Other Refrigeration Systems Applied In The Industry

Absorption Refrigeration Systems Two main absorption systems are used in industrial application: lithium bromide-water and ammonia-water. Lithium bromide-water systems are limited to evaporation temperatures above freezing because water is used as the refrigerant, while the refrigerant in an ammonia-water system is ammonia and consequently it can be applied for the lower-temperature requirements.

Single-effect indirect-fired lithium bromide cycle is shown in Fig. 11-99. The machine consists of five major components:

Evaporator is the heat exchanger where refrigerant (water) evaporates (being sprayed over the tubes) due to low pressure in the vessel. Evaporation chills water flow inside the tubes that bring heat from the external system to be cooled.

Absorber is a component where strong absorber solution is used to absorb the water vapor flashed in the evaporator. A solution pump sprays the lithium bromide over the absorber tube section. Cool water is passing through the tubes taking refrigeration load, heat of dilution, heat to cool condensed water, and sensible heat for solution cooling.

Heat exchanger is used to improve efficiency of the cycle, reducing consumption of steam and condenser water.

Generator is a component where heat brought to a system in a tube section is used to restore the solution concentration by boiling off the water vapor absorbed in the absorber.

Condenser is an element where water vapor, boiled in the generator, is condensed, preparing pure water (refrigerant) for discharge to an evaporator.

Heat supplied to the generator is boiling weak (dilute) absorbent solution on the outside of the tubes. Evaporated water is condensed on the outside of the condenser tubes. Water utilized to cool the condenser is usually cooled in the cooling tower. Both condenser and generator are located in the same vessel, being at the absolute pressure of about 6 kPa. The water condensate passes through a liquid trap and enters the evaporator. Refrigerant (water) boils on the evaporator tubes and cools the water flow that brings the refrigeration load.

Refrigerant that is not evaporated flows to the recirculation pump to be sprayed over the evaporator tubes. Solution with high water concentration that enters the generator increases in concentration as water evaporates. The resulting strong, absorbent solution (solution with low water concentration) leaves the generator on its way to the heat exchanger. There the stream of high water concentration that flows to the generator cools the stream of solution with low water concentration that flows to the second vessel. The solution with low water concentration is distributed over the absorber tubes. Absorber and evaporator are located in the same vessel, so the refrigerant evaporated on the evaporator tubes is readily absorbed into the absorbent solution. The pressure in the second vessel during the operation is 7 kPa (absolute). Heat of absorption and dilution are removed by cooling water (usually from the cooling tower). The resulting solution with high water concentration is pumped through the heat exchanger to the generator, completing the cycle. Heat exchanger increases the efficiency of the system by preheating, that is, reducing the amount of heat that must be added to the high water solution before it begins to evaporate in the generator.

The absorption machine operation is analyzed by the use of a lithium bromide-water equilibrium diagram, as shown in Fig. 11-100. Vapor pressure is plotted against the mass concentration of lithium bromide in the solution. The corresponding saturation temperature for a given vapor pressure is shown on the left-hand side of the diagram. The line in the lower right corner of the diagram is the crystallization line. It indicates the point at which the solution will begin to change from liquid to solid, and this is the limit of the cycle. If the solution becomes overconcentrated, the absorption cycle will be interrupted owing to solidification, and capacity will not be restored until the unit is desolidified. This normally requires the addition of heat to the outside of the solution heat exchanger and the solution pump.

The diagram in Fig. 11-101 presents enthalpy data for LiBr-water solutions. It is needed for the thermal calculation of the cycle. Enthalpies for water and water vapor can be determined from the table of properties of water. The data in Fig. 11-101 are applicable to saturated or subcooled solutions and are based on a zero enthalpy of liquid water at 0°C and a zero enthalpy of solid LiBr at 25°C. Since

Lithium Bromide Cycle
FIG. 11-99 Two-shell lithium bromide-water cycle chiller.
Water Water Heat Exchanger Schematics
FIG. 11-100 Temperature-pressure-concentration diagram of saturated LiBr-water solutions (W F. Stoecker and J. W. Jones: Refrigeration and Air-Conditioning)

the zero enthalpy for the water in the solution is the same as that in conventional tables of properties of water, the water property tables can be used in conjunction with diagram in Fig. 11-100.

