.However,dothisthecomplexityofthesystemhasgonefrom
Fig.35.1(a)toFig.35.3(a).Theeconomicsofthisentirelydependsontherefrigeration
temperaturelevelsandtheirloads.

ToshowthetemperatureliftsusedinFig.35.1toFig.35.3,Fig.35.4isplotted.

(b)
2 1
G
D
F
E
B
S
h
i
f
t
e
d

T
e
m
p
.
,

T
AMBIENT
Fig.35.3(a)Twolevelrefrigerationsystemand(b)GCCofprocess
Pinchpoint
C
H
3
4
8
7
Coolingwater

Process
stream
liquid
Vapor
Vapor+Liquid
Process
stream 3
4
(a)
1
2

Processstream
Vapor
Vapor+Liquid
Vapor Vapor+Liquid
H
R

5
6
5 6
7 8
Process
stream
AmbientTemperature
A
m
o
u
n
t

o
f

l
i
f
t

ForFig.35.1(a)
ForFig.35.2(a)
ForFig.35.3(a)
Fig.354TemperatureliftshownforFigs.35.1,35.2 and35.3
Lowtemperatureprocessdesign Module06 Lecture35

IllustrativeExample
Problem:Determinetherefrigerationrequirementofthelowtemperaturedistillationprocess
giveninTable35.1forT
min
=5
0
C
Table35.1Streamdatafortheillustrativeproblem
Stream Type T
S
(
0
C) T
T
(
0
C) CP(MW/K)
1 Hot 19 0 0.05
2 Hot 18 19 1.1
3 Hot 40 41 0.9
4 Cold 18 19 1.1
5 Cold 2 1 0.9
6 Cold 1 21 0.01
7 Cold 39 19 0.01

a) Plot the grand composite curve and determine the temperature and duties of the
refrigeration if two levels of refrigeration are to be used. Assume isothermal vaporization and
condensationoftherefrigerant.

b) Calculate the power requirements for the refrigeration for heat rejection to cooling water
operatingbetween15and20
0
CapproximatedbyEquationgivenbelow:

Appioximate C0P
REF
=
Q
c
W
=
u.6 T
EVAP
T
COND
-T
EVAP

Where,
T
EVAP
=EvaporationTemperature,
0
C

T
COND
=CondensationTemperature,
0
C

W=Refrigerationpowerrequirement,kW

COP=Coefficientofperformance

Q
C
=Coolingduty

c)RepeatthecalculationfromPartbusingrefrigerationpowertargeting,assumingpropylene
astherefrigerantandareciprocatingcompressor
Lowtemperatureprocessdesign Module06 Lecture35

d) Heat rejection from the refrigeration system into the process can be used to reduce the
refrigerationpowerrequirements.Calculatethepowerusingaboveequation.

e)RepeatthecalculationfromPartdusingrefrigerationpowertargeting,assumingpropylene
astherefrigerantandareciprocatingcompressor.

Solution:ThegriddiagramoftheaboveproblemisshowninFig.35.5

Fig.35.5Griddiagramoftheillustrativeproblem

The corresponding problem table cascade and GCC are shown in Fig. 35.7 & Fig. 35.6
respectively.

H CP(MW/K)

Fig.35.6GCC oftheproblem
Lowtemperatureprocessdesign Module06 Lecture35

a.)ThetwolevelsofrefrigerationareshowninFig.35.8withthedetailsgiveninTable35.2

Fig.35.7Problemtable
cascade
Lowtemperatureprocessdesign Module06 Lecture35

Table35.2
Levels T
*
(
0
C) T(
0
C) Q
EVAP
(MW)

Level1 248.5(24.5) 246(27) 1.13MW
Level2 226.5(46.5) 224(49) 0.9MW

b.)Forheatrejectiontocoolingwateroperatingbetween15and20
0
C,

Thus,

Now,forlevel1refrigeration,

T
COND
=CondensingTemperature=20+5=25
0
C=273+25=298K
T
EVAP
=EvaporationTemperature=246K
Q
C
=1.13MW
Thus,

1.13MW
0.9MW
Fig.35.8Twolevelrefrigeration
Lowtemperatureprocessdesign Module06 Lecture35

W
1
=
1.1S (298 -246)
u.6 246
= u.S98 NW

Similarly,forlevel2refrigeration,

T
COND
=CondensingTemperature=20+5=25
0
C=273+25=298K
T
EVAP
=EvaporationTemperature=224K
Q
C
=0.9MW
Thus,

W
2
=
u.9 (298 -224)
u.6 224
= u.496 NW
Hence,

Powerrequirement=0.398+0.496=0.894MW

c.)Inthispart,wewilldesigncycle1(Refrigerationlevel1)tooperatebetween27
0
Cto25
0
C
andcycle2(Refrigerationlevel2)tooperatebetween49
0
Cto25
0
C.

