AET 303 - BUILDING SERVICES III (HVAC, FIRE FIGHTING AND SAFETY) Module -2 HVAC SYSTEMS REFRIGERATION SYSTEMS COMPONENTSRefrigerant Compressors e@ Introduction Basics of compression process|——)- vapor Compression Regrigeration Cycle © The compressor is the heart of the system. ane © The compressor does just what it’s name is. © It compresses the low pressure refrigerant vapor from the evaparatar and compresses it into ahigh pressure vapor. External work done on the system Electric power (AC/DC) Solar > Electricity > Compressor Power ©Go06e Also, Thermal Compression (will study later) see coin — - Ideal vapor compression cycle © Ideal cycle consists of 1-2: Isentropic compression © 2.3: Constant pressure heat rejection in the condenser hrottling in an expansion valve Constant pressure heat addition the evaporator|) Compression process © During compression of vapor, work is done on it © Its enthalpy increases and so does its pressure © Inlet to the compressor should be in vapor state © Ideal compression (isentropic) is not possible in real operation, feagour, ‘viet a apr oar @ Types of Compressors ‘What? Why? Where?|) Classification of compressors © Positive displacement © Positive displacement compressors have chambers which decrease in volume during compression, © Non-po: e displacement (centrifugal). © _Non-positive displacement compressors have fixed-volume chambers. © Beyond this distinction, each type differs based on its specific mechanism for fluid compression. +— - Classification of compressors © Open types have a separate housing for the compressor and the motor. © They rely on lubricant in the system to splash on pump components and seals. © \fnot operated frequently, the system can leak its operating gases. © Open compressors can be driven by non-electric power sources such as combustion engines.| —(())- Classification of compressors © Hermetic types seal the compressor and motor together in the same housing. © These compressors are leak-free and can sit for long periods unused, but cannot be maintained or repaired. © Semi-hermetic types also contain the motor and compressor in one housing, but instead of a one-piece housing they incorporate gasketed/bolted covers. © These can be removed for maintenance and repair of the compressor cor motor. — - Open type compressors|) Semi-hermetic compressor units[— #- Types of comprssors © There are basically 5 types of air conditioner compressors that are commonly used in the HVAC industry: Reciprocating Scroll Screw Rotary Centrifugal e0000 — - Reciprocating/Piston Compressors Piston and cylinder arrangement to provide compressive force - like IC engines. Reciprocating motion of the piston due to external power compresses the refrigerant inside the cylinder. sucnov.cornession Low initial cost and a simple, easy to install design. ©® © © Large power output range - can reach extremely high pressures. However, maintenance costs are high, potential vibrational issues. © Not typically designed to run continuously at full|—))- Reciprocating Compressor © Suction and discharge valves © Valve position is controlled by the pressure difference across it © Can ke open, semi-hermetic or fully hermetic|) Rotary Compressors © Uses circular motion for compression (two rotating elements) © Rotating blade (vane) type © Refrigerant is trapped by rotating vanes © Refrigerant compresses as volume decreases © Stationary blade (vane) type © Equipped with only one blade or vane +—_@- Rotary compressors © Ingeneral, rotary compressors are © Fewer moving parts > quite efficient © Low rotational speeds, low initial and maintenance costs © Limited to smaller volumes of the gas © Produce less pressure than other types of compressors. © Actions of taking in refrigerant and ‘compressing refrigerant occurs simultaneously 10HK— - Rotary compressors agg i 7 ‘Sodes te vane hosing, er te vanes ‘Side of ct to marian cortct wth the cyrtica comeressor wal as lrters eine legest ceri andthe Congressed gos dscheeges fam the onallt epenba, — - Helical rotary (screw type compressors) © Screw compressors use a pair of helical rotors or screws which mesh together to compress the refrigerant between them. © The volume of the refrigerant decreases as it flows through the compressor © Acontinuous, flowing output is produced © Compressor capacity is controlled by a slide valve|) screw compressors © They can produce high pressure for a small quantity of gas and consume less power than reciprocating compressors. © They have low to medium initial and maintenance costs and few moving parts. © However, they have difficulty in dirty environments, high rotational speeds, and shorter life expectancies than other designs. — - Scroll type Compressors © Utilizes two identically machined scrolls - one scrolls stationary, the other orbits The nesting of the scrolls traps vapor Gas is introduced from the outer edge refrigerant © ® is discharged from the center © Scroll compressors are quiet, smooth-operating units with few moving parts oe! © Highest efficiency ratio of all compressor types. © However, as fully hermetic designs, they cannot = be easily repaired. They also typically cannot a rotate