Coefficient of performance of the absorption cycle is defined on the same principle as for the mechanical refrigeration:

useful effect refrigeration rate

heat input heat input at generator but it should be noted that here denominator for the COPabs is heat while for the mechanical refrigeration cycle it is work. Since these two forms of energy are not equal, COPabj is not as low (0.6-0.8) as it appears compared to COP for mechanical system (2.5-3.5).

The double-effect absorption unit is shown in Fig. 11-102. All major components and operation of the double-effect absorption machine is similar to that for the single-effect machine. The primary generator, located in the vessel 1, is using an external heat source to evaporate water from dilute-absorbent (high water concentration) solution. Water vapor readily flows to the generator II where it is condensed on the tubes. The absorbent (LiBr) intermediate solution from generator I will pass through the heat exchanger on the way to the generator II where it is heated by the condensing water vapor. The throttling valve reduces pressure from vessel 1 (about 103 kPa absolute) to that of vessel 2. Following the reduction of pressure some water in the solution flashes to vapor, which is liquefied at the condenser. In the high temperature heat exchanger intermediate solution heats the weak (high water concentration) solution stream coming from the low temperature heat exchanger. In the low temperature heat exchanger strong solution is being cooled before entering the absorber. The absorber is on the same pressure as the evaporator. The double-effect absorption units achieve higher COPs than the single stage.

The ammonia-water absorption system was extensively used until the fifties when the LiBr-water combination became popular. Figure 11-103 shows a simplified ammonia-water absorption cycle. The refrigerant is ammonia, and the absorbent is dilute aqueous solution of ammonia. Ammonia-water systems differ from water-lithium bromide equipment to accommodate major differences: Water (here absorbent) is also volatile, so the regeneration of weak water solution to strong water solution is a fractional distillation. Different refrigerant (ammonia) causes different, much higher pressures: about 11002100 kPa absolute in condenser.

Ammonia vapor from the evaporator and the weak water solution from the generator are producing strong water solution in the absorber. Strong water solution is then separated in the rectifier producing (1) ammonia with some water vapor content and (2) very strong water solution at the bottom, in the generator. Heat in the generator vaporizes ammonia and the weak solution returns to absorber. On its way to the absorber the weak solution stream passes through the heat exchanger, heating strong solution from the absorber on the way to the rectifier. The other stream, mostly ammonia vapor but with some water-vapor content flows to the condenser. To remove water as much as possible, the vapor from the rectifier passes through the analyzer where it is additionally cooled. The remaining water escaped from the analyzer pass as liquid through the condenser and the evaporator to the absorber.

Ammonia-water units can be arranged for single-stage or cascaded two-stage operation. The advantage of two-staging is it creates the possibility of utilizing only part of the heat on the higher and the rest on the lower temperature level but the price is increase in first cost and heat required.

Ammonia-water and lithium bromide-water systems operate under comparable COP. The ammonia-water system is capable achieving evaporating temperatures below 0°C because the refrigerant is ammonia. Water as the refrigerant limits evaporating temperatures to no lower than freezing, better to 3° C. Advantage of the lithium bromide-water system is that it requires less equipment and operates at lower pressures. But this is also a drawback, because pressures are below atmospheric, causing air infiltration in the system which must be purged periodically. Due to corrosion problems, special inhibitors must be used in the lithium-bromide-water system. The infiltration of air in the ammonia-water system is also possible, but when evaporating temperature is below -33° C. This can result in formation of corrosive ammonium carbonate.