Forcycle1:

UsingAntoineequation:
log P
LvAP
SA1
= A -
B
C +I
LvAP

Now,forpropylene,

A=7.0823
B=905.7
C=263.387
Thus,

log P
LvAP
SA1
= 7.u82S -
9uS.7
26S.S87 -27
= 7.u82S -S.8S1 = S.2S1S

P
LvAP
SA1
= 178S.61 mm Eg = 2.S78 bor
Also,

log P
C0N
SA1
= 7.u82S -
9uS.7
26S.S87 +2S
= 7.u82S -S.14 = S.9417

P
C0N
SA1
= 8744.S7 mm Eg = 11.6S8 bor
So,
Pressureratio=P
C0N
SA1
/P
LvAP
SA1
=(11.658/2.378)=4.9024

{WhenP(mmHg)andT(
0
C)}
Lowtemperatureprocessdesign Module06 Lecture35

Similarly,

Forcycle2:

P
LvAP
SA1
= u.96 bor

P
C0N
SA1
= 11.6S8 bor

Pressureratio=12.14

Thus,Table35.3canbegeneratedasfollows:
Table35.3
Pressure(bar)
Cycle1 Cycle2
Evaporator 2.378 0.96
Condenser 11.658 11.658
PressureRatio 4.9024 12.14

The pressure ratio is a little high for Cycle 2 to be carried out in a single compression stage.
However, singlestage compression will be assumed for the sake of comparison between
differentoptions.Also,inthisexample,theheatcapacityratiowillbeassumedtobeconstant
withavalueof1.13.

The next step involves the calculation of mass flow rate of the refrigerant by performing an
energybalancearoundtheevaporator.

m =

LvAP
E
2
-E
4

Where,
H
2
= Specific enthalpy at the evaporator outlet (sat. vapor enthalpy at the evaporator
pressure)

H
4
= Specific enthalpy at the condenser outlet (sat. liquid enthalpy at the condenser
pressure)

Thus,forcycle1,

LvAP
= 1.1S Hw

E
2
= 44S.8S1S
k[
kg

Lowtemperatureprocessdesign Module06 Lecture35

E
4
= 1S7.14
k[
kg

Hence,
m =

LvAP
E
2
-E
4
=
11Su
44S.8S1S -1S7.14
=
11Su
286.6912
= S.94
kg
s

Also,
p

= 4.859kg/m
3

So,
F
n
=
m
p

=
S.94
4.8S9
= u.81
m
3
s

Similarly.forcycle2,

m =

LvAP
E
2
-E
4
=
9uu
42u.8187 -1S7.14
= S.41S
kg
s

= 2.26
kg
m
3

F
n
=
S.41S
2.26
= 1.S1
kg
s

Thus,Table35.4canbegeneratedasfollows:
Table35.4
Cycle1 Cycle2

Q
EVAP
MW 1.13 0.9
H
2
H
1
kJ/kg 286.6912 263.6784
m Kg/s 3.94 3.413

v
Kg/m
3
4.859 2.26
F
in
m
3
/s 0.81 1.51

The isentropic compressor efficiency, polytrophic coefficient, outlet temperature and power
requirementcannowbecalculatedasshownbelowforcycle1&cycle2.

Forcycle1:

Theisentropicefficiencyofthecompressorcanbecalculatedby:

IS
=0.1091(lnr)
3
0.5247(lnr)
2
+0.8577lnr+0.3727

IS
=0.1091(ln4.9024)
3
0.5247(ln4.9024)
2
+0.8577ln4.9024+0.3727

=0.1091*(1.59^3)0.5247*(1.59^2)+0.8577*(1.59)+0.3727
Lowtemperatureprocessdesign Module06 Lecture35

=(0.1091*4.02)(0.5274*2.5281)+(0.8577*1.59)+0.3727

=0.4385821.3333+1.3637+0.3727=0.841682

Thepolytrophiccoefficient'n'canbecalculatedusing

n =
ln (
P
C0N
P
LvAP
)
ln |
p
IS
(
P
C0N
P
LvAP
)
p
IS
-1 +(
P
C0N
P
LvAP
)
y-1 y
]
=
1.S9
ln |
4.1262
1.u4
]
=
1.S9
1.S78
= 1.1SS8

Theoutlettemperatureisgivenby:
I
out
= I
LvAP
(
P
C0N
SA1
P
LvAP
SA1
)
n-1
n
= 246 1.2S6 = Su4
0
C