in both directions. De)t— - Centrifugal type compressors © Rely on centrifugal force - utilizes an impeller © No pistons, valves or cylinders © Unlike other designs, centrifugal compressors do not operate on the positive displacement principle, but have fixed volume chambers. © Well suited to compressing large volumes of refrigerant to relatively low pressures. © Typically used for very large applications © Capacity is controlled by inlet vanes Bice) Gaon +—_@- Centrifugal Compressors © The compressive force generated by an impeller wheel is small, so systems that use centrifugal compressors usually employ two or more stages (impellers wheels) in series to generate high compressive forces. © Centrifugal compressors are desirable for their simple design, few moviny BE 1p! 1p" ig 1B parts, and energy efficiency when operating multiple stages. a| —()}- compressor Specifications © There are a number of specifications to consider when selecting compressors. © These include © Compressor capacity Condensing temperature Evaporating temperature Refrigerant flaw rate Power consumption e000 +— - Compressor specifications: Capacity © Capacity (kW/hr — BTU/hr) measures the ability of a refrigerant compressor to remove heat from the refrigerant gas. © Nominal capacity ratings are based on a standard set of conditions which include condensing temperature (CT), evaporative temperature (ET), refrigerant, and motor rpm. © Typically, refrigeration compressors and air conditioning compressors can run at many different values for these parameters, with corresponding changes in their cooling capacity. © Once in use, compressors can be tweaked and adjusted to the desired capacity and operating conditions. “4| ——(()- compressor specifications: Other parameters © Condensing temperature is the range of condensing temperatures cover which the compressor is rated to operate. © Evaporating temperature is the range of evaporative temperatures cover which the campressor is rated to operate. © Flow rate is the rate (by mass) at which the fluid is passed through the compressor, measured in kilograms per hour (kg/hr). © Power (W) is the input power required to run the compressor motor al a specific operating point. +— - Compressor specifications: Other parameters © Refrigeration compressors and air conditioning compressors also carry power-source specifications defined by voltage/frequency/ phase. © Common choices include 12 VDC and 24 VDC, as well as 115/60/1, 230/50/1, 200-230/60/1, 208-230/60/3, 380-440/50/3 16° ° | ——())- compressor Features © RAC compressors incorporate a number of special features: Low noise = compressor operation generates less noise for applications where a quiet environment is desired. Light weight - compressor is compactly built or constructed with low-density materials for cooling systems which require low weight components. \Varlable speed - compressor has speed adjustment for running at varlous operating flow rates and conditions. ‘Thermal shut off - compressor features controls which turn the compressor off at high temperatures to prevent it irom overheating. They also can provide restart ance the compressor has cooled down below a certain temperature. Sealing - describes how the compressor and motor drive are situated in rel to the gas or vapor being compressed. 16Refrigerant Evaporators and Condensors e@ IntroductionL_@ Purpose ofan evaporator © The purpose of the evaporator is to receive low-pressure, low temperature fluid from the expansion valve and to bring it in close thermal contact with the load © The refrigerant takes up its latent heat from the load and leaves the evaporator as a dry gas. © The function of the evaporator will be to cool gas, liquid or other product loads. © In most cases air or a liquid is first cooled, and this is then used to cool the load. e.g., in a cold-room air is cooled and this air cools the stored produce and carries away heat leaking through the structure; ina water chiller, water is circulated to cool the load, etc. — - Thermal path/ Resistances © Heat has to pass from the hot water to cold refrigerant. © The thermal resistances include: Retrigerant —| © Water side heat transfer coefficient goundary Layer» t © Water side fouling Tube al X Fouling E © Conduction in tube wall Boundary Layer z ~\ © Refrigerant side fouling Water ESS eer eses] (usually low/negligible) © Refrigerant side heat transfer coefficient 8| ——())}- Classification of evaporators © Evaporators are classified according to their refrigerant flow pattern, their function, geometrical features. © Evaporators which cool water © Evaporators with cool air @ Evaporators which Cool Liquid ‘Types and characteristic features|) Flooded type evaporators Flooded evaporators. © (a) Shell-and-tube © (b) Jacketted © (©) Raceway the ‘Ata Laval DH ‘Sameer Khandokar — - Flooded shell and tube evaporator eS|) Flooded tank evaporator ‘A flooded tank evaporator showing the refrigerant rubes and the tank filled with secondary flula — - Baudelot cooler © Baudelot Coolers are used in industrial applications for chilling =e a liquid to near its freezing point. © Normally these coolers are used in systems where water is the cone liquid being chilled. — tm a| 0) Shell and coil evaporators © Commonly, the multi-pass Hx reverses the flow in the tubes by use of one or more sets of "U" bends in the tubes, which allow the fluid to flow back and forth across the length of the Hx. © Asecond method to achieve multiple passes is to insert baffles on the shell side. These direct the shell side fluid back and forth across the tubes to achieve the multi-pass effect. 