ABSORPTION REFRIGERATION SYSTEM

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 Absorption Refrigeration Unit

NOTE:

Every effort has been made to ensure that the information contained in this manual is accurate;
however no labiality is accepted for errors. Should an error be discovered please inform the
company in writing, giving full details. Any experimental results given are for guidance only and
are not guaranteed as exact answers that can be obtained for a given apparatus; due to the
complex variables applicable to most experiments.

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 Absorption Refrigeration Unit

Table of Contents
Page
1. INTRODUCTION........................................................................................................... 1

2. GENERAL DESCRIPTION .......................................................................................... 2

2.1 Unit Assembly ............................................................................................................ 3

3. SUMMARY OF THEORY ............................................................................................ 4

3.1 Absorption Systems Principle and Applications......................................................... 4
3.2 Solid Absorption System ............................................................................................ 6
3.3 Intermittent Absorption System .................................................................................. 6
3.4 Continuous Absorption System .................................................................................. 8
3.5 Working Of Model ...................................................................................................... 12
3.6 Absorption Refrigeration Process Flow Diagram ....................................................... 13

4. GENERAL OPERATING PROCEDURES ................................................................ 15

5. EXPERIMENTAL PROCEDURES ............................................................................ 16

5.1 Objective ..................................................................................................................... 16
5.2 Procedure .................................................................................................................... 16
5.3 Observations ............................................................................................................... 16

6. SAFETY PRECAUTIONS............................................................................................. 17

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1 INTRODUCTION:

The EES® Absorption Refrigeration Unit will familiarize students with the principles
of absorption refrigeration systems in use today. Typically absorption systems are used in
applications that require lower power usage such as refrigeration in recreational vehicles.
They are also useful in remote locations far away from the common availability of
electricity and can be easily to LPG, kerosene and solar power. Larger systems are also
suited for industrial use.

The trainer features a dual power source of LPG and electricity. The heat generated by
these sources makes ammonia evaporate from a water/ammonia solution. The ammonia
vapor rises and condenses into a liquid by flowing, through a finned heat exchanger. The
water is separated off and returns to the absorber. The ammonia then falls to the
condenser whereby it boils (due to the lower pressure in the evaporator) and vaporizes
thereby absorbing heat which cools the refrigerator. The vapor then falls back the
absorber vessel and is reabsorbed by the water solution and the cycle repeats.

Components are clearly laid out and mounted onto a mobile stand that incorporates a
work surface. A dual energy source is provided which includes both electrical and an
LPG source.

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 Absorption Refrigeration Unit

2 GENERAL DISCRIPTION:

This refrigeration system consists of some main components as follow:

1. Absorption refrigeration system
2. Electrical control
3. Board and frame

This absorption refrigeration system uses

1. Ammonia
2. Water
3. Hydrogen (auxiliary gas)

There are some main components in this absorption refrigeration system, they are

1. Boiler
2. Condenser
3. Evaporator
4. Absorber vessel

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2.1 Unit Assembly:

6 5

1
7

2
3

4
8

10

1. Temperature Display 2. Heater Watt Display

3. Power Controls 4. Heater Indicator
5. Condenser 6. Separator
7. Evaporators (High & Low Cooling) 8. Burner
9. Absorber 10. Absorber Vessel

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3 SUMMARY OF THEORY:

3.1 Absorption Systems Principles and Applications:

The absorption system is different from the compression system. It uses heat
energy instead of mechanical energy to make a change in the conditions necessary
to complete a refrigeration cycle. The absorption system may use natural gas,
LPG, kerosene, steam or electric heating element as a source of heat.

The system has few moving parts. Smaller units have which parts only in the heat
source valves and in controls which are used. Some larger units also use
circulating pumps and fans.

3.1.1 The Absorption System:

The condenser, receiver, and evaporator (cooling coil) are quite similar to
those used in the compression system. The compressor has been replaced
by a heater and generator. Systems shown have been simplified by leaving
out various controls. These will be recovered later. The figure below
illustrates a basic absorption system. It is the liquid/absorbent type. It uses
a water-cooled condenser.

Above figure shows the Simple liquid absorbent refrigeration unit. A-generator,
B-condenser. C-receiver. D-Evaporator. E-burner. F-water in. G-water out. H-
check valve.