Further readings: ASHRAE Handbook 1994 Refrigeration Systems and Applications; Bogart, M., 1981: Ammonia Absorption Refrigeration in Industrial Processes, Gulf Publishing Co. Houston; Stoecker W. F. and Jones J. W. 1982: Refrigeration and Air-Conditioning, McGraw-Hill Book Company, New York.

Steam-Jet (Ejector) Systems These systems substitute an ejector for a mechanical compressor in a vapor compression system. Since refigerant is water, maintaining temperatures lower than the environment requires that the pressure of water in the evaporator must be

Refrigeration Enthalpy
FIG. 11-101 Enthalpy of LiBr-water solutions (W F. Stoecker and J. W Jones: Refrigeration and Air-Conditioning).

below atmospheric. A typical arrangement for the steam-jet refrigeration cycle is shown in Fig. 11-104.

Main Components The main components of steam-jet refrigeration systems are:

1. Primary steam ejector. A kinetic device that utilizes the momentum of a high-velocity jet to entertain and accelerate a slower-moving medium into which it is directed. High-pressure steam is delivered to the nozzle of the ejector. The steam expands while flowing through the nozzle where the velocity increases rapidly. The velocity of steam leaving the nozzle is around 1200 m/s. Because of this high velocity, flash vapor from the tank is continually aspired into the moving steam. The mixture of steam and flash vapor then enters the diffuser section where the velocity is gradually reduced because of increasing cross-sectional area. The energy of the high-velocity steam compresses the vapor during its passage through the diffuser, raising it's temperature above the temperature of the condenser cooling water.

2. Condenser. The component of the system where the vapor condenses and where the heat is rejected. The rate of heat rejected is:

where: Qoond = heat rejection (kW)

Ws = primary booster steam rate (kg/s) Ww = flash vapor rate (kg/s) hfg = latent heat (kJ/kg)

The condenser design, surface area, and condenser cooling water quantity should be based on the highest cooling water temperature likely to be encountered. If the inlet cooling water temperature becomes hotter then the design, the primary booster (ejector) may cease functioning because of the increase in condenser pressure.

Two types of condensers could be used: the surface condenser (shown in Fig. 11-104) and the barometric or jet condenser (Fig. 11-105). The surface condenser is of shell-and-tube design with water flowing through the tubes and steam condensed on the outside surface. In the jet condenser, condensing water and the steam being condensed are mixed directly, and no tubes are provided. The jet condenser can be barometric or a low-level type. The barometric condenser requires a height of -10 m above the level of the water in the hot well. A tailpipe of this length is needed so that condenser water and condensate can drain by gravity. In the low-level jet type, the tailpipe is eliminated, and it becomes necessary to remove the con-

Condensate Tanks With Heat Exchanger
FIG. 11-102 Double-effect absorption unit.
Absorption Cooling Cycles
FIG. 11-103 Simplified ammonia-water absorption cycle.
Steam Jet Refrigeration
FIG. 11-104 Ejector (steam-jet) refrigeration cycle (with surface-type condenser).

denser water and condensate by pumping from the condenser to the hot well. The main advantages of the jet condenser are low maintenance with the absence of tubes and the fact that condenser water of varying degrees of cleanliness may be used.

3. Flash tank. This is the evaporator of the ejector system and is usually a large-volume vessel where large water-surface area is needed for efficient evaporative cooling action. Warm water returning from the process is sprayed into the flash chamber through nozzles (sometimes cascades are used for maximizing the contact surface, being less susceptible to carryover problems) and the cooled effluent is pumped from the bottom of the flash tank.

When the steam supply to one ejector of a group is closed, some means must be provided to for preventing the pressure in the condenser and flash tank from equalizing through that ejector. A com-partmental flash tank is frequently used for such purposes. With this arrangement, partitions are provided so that each booster is operating on its own flash tank. When the steam is shut off to any booster, the valve to the inlet spray water to that compartment also is closed.

A float valve is provided to control the supply of makeup water to replace the water vapor that has flashed off. The flash tank should be insulated.