3) Evaporators which Cool Air Basics of evaporation process|—)- Direct air-cooled evaporators — a a | cnn sc High Pressure: = oO ia Expansion Valve ay Distributor & Distributor Tubes — - Roof hanging units|) Floor mounted units ‘mbit(@)_ Tube Geometry — - Finned tube evaporators © Finning improves heat transfer capacity and hence performance + Coiled fins * Serrated fins + Serpentine fins 25|") Some Finning Methods — - Other methods|) Bare Tube Evaporators © These are simple and cheap Sere — - Plate surface evaporator(®_ Defrosting of Evaporators Need, Process, Ways — - Defrosting © Air cooling evaporators working below 0°C will accumulate frost which must be removed periodically, since it will obstruct heat transfer. 28t— - Defrosting © Evaporators of suitable and robust construction can be defrosted by brushing, scraping or chipping. © However, these methods are labour intensive and may lead to damage of the plant. © Where the surrounding air is always at + 4°C or higher, it will be sufficient to stop the refrigerant for a period and allow the frost to melt off (as in the auto-defrost domestic refrigerator). © This method can be used for cold-rooms, packaged air- conditioners etc., where the service period can be interrupted. +— - Defrosting methods For lower temperatures, heat must be applied to melt the frost within a reasonable time and ensure that it drains away. Methods used are: in the coil or directly under it. © Electric resistance heaters: Elements are wil © Hot gas: A branch pipe from the compressor discharge feeds superheated gas to the coil. The compressor must still be working on another evaporator to make hot gas available. Heat storage capsules can be built into the circuit to provide a limited reserve of heat for a small installation. © Reverse cycle: The direction of flow of the refrigerant is reverse to make the evaporator act as a condenser. Heat storage or another evaporator are needed as a heat source. In each of these cases, arrangements must be made to remove cold refrigerant from the coil while defrosting is in progress. 28(®) Refrigerant Condensers Nee clasticaon Design +— - Classification of condensers © Like evaporators, condensers are also classified into several types: © Air cooled condensers © Water cooled condensers © Evaporative condensers|) Air cooled condensers © Heat is removed by air either by natural convection or by forced convection. © Refrigerant usually flows in metallic tubes (Cu/AI/SS etc.). © Air velocities are usually below 5 m/s © Typically not for large systems G5 TR, for example): high pressure drop, noise, increase in power consumption © HTCis usually low and hence nearly always finned Forced convection Wall mounted/nanging Forced convection Rooftop/fioor mounted if Natural convection [K—— - Water cooled condensers © Water cooled condensers are of three types © Shell and Tube Condensers © Shell and Coil Condensers © Double tube condensers Shell and tube water cooled condensers a|) water cooled condensers © The shell can also function as a refrigerant receiver/collector. © Usually, some sub-cooling also takes place inside the shell. © Water cooled condensers are used in conjunction with cooling towers. © Water side heat transfer coefficient can be quite high. © Cooling towers can be of two types: © Natural draft © Forced draft — - Evaporative condensers Hot Saturated Discharge Air © Here, the refrigerant first looses — its heat to water. © The water is cooled by self oat evaporation, by forced air flow. “S=" ee negeact © Thus,an evaporative condenser ™ sons ‘combines the functions of > ioe condenser + cooling tower. rants oy ing. a+—_@- Evaporative condensersEXPANSION DEVICES The basic functions of an expansion device are: 1. Reduce pressure from condenser pressure to evaporator pressure, and 2. Regulate the refrigerant flow from the high-pressure liquid line into the evaporator at a rate equal to the evaporation rate in the evaporator.Types FIXED OPENING TYPE VARIABLE OPENING TYPE * The flow area * The flow area changes with . 