The figure below illustrates the fundamentals of a basic absorption system.

This diagram shows the solid absorbent type.

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 Absorption Refrigeration Unit

Above Figure shows the elementary solid absorbent refrigeration unit.

Note water cooled condenser.

3.1.2 Types of Absorption System:

Absorption systems are based on several combinations of substances

which have an unusual property. One substance will absorb the other
without any chemical action taking place. It will absorb the other
substance when cool and release it when heated. If the substance is a
liquid, the process is called absorbing; there are two of absorption
refrigerators. One uses a solid absorbent material; the other uses a liquid
absorbent.

Absorption systems are further classified as:

1. Intermittent systems.
2. Continuous systems.

Absorption systems have had several applications:

1. Domestic.
2. Recreational vehicle.
3. Industrial.
4. Air conditioning.

Absorption systems are also identified by heat source:

1. Kerosene.
2. Natural gas.
3. Steam.
4. Electrical heat.
5. Solar energy.

Some absorption units used in family trailers and mobile homes can be
heated either electrically of by LPG.

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3.2 Solid Absorption System:

3.2.1 Principle of the Solid Refrigeration System:

Solid absorption systems operate on principles discovered by Michael

Faraday in 1824. Through experiments, he succeeded in liquefying
ammonia, which scientists had believed to be a “fixed” gas. That is to say,
it was considered impossible to change it to either a solid or a liquid.

3.3 Intermittent Absorption System:

3.3.1 Principle of the Intermittent Absorption System:

A convenient refrigeration cycle for localities having neither gas or

electricity is the super fex and truckload cycle. The super fex cycle is
about the same as the Faraday principle but it has some different features.

In figure below, ammonia is mixed with water in a sealed tank or

generator shown at A. Underneath, a kerosene burner, M, heats it. Heat
from the burner drives the ammonia, in vapor form, out of the mixture.
This vapor is forced up the pipe marked D and through a condenser, E.
This is imm0ersed in water from a tank at B on top of the refrigerator.

Generation or heating interval, in typical intermitted type absorption refrigeration

Cooling effect of the water causes the ammonia vapor to change back into
a liquid (condenses) at the high generating pressure. This liquid ammonia
drops through a pipe into the liquid receiver, C. From here it passes to the
evaporator, K, which is surrounded by brine at H. The liquid receiver is
insulated at F to prevent this container from overcooling the food
compartment by acting as the evaporator.

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The process continues for a short time until the kerosene is used up and
the burner goes out.
As the absorber cools to room temperature, the ammonia will evaporate at
a low temperature in the evaporator. This is because as the generator
cools, it tends to reabsorb the ammonia vapor. This reduces the pressure
and permits the liquid ammonia in the evaporator to boil at low
temperature. This evaporation causes the cooling effect or refrigeration
required to preserve the contents of the food compartment.

In other words, heat from the oil burner driver the ammonia from the
generator, A, into the evaporator, K, in a short time. The ammonia in the
evaporator vaporizes and passes back to the generator slowly over a period
of 24 to 36 hours. The vaporization of the ammonia in the evaporator
produces a refrigerating effect. For additional efficiency in unusually hot
climates or handling extra large loads, a depression, L, in the top of the
condenser tank may be filled with water. The water will evaporate rapidly
and aid the cooling of the condenser.
Absorption mechanisms are provided with a fuse plug. The fuse plug will
release the charge from the mechanism if the temperature of the unit
becomes excessive (175°F to 200°F or 79°C to 93°C), as might be
experienced in a fire. This prevents the mechanism from exploding.

Refrigeration part of cycle in intermittent type absorption refrigeration

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3.4 Continuous Absorption System:

3.4.1 Principle of the Continuous Absorption System:

The absorption system uses ammonia, water and hydrogen. When it

provides refrigeration constantly, it is called a continuous absorption
system. A continuous refrigerating cycle operates automatically through
the use of automatic controls.