Applications The steam-jet refrigeration is suited for:

1. Processes where direct vaporization is used for concentration or drying of heat-sensitive foods and chemicals, where, besides elimination of the heat exchanger, preservation of the product quality is an important advantage.

2. Enabling the use of hard or even sea water for heat rejection e.g. for absorption of gases (CO2, SO2, ClO2. . . ) in chilled water (desorption is provided simultaniously with chilling) when a direct contact barometric condenser is used.

Despite being simple, rugged, reliable, requiring low maintenance, low cost, and vibration free, steam-jet systems are not widely accepted in water chilling for air-conditioning due to characteristics of the cycle.

Factors Affecting Capacity Ejector (steam-jet) units become attractive when cooling relatively high-temperature chilled water with a source of about 7 bar gauge waste steam and relatively cool condensing water. The factors involved with steam-jet capacity include the following:

1. Steam pressure. The main boosters can operate on steam pressures from as low as 0.15 bar up to 7 bar gauge. The quantity of steam required increases rapidly as the steam pressure drops (Fig. 11-106). The best steam rates are obtained with about 7 bar. Above this pressure the change in quantity of steam required is practically negligible. Ejectors must be designed for the highest available steam pressure, to take advantage of the lower steam consumption for various steam-inlet pressures.

The secondary ejector systems used for removing air require steam pressures of 2.5 bar or greater. When the available steam pressure is lower than this, an electrically driven vacuum pump is used for either the final secondary ejector or for the entire secondary group. The secondary ejectors normally require 0.2-0.3 kg/h of steam per kW of refrigeration capacity.

2. Condenser water temperature. In comparison with other vapor-compression systems, steam-jet machines require relatively large water quantities for condensation. The higher the inlet-water temperature, the higher are the water requirements (Fig. 11-107).

Barometric Condenser
FIG. 11-105 Barometric condenser for steam-jet system.
Barometric Condenser
FIG. 11-106 Effect of steam pressure on steam demand at 38° C condenser temperature (ASHRAE 1983 Equipment Handbook).
Large Steam Condensers
FIG. 11-107 Steam demand versus condenser-water flow rate.
Chilled Water System Pressure
FIG. 11 -108 Steam demand versus chilled-water temperature for typical steam-jet system (ASHRAE 1983 Equipment Handbook).

The condensing water temperature has an important effect on steam rate per refrigeration effect, rapidly decreasing with colder condenser cooling water. Figure 11-108 presents data on steam rate versus condenser water inlet for given chilled-water outlet temperatures and steam pressure.

3. Chilled-water temperature. As the chilled-water outlet temperature decreases, the ratio of steam/refrigeration effect decreases, thus increasing condensing temperatures and/or increasing the con-densing-water requirements.

Unlike other refrigeration systems, the chilled-water flow rate is of no particular importance in steam-jet system design, because there is, due to direct heat exchange, no influence of evaporator tube velocities and related temperature differences on heat-transfer rates. Widely varying return chilled-water temperatures have little effect on steam-jet equipment.

Multistage Systems The majority of steam-jet systems being currently installed are multistage. Up to five stage systems are in commercial operation.

Capacity Control The simplest way to regulate the capacity of most steam vacuum refrigeration systems is to furnish several primary boosters in parallel and operate only those required to handle the heat load. It is not uncommon to have as many as four main boosters on larger units for capacity variation. A simple automatic on-off type of control may be used for this purpose. By sensing the chilled-water temperature leaving the flash tank, a controller can turn steam on and off to each ejector as required.

Additionally, two other control systems which will regulate steam flow or condenser-water flow to the machine are available. As the condenser-water temperature decreases during various periods of the year, the absolute condenser pressure will decrease. This will permit the ejectors to operate on less steam because of the reduced discharge pressure. Either the steam flow or the condenser water quantities can be reduced in order to lower operating costs at other then design periods. The arrangement selected depends on cost considerations between the two flow quantities. Some systems have been arranged for a combination of the two, automatically reducing steam flow down to a point, followed by a reduction in condenser-water flow. For maximum operating efficiency, automatic control systems are usually justifiable in keeping operating cost to a minimum without excessive operator attention. In general, steam savings of about 10 percent of rated booster flow are realized for each 2.5° C reduction in condens-ing-water temperature below the design point.