Thepowerrequiredforcompression:

w = _
y
y -1
]
P
LvAP
F
n
p
IS
|1 -(
P
C0N
P
LvAP
)
y-1y
]
Or,

w = _
1.1S
u.1S
] _
2.S78 u.81
u.841682
] |1 -1.2] = u.S9784S Hw

Thus,Table35.5canbegeneratedforcycle1&cycle2:
Table35.5
Cycle1 Cycle2

Isentropicefficiency(
IS
) 0.841682 0.941288
Polytrophiccoefficient(n) 1.1SS8 1.1379
OutletTemperature(T
out
,K) 304 303.1395
Power(W,MW) u.S9784S 0.445

Therefore,

Totalpowerforheatrejectiontocoolingwater=0.397845+0.4453=0.843145MW
d.) Now, consider that part of level 2 heat can be rejected to the process above the pinch as
shown in Fig.35.9. The heat exchangers shown in the figure may be several exchangers in
practice.Therejectionload=0.54MWasclearfromthefigure.
Lowtemperatureprocessdesign Module06 Lecture35

Now,

W=0.1628MW
Therefore, process cooling by level 2 by this arrangement across the pinch = 0.54 0.1628 =
0.3772MW
Balanceofcoolingdemandatlevel2=0.90.3772=0.5228MW

ThisbalanceofthecoolingdemandonLevel2(0.5228MW)togetherwiththeloadfromLevel1
must be either rejected to the process at a higher temperature above the pinch or to cooling
1.13MW
0.9MW
0.54 MW
Fig.35.9Twolevelrefrigerationwithheatrejected
abovepinch
Lowtemperatureprocessdesign Module06 Lecture35

water.Theprocesshasaheatingdemandat23C,whichmeansthatheatcouldberejectedat
28C.

However, rejection to the process would add to the complexity of both design and operation.
Also, there seems little advantage in such an arrangement since the heat can be rejected to
cooling water at 30C, Therefore, the rest of the rejection heat will be assumed to go to the
coolingwater.

Thus,

W
1
=
1.1S (298 -246)
u.6 246
= u.S98 NW

W
2
=
u.S228 (298 -224)
u.6 224
= u.2878S NW

Therefore,totalrefrigerationpowerforpartrejectionoflevel2totheprocess

=0.398+0.28785+0.1628=0.84865MW

Hence,savingintherefrigerationprocessduetointegrationwiththebackgroundprocess

=0.8940.84865=0.04535MW
e.)Thedutyoncycle1willremainunchangedfrompart(c).Hence,

w
1
= u.S9784SHw

However,thedutyoncycle2mustbereducedfrompart(c)tocompensatebythedutyoncycle
3.Forcycle2:

LvAP
= u.S228 Hw

Now,thecalculationinpart(c)willbeadjustedtoreduceQ
EVAP
to0.5228MW.Thus,

m=1.9827kg/s
F
in
=0.8773m
3
/s
W=0.25MW

Forcycle3,thecyclewillbedesignatedtooperatebetween224k(49
0
C)and9
0
C.Thus,the
calculationsforcycle3aregiveninTable35.6below:

Table35.6
Pressureofevaporator (bar) 0.96
Pressureofcondenser (bar) 7.6
Lowtemperatureprocessdesign Module06 Lecture35

Pressureratio 7.91667
Q
EVAP
(MW) 0.3772
H
2
H
4
(kJ/kg) 42u.8187114.98=305.84
m (kg/s) 1.2343

V
(kg/m
3
) 2.26
F
in
(m
3
/s) 0.546

IS
0.8736
n 1.136
T
out
(K) 287.1264
W (MW) 0.14
Q
COND
(MW) 0.5172

Now,TotalrefrigerationpowerforpartrejectionofLevel2totheprocessfromrefrigeration
targeting

=0.397845+0.25+0.14
=0.787845

Hence,

The saving in the refrigeration power by integration with the process from refrigeration
targeting

=0.8431450.787845
=0.0553MW

References
1. http://www.heatpumpcentre.org/en/aboutheatpumps/howheatpumpsachieveenergysa
vings/Sidor/default.aspx
2. PongsidSrikhirin,SathaAphornratanaandSupachartChungpaibulpatana,Areviewof
absorptionrefrigerationtechnologies,RenewableandSustainableEnergyReviews,5
(2001)343372
3. XiaoFengandThoreBerntssont,CriticalCopForAnEconomicallyFeasibleIndustrial
HeatPumpApplication,AppliedThermalEngineeringVol.17,No.I.pp.93101,1997