Although many companies have variations of the basic system, the

principle of operation remains the same. When the burner is lighted or
heater is turned on and its head applied to the generator at 1 in Fig below,
ammonia vapor is released from the solution. This hot vapor passes
upward through the percolator tube at 2. As the hot ammonia vapor rises
through this tube, it carries the solution to the upper level of the separator
at 3.Most of the liquid solution settles in the bottom of the separator and
flows into the absorber. The hot ammonia vapor, being light, rises to the
top of the tube, marked 4, into the condenser. The hot ammonia vapor then
condenses into a liquid. Then ammonia is now in pure state and it flows by
gravity into the evaporator.

Because a liquid will always seek its own level, the liquid ammonia flows
through the liquid ammonia tube and spills into the evaporator. There it
forms in large shallow pools on a series of horizontal baffle plates. The
hydrogen gas that is being fed to the evaporator in large quantities permits
the liquid ammonia to evaporate at a low pressure and at a low
temperature (Dalton’s principle). During this process of evaporation, the
ammonia absorbs heat from the food compartment of the refrigerator and
causes the water in the ice cube containers to freeze. The more hydrogen
and less ammonia, the lower the temperature. The evaporated ammonia
mixes with the hydrogen gas.

Air cooled continues refrigeration cycle. Note water circuit, ammonia flow, and hydrogen circuit

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Mean while, a weak solution of ammonia and water, is flowing by gravity

from the separator, at 3, down to the top of the absorber. Here it meets the
mixture of hydrogen gas and ammonia vapor coming from the evaporator.
The weak and fairly cool solution absorbs the ammonia vapor. The
hydrogen gas is left free since hydrogen will not mix the water. Because
the hydrogen is also very light, it now rises to the top of the absorber and
returns to the evaporator. Being air cooled, the absorber has fins. The
cooling of the weak solution helps it to reabsorb the ammonia gas out of
the mixture of ammonia vapor and hydrogen gas

As the weak water solution reabsorbs the ammonia vapor, considerable

heat is liberated. The air-cooled fins remove this heat to permit
refrigeration to continue.

The ammonia liquid and water mixture flows back to the generator, where
it again starts its cycle.

The apparatus is a welded assembly. There are no moving parts to wear

out or get out of adjustment. Since the total pressure throughout the cycle
is about 400 psi (2864 kPa) at a room (ambient) temperature of 100°F
(38°C), construction must be rugged to insure a long life.

To produce a temperature of 0°F (-18°C) in the evaporator, the ammonia

must boil at 15.7 psi (211.8 kPa). This means the hydrogen must make up
the reminder of the pressure (384.3 psi)

3.4.2 Continuous Absorption System with Pump:

The continuous absorption refrigerating system with a pump, in Fig below,

uses ammonia as the refrigerant and an aqueous ammonia solution as the
absorbent. Any means of heating can be used, but natural gas, steam, or
LPG are the most popular.

The system operates under two pressures. The high -side pressure is from
200 to 300 psi (1484 to 2174 kPa) and the low-side, 40 to 60 psi (380 to
518 kPa). The high and low sides are separated by check valves, liquid
traps, a pump, or other controlling devices.

The operational system can be divided into four sections including

generator, condenser, evaporator, and absorber.

The generator at 1 in Fig. below is heated by a vertical burner. Heat causes

the liquid to boil and the ammonia in the liquid turns into vapor. The
vapor will rise up through the tube to the air-cooled condenser. In the
condenser, heat from the vapor is removed by cooler air passing across it.
The vapor will condense into a liquid, which then acts as the refrigerant.
The liquid refrigerant now passes, at a high pressure, to the evaporator at

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3. In the evaporator, water carrying heat from the cooled area passes
through the tubes. The heat from the water tubes is transferred to the
refrigerant liquid. The water in the tubes returns to the area that needs to
be cooled. Being at a low temperature, the water can absorb heat from the
area that is to be cooled.

The heat that the refrigerant has absorbed from the chilled water circuit
causes it to boil and turn into a vapor. This vapor refrigerant is drawn back
to the solution-cooled absorber at 4, where the heat is sent to the outside
air. The liquid refrigerant is then pumped back-preheated-by the solution
pump to the generator, where the procedure is repeated.

Continuous Absorption System uses pump to maintain pressure difference between low pressure
side and high pressure side of system. Same pump transfers strong-in-ammonia, weak-in-water
solution. 1-Generator. 2-Condenser. 3-Evaporator. 4-Absorber. 5-Check valves.