7 changing mass flow rates. remains fixed. ; 1. Hand (manual) expansion valves 1. Capillary Tube 2. Constant pressure or Automatic Expansion Valve 2. Orifice (AEV) 3. Thermostatic Expansion Valve (TEV) 4. Float type Expansion Valve a) High Side Float Valve b) Low Side Float Valve 5. Electronic Expansion ValveCapillary Tube * A capillary tube is a long, narrow tube of constant diameter. ¢ Diameter range from 0.5 mm to 3 mm and the length ranges from 1.0 m to 6 m. The pressure reduction occurs due to: 1. The refrigerant has to overcome the frictional resistance offered by tube walls. This leads to some pressure drop. 2. The liquid refrigerant flashes (evaporates) as its pressure reduces. So the average density decreases. The mass flow rate and tube diameter (hence area) being constant, the velocity of refrigerant increases. This requires pressure drop.Its mass flow rate is totally dependent upon the pressure difference across it; it cannot adjust itself to variation of load effectively. The balance point : The compressor and the capillary tube, under steady state must arrive at some suction and discharge pressures, which allows the same mass flow rate through the compressor and the capillary tube.Compressor » Capillary Variation of refrigerant mass flow with evaporator temperatures = *Advantages: * Itis inexpensive. * It does not have any moving parts hence it does not require maintenance * Open connection - during off-cycle, pressure equalization occurs between condenser and evaporator. This reduces the starting torque requirement of the motor. Hence, a motor with low starting torque (squirrel cage Induction motor) can be used.Disadvantages * It cannot respond to daily and seasonal variation in ambient temperature and load - COP low under off design conditions. It is susceptible to clogging because of narrow bore of the tube. A filter-drier should be used ahead of the capillary to prevent entry of moisture or any solid particles. During off-cycle liquid refrigerant flows to evaporator because of pressure difference. The evaporator may get flooded and the liquid refrigerant may flow to compressor and damage it when it starts. So it is used only with hermetically sealed compressors where refrigerant does not leak. .Automatic Expansion Valve (AEV) * Also known as a constant pressure expansion valve - maintain a constant pressure and thereby a constant temperature in the evaporator. Adjustable screw |-— Adjustable spring : —=y Diaphragm Needle =—> To evaporator Strainer |-——__ orifice | Follow-up spring From condense!* The adjustment spring is usually set such that during off-cycle the valve is closed. * During the off-cycle, the refrigerant remaining in the evaporator will vaporize but will not be taken out by the compressor - the evaporator pressure rises.¢ At equilibrium position Fe +Fis=Fs+Fo = constant ¢ The valve acts in such a manner that the evaporator pressure remains constant as long as the refrigeration load is constant. * At this point, the mass flow rate through the valve is the same as that through the compressor.Thermostatic Expansion Valve (TEV) A thermostatic expansion valve maintains a constant degree of superheat(AT,) at the exit of evaporator - prevent the slugging of the compressors. Feeler bulb at evaporator exit - senses the temperature at the exit of evaporator. The feeler bulb is connected to the top of the bellows by a capillary tube. The feeler bulb and the narrow tube contain some fluid called power fluid. .Capillary tube compressor Feeler bulb Suction line Superheated refrigerant to EvaporatorThe power fluid is the same as the refrigerant or different(TEV is called TEV with cross charge). The power fluid senses the evaporator exit temperature T,+AT, by the feeler bulb and its pressure P,, is the saturation pressure at this temperature. Fp = Ab Pp & Fe =Ap Pe In steady state there will be a force balance on the needle stand, that is, F,=Fp-F.During off-cycle, evaporator temperature is same as room temperature, ie, AT, =0. Then P,= P, and F,= F,. So the spring force F, acting upwards will keep the TEV closed. As the compressor is started - evaporator pressure decreases so the force F, decreases at a very fast rate but F,, does not change. Hence, the difference FF, increases as the compressor runs for some time after starting. At one point this difference becomes greater than the spring force F, and the valve is said to open up. Since a finite downward force is required to open the valve, a minimum degree of superheat is required for a finite mass flow rate. .The spring gets compressed as the needle stand moves downward. If F.,is the spring force in the rest position, that is, off-cycle, then during open valve position: F, = Fs9 + AF; Eventually, the needle stand reaches a position such that, Fs = Fp - Fe =Ap( Pp — Pe) le, F, > F,or P,> P,. The pressure P, and P, are saturation pressures at temperature (T, + AT,) and T, respectively. Hence, for a given setting force F, of the spring, TEV maintains the difference between F, and F, or the degree at superheat AT, constant.Float type expansion valves: Normally used with flooded evaporators in large capacity refrigeration systems. It opens or closes depending upon the liquid level as sensed a float(a hollow metal or plastic ball) The float valve always maintains a constant liquid level in a chamber called as float chamber. Depending upon the location of the float chamber, a) Low-side float valve b) High-side float valve.Low-side float valve It maintains a constant liquid level in a flooded evaporator or a float chamber attached to the evaporator. When the load increases, more amount of refrigerant evaporates from the evaporator. As a result, the refrigerant liquid level in the evaporator or the low-side float chamber drops. The float then moves such that the valve opening is increased and more amount of refrigerant flows into the evaporator and the liquid level is restored. When the load falls, the float reduces the opening of the valve and less amount of refrigerant flows into the evaporator. »High-side float valves From condenser => Float valve High side float chamber Maintains the liquid level constant in a float chamber connected to the condenser on the high pressure side. When the load increases, more amount of refrigerant evaporates and condenses. As a result, the liquid level in the float chamber rises momentarily. The float then opens the valve more to allow a higher amount of refrigerant flow so the liquid level drops back to the original level. .