In some cases, with relatively cold inlet condenser water it has been possible to adjust automatically the steam inlet pressure in response to chilled-water outlet temperatures. In general, however, this type of control is not possible because of the differences in temperature between the flash tank and the condenser. Under usual conditions of warm condenser-water temperatures, the main ejectors must compress water vapor over a relatively high ratio, requiring an ejector with entirely different operating characteristics. In most cases, when the ejector steam pressure is throttled, the capacity of the jet remains almost constant until the steam pressure is reduced to a point at which there is a sharp capacity decrease. At this point, the ejectors are unstable, and the capacity is severely curtailed. With a sufficient increase in steam pressure, the ejectors will once again become stable and operate at their deign capacity. In effect, steam jets have a vapor-handling capacity fixed by the pressure at the suction inlet. In order for the ejector to operate along its characteristic pumping curve, it requires a certain minimum steam flow rate which is fixed for any particular pressure in the condenser. (For further information on the design of ejectors, see Sec. 6)

Further reading and reference: ASHRAE 1983 Equipment Handbook; Spencer, E., 1961, New Development in Steam Vacuum Refrigeration, ASHRAE Transactions Vol. 67, p. 339

Refrigerants A refrigerant is any body or substance which acts as a cooling agent by absorbing heat from another body or substance which has to be cooled. Primary refrigerants are those that are used in the refrigeration systems, where they alternately vaporize and condense as they absorb or and give off heat respectively. Secondary refrigerants are heat transfer fluids or heat carriers. Refrigerant pairs in absorption systems are ammonia-water and lithium bromide-water, while steam (water) is used as a refrigerant in ejector systems. Refrigerants used in the mechanical refrigeration systems are far more numerous.

A list of the most significant refrigerants is presented in the ASHRAE Handbook Fundamentals. More data are shown in the Chap. 3 of this handbook—"Physical and Chemical Data." Due to rapid changes in refrigerant, issue readers are advised to consult the most recent data and publications at the time of application.

The first refrigerants were natural: air, ammonia, CO2, SO2, and so on. Fast expansion of refrigeration in the second and third quarters of the 20th century is marked by the new refrigerants, chlorofluorocar-bons (CFC) and hydrochlorofluorocarbons (HCFC). They are halo-carbons which contain one or more of three halogens chlorine, fluorine, and bromine (Fig. 11-109). These refrigerants introduced many advantageous qualities compared to most of the existing refrigerants: odorless, nonflamable, nonexplosive, compatible with the most engineering materials, reasonably high COP, and nontoxic.

In the last decade, the refrigerant issue is extensively discussed due to the accepted hypothesis that the chlorine and bromine atoms from halocarbons released to the environment were using up ozone in the stratosphere, depleting it specially above the polar regions. Montreal Protocol and later agreements ban use of certain CFCs and halon compounds. It seems that all CFCs and most of the HCFCs will be out of production by the time this text will be published.

Chemical companies are trying to develop safe and efficient refrigerant for the refrigeration industry and application, but uncertainty in CFC and HCFC substitutes is still high. When this text was written HFCs were a promising solution. That is true especially for the R134a which seems to be the best alternative for R12. Substitutes for R22 and R502 are still under debate. Numerous ecologist and chemists are for an extended ban on HFCs as well, mostly due to significant use of CFCs in production of HFCs. Extensive research is ongoing to find new refrigerants. Many projects are aimed to design and study refrigerant mixtures, both azeotropic (mixture which behaves physically as a single, pure compound) and zeotropic having desirable qualities for the processes with temperature glides in the evaporator and the condenser.