Continuous operation absorption unit can be heated by fuel gas electricity.

A-condenser
B-Low-temperature evaporator
C-High-temperature evaporator
D-Absorber
E-Generator

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Continuous operation absorption unit

3.4.3 Continuous System Gas Supply:

The fuel most often used for absorption system refrigerators is natural or
LPG. Using clean fuel such as gas prevents formation of carbon monoxide
or carbon deposits in the burner. The cleaner the fuel, the less frequently
the burners will need cleaning.

Gas refrigerators should by supplied with gas under steady pressure. The
burner should be designed for the type of gas being used. The gas must be
strained before entering the burners. It must have a pressure regulator to
provide a constant, unchanging pressure on the burner. Figure 3.4-8 is a
diagram showing suitable gas connections. It is important to know the
local laws and codes about installation of these refrigerators before
installing them.

In case of burner difficulty, check to make sure the burner is the correct
one for the gas being used. Three different gases are used as fuel for gas
refrigerator units. Heating quality of each is given as follows:

1. Artificial gas (500 to 600 Btu/cu.ft)

2. Natural gas (1000 to 1100 Btu/cu.ft)
3. Liquid petroleum LPG (2500 to 3200 Btu/cu.ft)

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3.5 Working of Model:

The typical cooling core consists of four major components; the boiler, condenser,
evaporators and absorber. The cooling unit is a weirdly constructed apparatus of
tubes within tubes connecting the four major components The contents of the
sealed system include water, liquid ammonia (and associated vapors), hydrogen
gas and sodium chromate, a rust inhibitor used to line the internal tubing to
protect it from the corrosiveness of the ammonia. During a typical cycle, heat is
applied to the boiler by either an electric heating element or an open LP flame.
Water and liquid ammonia begin to boil and ammonia vapor rises up to the
condenser, the highest portion of the cooling unit. Any water molecules reaching
the condenser are separated and returned to the boiler section. After passing
through the condenser and turning back into a liquid, hydrogen vapor is
introduced to the liquid ammonia at the low temperature evaporator located in the
freezer compartment (see photo). Heat from inside the freezer is transferred
through the tubing of the low temperature evaporator and released to the exterior
of the refrigerator.

Next, a remnant of mixed hydrogen vapor and liquid ammonia passes to the high
temperature evaporator located behind the main food storage compartment fins
and the process of removing the heat continues, albeit less assertively. The food
storage compartment/high temperature evaporator becomes cold, but not as cold
as the low temperature evaporator in the freezer.

Upon leaving the evaporator sections, the weakened ammonia liquid then flows
through the absorber coils. Here the hydrogen gas rises back up to the evaporator
sections while the liquid ammonia is mixed with water in the absorber coils. This
mixture now flows to the absorber vessel and back to the boiler and the next cycle
begins.

From the point where liquid ammonia leaves the condenser until it reaches the
absorber and re-mixes with the water, gravity provides the motivation. Off level
operation slows the pace and causes overheating in the boiler section. Continued
operation in an over-heated condition results in cooling unit blockage whereby the
rust inhibitor becomes crystallized and blocks sections of the internal tubing in the
boiler. Unfortunately, this process cannot be reversed. The only remedy for a
blocked cooling unit is replacement, even though unfortunately, a lot of old
wives’ tales are yet uttered around the campfire.

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A cutaway view of the boiler section, (black tubing). The green section is the flue
pipe which is positioned directly over the propane burner flame. The red portion
is the sleeve or pocket into which the electrical heating element slips.

The percolator tube (yellow tube) will be positioned inside the boiler tube. This is
the tube that becomes plugged with the crystallized chromate when the
refrigerator is chronically run off-level or when a leak develops; both of which
will overheat the boiler section. Cooled tubing within the refrigerator attracts
moisture in the form of condensation. This moisture envelopes the tubing and is
typically retained there because the insulating foam prohibits it from being
evaporated.