*It allows only a fixed amount of refrigerant on the high pressure side(condenser), the bulk of the refrigerant is stored in the low- pressure side (evaporator). Hence there is a possibility of flooding of evaporator followed by compressor slugging. But it can be used with both flooded as well as direct expansion type evaporators .Electronic Type Expansion Valve Applied voltage Lt Liquid sensing thermistor EEV : —, Refrigerant Evaporator out 1 Sot RefrigerantThe needle moves up and down in response to magnitude of current in the heating element. A small resistance allows more current to the heater, hence the valve opens wider. A thermistor is placed in series with the heater. The heater current depends upon the thermistor resistance that depends upon the refrigerant condition. Superheated vapour lowering the thermistor resistance and increasing the heater current. This opens the valve wider and increases the mass flow rate. .This continues until the vapour becomes saturated and some liquid refrigerant droplets appear. The liquid refrigerant cool the thermistor and increase its resistance, so it allows a small current to flow through the heater making the valve opening narrower. The control of this valve is independent of refrigerant and refrigerant pressure; hence it works in reverse flow direction also. It is convenient to use it in year-round-air- conditioning systems, which serve as heat pumps in winter with reverse flow.APPLICATIONS OF REFRIGERATIONDOMESTIC REFRIGERATORS Often called a “fridge”, has become an essential household appliance. Used to store fruits, vegetables and other edible products which perish if not kept well below the room temperatures, normally a few degrees above 0°C, the freezing point of water. A refrigerator is a cooling appliance that transfers heat from its thermally insulated compartment to the external environment, and thus cooling the stored food in the compartment. It also normally houses a “freezer’, where temperatures below the freezing point of water are maintained, primarily to make ice and store frozen food. It also have Crisper which draws inside moisture to keep vegetables and fruits fresh for longer time, is normally inbuilt in most of home refrigerators. aREFRIGERATOR COMPARTMENTS LOWER - COMPARTMENTTYPES Two types of home refrigerators are typically available in market. 1. DIRECT COOL REFRIGERATORS: These refrigerators are with or without crisper, ice making or frozen food storage compartment. Cooling of food is primarily obtained by natural convection within the refrigerator. However, some refrigerators may have a fan to avoid internal condensation of water but are not claimed as ‘frost free: Formation of frost/ice in the refrigerator reduces cooling. Therefore these refrigerators need manual defrosting periodically. °ICE BUILT UP IN DIRECT COOLING REFRIGERATION SYSTEM The ice built up on the surface of the evaporator coil provides an additional resistance to heat transfer. This decreases the heat absorption rate. So this ice should be removed manually periodically . ©2. FROST FREE REFRIGERATORS: * These refrigerators cool the stored food through continuous internal movement of air that restricts the formation of frost and sticking of food items with each other. A frost free freezer has three basic parts a timer, a heating coil and a temperature sensor. The heating coil is wrapped around the freezer coils. Every six hour or so, the timer turns on the heating coil and this melts the ice off the coil. When all the ice is removed, the temperature sensor senses the temperature rising above orc and turns off the heating coil.DEFROST MECHANISM TIMER Hot refrigerant Heating Coil wrapped over Evaporator tube cold refrigerant to expansion valve Hot refrigerant From compressorICE PLANT It consists an ice box having heavy insulation. The size depends on the capacity of ice plant. Should contain sufficient no. of cans for ice harvest. Water level in the can should be around 20 to 30 mm below the brine level. Provided piping for air blowing into ice cans for air agitation. It helps form ice in the whole of can otherwise a small amount water remains at the center.Heat transfer between water and brine is either by free convection or forced convection. Latter is caused by suitable no. of agitators. The ice cans are usually tapered around 10 to 20 mm per meter depth. Cooling is achieved by _ brine(calcium chloride solution) circulation. Daily output of an ice