Ammonia (R717) is the single natural refrigerant being used extensively (beside halocarbons). It is significant in industrial applications for its excellent thermodynamic and thermophysical characteristics. Many engineers are considering ammonia as a CFC substitute for various applications. Significant work is being done on reducing the refrigerant inventory and consequently problems related to leaks of this fluid with strong odor. There is growing interest in hydrocarbons in some contries, particularly in Europe. Indirect cooling (secondary refrigeration) is under reconsideration for many applications.

Due to the vibrant refrigerant issue it will be a challenge for every engineer to find the best solution for the particular application, but basic principles are the same. Good refrigerant should be:

• Safe: nontoxic, nonflamable, and nonexplosive

• Environmentally friendly

• Compatible with materials normally used in refrigeration: oils, metals, elastomers, etc.

• Desirable thermodynamic and thermophysical characteristics: High latent heat

Low specific volume of vapor Low compression ratio Low viscosity

Reasonably low pressures for operating temperatures Low specific heat of liquid High specific heat of vapor

High conductivity and other heat transfer related characteristics

Reasonably low compressor discharge temperatures

Easily detected if leaking

High dielectric constant

Good stability

Secondary Refrigerants (Antifreezes or Brines) These are mostly liquids used for transporting heat energy from the remote heat source (process heat exchanger) to the evaporator of the refrigeration system. Antifreezes or brines do not change state in the process, but there are examples where some secondary refrigerants are either changing state themselves, or just particles which are carried in them.

Indirect refrigeration systems are more prevalent in the chemical industry than in the food industry, commercial refrigeration, or comfort air-conditioning. This is even more evident in the cases where a large amount of heat is to be removed or where a low temperature level is involved. Advantage of an indirect system is centralization of refrigeration equipment, which is specially important for relocation of refrigeration equipment in a nonhazardous area, both for people and equipment.

Salt Brines The typical curve of freezing point is shown in Fig. 11-110. Brine of concentration x (water concentration is 1-x) will not solidify at 0° C (freezing temperature for water, point A). When the temperature drops to B, the first crystal of ice is formed. As the temperature decreases to C, ice crystals continue to form and their mixture with the brine solution forms the slush. At the point C there will be part ice in the mixture l2/ft +l2), and liquid (brine) lj(li +l2). At point D there is mixture of m1 parts eutectic brine solution D1 [concentration m1/(m1 + m2)], and m2 parts of ice [concentration m2/(mi + m2)]. Cooling the mixture below D solidifies the entire solution at the eutectic temperature. Eutectic temperature is the lowest temperature that can be reached with no solidification.

It is obvious that further strengthening of brine has no effect, and can cause a different reaction—salt sometimes freezes out in the installations where concentration is too high.

Sodium chloride, an ordinary salt (NaCl), is the least expensive per volume of any brine available. It can be used in contact with food and in open systems because of its low toxicity. Heat transfer coefficients are relatively high. However, its drawbacks are it has a relatively high freezing point and is highly corrosive (requires inhibitors thus must be checked on a regular schedule).

Calcium chloride (CaCl2) is similar to NaCl. It is the second lowest-cost brine, with a somewhat lower freezing point (used for temperatures as low as -37° C). Highly corrosive and not appropriate for direct contact with food. Heat transfer coefficients are rapidly reduced at temperatures below -20°C. The presence of magnesium salts in either sodium or calcium chloride is undesirable because they tend to form sludge. Air and carbon dioxide are contaminants and excessive aeration of the brine should be prevented by use of close systems. Oxygen, required for corrosion, normally comes from the atmosphere and dissolves in the brine solution. Dilute brines dissolve oxygen more readily and are generally more corrosive than concentrated brines. It is believed that even a closed brine system will not prevent the infiltration of oxygen.

To adjust alkaline condition to pH 7.0—8.5 use caustic soda (to correct up to 7.0) or sodium dichromate (to reduce excessive alkalinity

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