3.6 Absorption Refrigeration Process Flow Diagram:

The heat is supplied by a burner which is fitted underneath the central tube (A)
and when the unit operates on electricity the heat is supplied by a heating element
inserted in the pocket (B).The unit charge consists of a quantity of ammonia,
water and hydrogen at a sufficient pressure to condense ammonia at the room
temperature for which the unit is designed. When heat is supplied to the boiler
system, bubbles of ammonia gas are produced which rise and carry with them
quantities of weak ammonia solution through the siphon pump (C). This weak
solution passes into the tube (D), whilst the ammonia vapor passes into the vapor
pipe (E) and on to the water separator. Here any water vapor is condensed and
runs back into the boiler system leaving the dry ammonia vapor to pass to the
condenser. Air circulating over the fins of the condenser removes heat from the
ammonia vapor to cause it to condense to liquid ammonia in which state it flows
into the evaporator.The evaporator is supplied with hydrogen. The hydrogen
passes across the surface of the ammonia and lowers the ammonia vapor pressure
sufficiently to allow the liquid ammonia to evaporate. The evaporation of the
ammonia extracts heat from the food storage space, as described above, thereby
lowering the temperature inside the refrigerator. The mixture of ammonia and
hydrogen vapor passes from the evaporator to the absorber. Entering the upper
portion of the absorber is a continuous trickle of weak ammonia solution fed by
gravity from the tube (D). This weak solution, flowing down through the absorber
comes into contact with the mixed ammonia and hydrogen gases which readily

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absorbs the ammonia from the mixture, leaving the hydrogen free to rise through
the absorber coil and to return to the evaporator. The hydrogen thus circulates
continuously between the absorber and the evaporator.

The strong ammonia solution produced in the absorber flows down to the
absorber vessel and thence to the boiler system, thus completing the full cycle of
operation. The liquid circulation of the unit is purely gravitational. Heat is
generated in the absorber by the process of absorption. This heat must be
dissipated into the surrounding air. Heat must also be dissipated from the
condenser in order to cool the ammonia vapor sufficiently for it to liquefy. Free
air circulation is therefore necessary over the absorber and condenser.

The whole unit operates by the heat applied to the boiler system and it is of
paramount importance that this heat is kept within the necessary limits and is
properly applied.

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4 GENERAL OPERATING PROCEDURES:

Do the following procedures before operating the trainer:

1. Place the trainer in a room with sufficient area and ventilation.

2. Connect power plug to power source, make sure all the instrument on control panel at
off position.
3. Operate Absorption Refrigeration Trainer by using gas flame
4. Prepare the gas and ensure it is full for heating process.

Note: For this operation the electric heater is not used because the heating-energy is from the gas
(propane).

5. Ensure that the system is connected to the correct power source (220-240VAC).
6. Operate Absorption Refrigeration Trainer by electric heater.
7. Ensure that the gas is not connected to the system.

Note: For this operation the gas flame is not used because the heating-energy is from the electric
heater.

8. Ensure that the system is connected to the correct power source (220-240VAC).
9. Check Voltage source by multi meter and make sure that source has suitable voltage
for the trainer, then turn MCB on.
10. Check the temperature meter on the panel, and check ambient temperature by digital
temperature meter.
11. The trainer is ready to used for experiments after all steps above are completed.

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5 EXPERIMENTAL PROCEDURE:

5.1 Objective:

After completing this exercise, student will understand how to operate absorption
refrigeration trainer by using electric heater OR with gas

5.2 Procedure:

1. Prepare all equipment for this exercise.

2. Ensure that the gas is not connected to the system.

Note: For this operation the gas flame is not used because the heating-energy is from the
electric heater.

3. Ensure that the system is connected to the correct power source (220-
240VAC).
4. Adjust the thermostat to 5°C by turning the adjuster.
5. Switch ON the MCB and main power switch. Ensure that the system is
powered by correct power source (220-240VAC).
6. Switch ON the electric heater.
7. Let the system is running for about 30 minutes.
8. After you understand how to operate this system by using electric heater,
switch OFF the electric heater, main power switch and the MCB.

5.3 Observations:

Measurement Value
T1 (°C)
T2 (°C)
T3 (°C)
T4 (°C)
T5 (°C)
T6 (°C)
T7 (°C)
T8 (°C)

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6 SAFETY PRECAUTIONS:

For the safety during operate the absorption refrigeration trainer, follow advice below:

1. Make sure that there is no leakage in the refrigeration system before operating the
system.
2. Make sure that the trainer is powered by 220-240VAC before activating the system.

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