plant is a function of the brine temperature. Number of cans needed for a plant of capacity 50 tons of ice per day is 715.WATER COOLERS* Used to produce cold water at about 280 to 286K. * The temp is controlled by a thermostatic switch within 280 to 286 K range. Types 1. Storage type: Cooling coil is wrapped around the water tank. There is a reservoir of cold water all the time. 2. Instantaneous type: Cooling coil is wrapped around the pipeline such that by the time water reaches the tank, it is cooled to the desired temp.Instantaneous type a) Bottle type b) Pressure type and c) Self contained remote type.RefrigerantsWhat is a Refrigerant? “Refrigerant is the fluid used for heat transfer in a refrigerating system that absorbs heat during evaporation from the region of low temperature and pressure, and releases heat during condensation at a region of higher temperature and pressure.”Classification Refrigerants * Primary refrigerants * Secondary refrigerants * Primary refrigerants * These are the refrigerants which cool the substance or space directly by absorbing latent heat. * It absorbs heat during evaporation in the evaporator and releases heat energy during condensation in condensor. * It is also known as direct expansion system * Esg. Ammonia, Freon, SOo, Co) etc. * These fluids provide refrigeration by undergoing a phase change process in the evaporator. * Secondary Refrigerants * In refrigeration plant a secondary coolant is used as cooling medium which absorb heat from refrigerated space and transfer to primary refrigerant in evaporator. Secondary refrigerants are also known under the name brines or antifreezesClassification Of Primary Refrigerant *Halo-carbon Refrigerant * Azeotrope Refrigerant * Inorganic Refrigerant * Hydro-carbon RefrigerantHalocarbon Refrigerants * Halocarbon Refrigerant are all synthetically produced and were developed as the Freon family of refrigerants. ~ They are fluorocarbons of methane and ethane series. ~ They contain | or more of these halogens (chlorine, bromine, fluorine) ~ Non toxic, non-flammable, non-explosive, non- corrosive, non-irritant to human body and eyes. ~ Odourless, colourless ~ Will not react with food product stored in the refrigerated space. ~ Will not react with lubricating oil. ~ Has excellent thermodynamic properties ~ Only disadvantage is ozone layer is damaged. Examples : * CEC’s: R11, R12, R113, R114, RIS * HCFC’s : R22, R123 * HFC’s : R134a, R404a, R407C, R410aFREON 12 (Dichloro-difluro methane —ccl2F2) ~ Mostly used in domestic and commercial refrigerants (in ice cream cabinets, display cabinets, deep freezer) ~ It is very widely used, colourless gas with mild odour ~ Heavier than air ~ Does not dissolve in water, moisture content should not exceed 0.0025% by weigh v Refrigerating effect per unit volume of ammonia is about 1.5 times that of Freon-12 Vv It does not react with ferrous metals, aluminium, phosphor bronze ~ It attacks copper, copper alloys, zinc and bronze and dissolves in water Vv It does not react with lubricating oils in the absence of moisture, but oxidizes them in the presence of water vapourRefrigerant CFC 11(R11) CFC 12 (R12) CFC 13 (R 13) CFC113 (R113 ) CFC114 (R114) Blend of R22 and R115 (R502) Freon Group Refrigerants Application and ODP Values Areas of Application Air-conditioning Systems ranging from 200 to 2000 tons in capacity. It is used where low freezing point and non- corrosive properties are important. It is used for most of the applications. Air-conditioning plants, refrigerators, freezers, ice-cream cabinets, water coolers, window air-conditioners, automobile air conditioners. For low temp refrigeration up to — 90 °C in cascade system Small to medium air-conditioning system and industrial cooling In household refrigerators and in large industrial cooling Frozen food ice-cream display cases and warehouses and food freezing plants. An excellent general low temp refrigerant ODP 1.0 1.07 0.8 0.34Inorganic Refrigerants Inorganic refrigerant were exclusively used before the introduction of halocarbon. These refrigerant are still in use due to there inherent thermodynamic and physical properties. *Carbon Dioxide *Water *Ammonia Air *Sulphur dioxideVv Vwvvyv Ammonia (NH3) R-717 Used for commercial purposes. Mainly in cold stored and ice plants. The boiling temperature of NH3 at atmospheric pressure is -33 °c and melting point from solid is -78°C The low boiling points makes it possible to have refrigeration considerably below 0°C without using pressure below atmospheric in the evaporator. Its latent heat of vaporization at-15°C is 1315 k/kg It is colorless gas with a sharp pungent smell Has good thermodynamic properties It is neutral to all metals, highly soluble in oil. Volatile and non toxic but in higher conc.Sulphur Dioxide (So2) ~ Previously used in household refrigerators ~ Toxic, non-explosive and non-flammable, non-corrosive ~ Irritant to human body ~ Non mixable with oil ~ Has pungent odour and low latcnt heat valucAzeotrope Refrigerants * This group of refrigerants consist of mixture of different refrigerants which can not separated under pressure and temperature and have fixed thermodynamic properties. *A stable mixture of two or several refrigerants whose vapour and liquid phases retain identical compositions over a wide range of temperatures. * Azeotropic mixtures are designated by 500 series * Examples : R-500 :( 73.8% R12 and 26.2% R152) R-502 : (8.8% R22 and 51.2% R115) R-503 : (40.1% R23 and 59.9% R13)Zeotropic Refrigerants *A zeotropic mixture is one whose composition in liquid phase differs to that in vapour phase. Zeotropic refrigerants therefore do not boil at constant temperatures unlike azeotropic refrigerants. *zeotropic refrigerants (e.g. non-azeotropic mixtures) are designated by 400 series. * Examples :R404a : R125 /R143a /R134a (44%,52%,4%) R407c : R32/R125/R134a (23%, 25%, 52%) R410a : R32/R125 (50%, 50%) R413a : R600a/ R218/R134a (3%, 9%, 88%)Hydrocarbons *Most of the hydrocarbon refrigerant are successfully used in industrial and commercial installation . They possess satisfactory thermodynamic propcrtics but arc highly flammable and explosive. * Growing use in very small commercial systems like car air-conditioning system *Examples: R170, Ethane, C,H, R290 , Propane C,H, R600, Butane, C,H, R600a, Isobutane, C,H, Blends of the above GasesSecondary Refrigerant * The refrigerants are brine which is used as intermediate fluid between evaporator and the substance or space to be cooled. They cool the substance and the space by absorbing their sensible heat. Also called indirect expansion system. + Eg. Brine solution made of calcium chloride or sodium chloride ~ Water cannot be used as secondary refrigerant because at 0 °C itself it will become ice and circulation is not possible ~In brine solution CaCl2 is much preferred, it is very costly ~ Substances that take away heat from the medium to be cooled and give itto the boiling refrigerant are called secondary refrigerants ~ They do not change their physical condition> > > Cheap and harmless, chemically neutral to metals and packing material Should have a low freezing point and large heat capacity Choice of brine depends on temperature to which a material is to be cooled and industrial process in which it is to be used The calcium chloride brine has eutectic temperature of -55 °C at salt concentration of 30% by mass The sodium chloride brine has eutectic temperature of -21.1 °C at salt concentration of 23% by mass NaCl is used when it is desired to have direct contact between brine and product. Freezing point of brine depends on its concentration Cheapest secondary refrigerants are water and air but their application is limited. Since, water has a high freezing point (00C) and air has a low heat capacity.Designation of refrigerants: * Since a large number of refrigerants have been developed over the years for a wide variety of applications, a numbering system has been adopted to designate various refrigerants. From the number one can get some useful information about the type of refrigerant, its chemical composition, molecular weight etc. All the refrigerants are designated by R followed by a unique number.i) Fully saturated, halogenated compounds: * These refrigerants are derivatives of alkanes (C'H™’) such as methane (CH’), ethane (C’H’). These refrigerants are designated by R XYZ, where: * X+1 indicates the number of Carbon (C) atoms * Y-1 indicates number of Hydrogen (H) atoms, * Z indicates number of Fluorine (F) atoms * The balance indicates the number of Chlorine atoms. * Only 2 digits indicates that the value of X is zero. * Ex: R22 * X=0 5 No. of Carbon atoms = 0+1 = 1 = derivative of methane (CH'‘) * Y=2 No. of Hydrogen atoms = 2-1 = 1 * Z=2 >No. of Fluorine atoms = 2 * The balance = 4 — no. of (H+F) atoms = 4-1-2 = 1 > No. of Chlorine atoms = 1 * .The chemical formula of R 22 = CHCIF*i) Fully saturated, halogenated compounds: * Similarly it can be shown that the chemical formula of: *R12=CCrF *R134a = C'H'F'(derivative of ethane)ii) Inorganic refrigerants: * These are designated by number 7 followed by the molecular weight of the refrigerant (rounded-off). * Ex.: Ammonia: Molecular weight is 17, :. the designation is R 717 * Carbon dioxide: Molecular weight is 44, .. the designation is R 744 * Water: Molecular weight is 18, .. the designation is R 718Physical characteristics of refrigerants Boiling and condensing temperature and pressures Freezing temperature Critical temperature Discharge temperature Latent heat of vapourisation Specific heat Density ViscosityThermodynamic Properties of Refrigerants Boiling and condensing temperature and pressures The boiling temp of refrigerant at atmospheric pressure should be low. ~ The evaporator and condensing temperatures determine the pressures © The maximum cordensing temperature is largely affected by climatic condition ~ It is desirable to select a refrigerant whose saturation pressure (at min, operating temperature) is a few pounds above atmospheric pressure. + If the boiling temperature of of the refrigerant is high at atmospheric pressure then compressor has to operate at high vacuums. ~ Both evaporator and condenser pressure should be positive and it should be near to atmospheric pressure.Boiling Temperature R-I1 +21.77 R-12 -29 R-21 +9 R-22 -41 R-30 +39.8 R-40 -23.7 R-113 +47.6 R-717 -33.3 R-764 -10Thermodynamic Properties Of Refrigerant * Freezing temperature ~ Should have low freezing temperature . Since the freezing temperature of most of refrigerant is below -35 ec. Critical temperature ~ Should be well above the maximum condensing temperature Discharge temperature ~ High discharge temperatures from the compressor should be avoided ~ It causes some refrigerant breakdowns as well as poor lubrication effectivenessFreezing Temperature R-1l -111 R-12 -157.5 R21 -135 R-22 -160 R-30 -96.9 R-40 -97.5 R-113 -35 R-717 -718 R-764 -75.6~ Evaporator and condenser pressure Latent heat of vaporization ~ Heat which converts the refrigerant from the liquid state to vapour ~ It should have a higher value Density ~ Low vapour density refrigerants are preferred Viscosity ~ Low viscosity of the liquid refrigerant is desired to reduce the pressure drop in the linesCoefficient of performance and power requirements Refrigerant | Coefficient of performance kW/TR R-ll 5.09 0.694 R-12 470 0.746 R-22 4.66 0.753 R30 490 0716 R-40 490 0716 R-L3 492 0716 R-717 476 0.738 R729 574 0619 R144 256, 1372 R-764 487 0.74Chemical properties of refrigerants * Toxicity ~ Flammability and explosion hazard ~ Refrigerant odours * Toxicity ~ Rated based on its effect on human beings over specified periods ~ Should be non toxic and non irritation * Flammability and explosion Hazard ~ Should be non-flammable and non-explosive * Refrigerant Odours ~ Can be both an asset and a hazard ~ Makes it easy to detect the leaks but at the same time may contaminate foodstuffs in storageChemical properties...contd Should be non-flammable Should be non-explosive Should be not-toxic Should not react with lubricating oil Should not react with moisture Should not contaminate the food materials kept inside the refrigerating systemEnvironmental and safety properties * At present the environment friendliness of the refrigerant is a major factor in deciding the usefulness of a particular refrigerant. The important environmental and safety properties are: * a) Ozone Depletion Potential (ODP): According to the Montreal protocol, the ODP of refrigerants should be zero, i.e., they should be non-ozone depleting substances. Refrigerants having non-zero ODP have either already been phased-out (e.g. R 11, R 12) or will be phased-out in near-future(e.g. R22). Since ODP depends mainly on the presence of chlorine or bromine in the molecules, refrigerants having either chlorine (i.e, CFCs and HCFCs) or bromine cannot be used under the new regulations.Environmental Effects of Refrigerants Global warming : Refrigerants directly contributing to global warming when released to the atmosphere Indirect contribution based on the energy consumption of among others the compressors ( CO,produced by power stations )Environmental and safety properties... * b) Global Warming Potential (GWP): Refrigerants should have as low a GWP value as possible to minimize the problem of global warming. Refrigerants with zero ODP but a high value of GWP (e.g. R134a) are likely to be regulated in future. * c) Total Equivalent Warming Index (TEWN): The factor TEWI considers both direct (due to release into atmosphere) and indirect (through energy consumption) contributions of refrigerants to global warming. Naturally, refrigerants with as a low a value of TEWI are preferable from global warming point of view.Environmental and safety properties... contd... * d) Toxicity: Ideally, refrigerants used in a refrigeration system should be non- toxic. Toxicity is a relative term, which becomes meaningful only when the degree of concentration and time of exposure required to produce harmful effects are specified. Some fluids are toxic even in small concentrations. Some fluids are mildly toxic, ie., they are dangerous only when the concentration is large and duration of exposure is long. In general the degree of hazard depends on... + - Amount of reftigerant used vs total space + - Type of occupancy + - Presence of open flames * - Odor of refrigerant, and * - Maintenance conditionEnvironmental and safety properties... contd... * e) Flammability: The refrigerants should preferably be non- flammable and non-explosive. For flammable refrigerants special precautions should be taken to avoid accidents. * f) Chemical stability: The refrigerants should be chemically stable as long as they are inside the refrigeration system. * g) Compatibility with common materials of construction (both metals and non-metals) * h) Miscibility with lubricating oils: Oil separators have to be used if the refrigerant is not miscible with lubricating oil (e.g. ammonia). Refrigerants that are completely miscible with oils are easier to handle(R12). + Ease of leak detection: In the event of leakage of refrigerant from the system, it should be easy to detect the leaks.Ozone Depletion...effects The health and environmental concerns caused by the breakdown of the ozone layer include: *Increase in skin cancers *Suppression of the human immune response system *Increase in cataracts *Damage to crops *Damage to aquatic organisms *Increase in global warmingThank You