Refrigeration & Air Conditioning

Refrigeration & Air
Electrical Equipment/
Refrigeration & AC
Conditioning
Presentation from the
“Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org
1 © UNEP 2006
Training Agenda: Refrigeration &
Air Conditioning
Introduction
Refrigeration & AC
Type of refrigeration
Assessment of refrigeration and AC
Energy efficiency opportunities
2
© UNEP 2006
Introduction
How does High Temperature

Reservoir
Refrigeration & AC
it work?
Heat Rejected
R Work Input
Heat Absorbed
Low Temperature Reservoir
3
© UNEP 2006
Introduction
How does it work?

Thermal energy moves from left to right through five

Refrigeration & AC
loops of heat transfer:

1) 2) 3) 4) 5)
Indoor air Chilled Refrigerant Condenser Cooling
loop water loop loop water loop water loop
4 (Bureau of Energy Efficiency, 2004)

© UNEP 2006
Introduction
AC Systems
Refrigeration & AC
AC options / combinations:
• Air Conditioning (for comfort / machine)

• Split air conditioners
• Fan coil units in a larger system
• Air handling units in a larger system
5
© UNEP 2006
Introduction
Refrigeration systems for industrial

Refrigeration & AC
processes
• Small capacity modular units of direct
expansion type (50 Tons of Refrigeration)
• Centralized chilled water plants with
chilled water as a secondary coolant (50 –
250 TR)
• Brine plants with brines as lower

temperature, secondary coolant (>250 TR)
6
© UNEP 2006
Introduction
Refrigeration at large companies

Refrigeration & AC
• Bank of units off-site with common

• Chilled water pumps
• Condenser water pumps
• Cooling towers
• More levels of refrigeration/AC, e.g.

• Comfort air conditioning (20-25 oC)
• Chilled water system (8 – 10 oC)
7
• Brine system (< 0 oC)
© UNEP 2006
Air Conditioning
Introduction
Refrigeration & AC
8
© UNEP 2006
Types of Refrigeration
Refrigeration systems
Refrigeration & AC
• Vapour Compression
Refrigeration (VCR): uses
mechanical energy
• Vapour Absorption Refrigeration
(VAR): uses thermal energy
9
© UNEP 2006
Type of Refrigeration
Vapour Compression Refrigeration

Refrigeration & AC
• Highly compressed fluids tend to get

colder when allowed to expand
• If pressure high enough
• Compressed air hotter than source
of cooling
• Expanded gas cooler than desired
cold temperature
10
© UNEP 2006

Refrigeration & AC
Two advantages
• Lot of heat can be removed (lot of
thermal energy to change liquid to
vapour)
• Heat transfer rate remains high
(temperature of working fluid much
lower than what is being cooled)
11
© UNEP 2006

Refrigeration & AC
Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
12
© UNEP 2006
Low pressure liquid
refrigerant in evaporator
absorbs heat and

Refrigeration & AC
changes toRefrigeration
a gas cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
13
© UNEP 2006
The superheated vapour
enters the compressor
where its pressure is

Refrigeration & AC
raised Refrigeration cycle

3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
14
© UNEP 2006
The high pressure
superheated gas is
Vapour
cooled in several Compression
stages Refrigeration
in the condenser
Refrigeration & AC
Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
15
© UNEP 2006
Liquid passes through expansion
device, which reduces its
pressure and controls the flow
Refrigeration & AC
into the evaporator

Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
16
© UNEP 2006

Refrigeration & AC
Type of refrigerant
• Refrigerant determined by the
required cooling temperature
• Chlorinated fluorocarbons (CFCs) or
freons: R-11, R-12, R-21, R-22 and R-
502
17
© UNEP 2006

Refrigeration & AC
Choice of compressor, design of

condenser, evaporator determined by
• Refrigerant
• Required cooling
• Load
• Ease of maintenance
• Physical space requirements
18
• Availability of utilities (water, power)
© UNEP 2006
Vapour Absorption Refrigeration

Refrigeration & AC
Condenser Generator
Hot
Side
Evaporator
Cold Absorber
Side
19
© UNEP 2006

Refrigeration & AC
Evaporator
20
© UNEP 2006

Refrigeration & AC
Absorber
21
© UNEP 2006

Refrigeration & AC
High pressure generator
22
© UNEP 2006

Refrigeration & AC
Condenser
23
© UNEP 2006
Evaporative Cooling
• Air in contact with water to cool it close to ‘wet

Refrigeration & AC
bulb temperature’
• Advantage: efficient cooling at low cost
• Disadvantage: air is rich in moisture
Sprinkling
Water
Hot Air Cold

(Adapted from
Air
Munters, 2001)
24
© UNEP 2006
Air Conditioning
Introduction
Refrigeration & AC
25
© UNEP 2006
Assessment of Refrigeration and AC
Assessment of Refrigeration
Refrigeration & AC
• Cooling effect: Tons of Refrigeration

1 TR = 3024 kCal/hr heat rejected
• TR is assessed as:
TR = Q xCp x (Ti – To) / 3024

Q= mass flow rate of coolant in kg/hr
Cp = is coolant specific heat in kCal /kg deg C
Ti = inlet, temperature of coolant to evaporator (chiller) in 0C
To = outlet temperature of coolant from evaporator (chiller) in 0C
26
© UNEP 2006
Refrigeration & AC
Specific Power Consumption (kW/TR)

• Indicator of refrigeration system’s
performance
• kW/TR of centralized chilled water
system is sum of
• Compressor kW/TR
• Chilled water pump kW/TR
• Condenser water pump kW/TR
27
• Cooling tower fan kW/TR © UNEP 2006
Coefficient of Performance (COPCarnot)

Refrigeration & AC
• Standard measure of refrigeration efficiency

• Depends on evaporator temperature Te and
condensing temperature Tc:
COPCarnot = Te / (Tc - Te)
• COP in industry calculated for type of

compressor:
Cooling effect (kW)
COP =
28 Power input to compressor (kW)
© UNEP 2006
Refrigeration & AC
COP increases with rising COP increases with

evaporator temperature decreasing condensing
29 (Te) temperature (Tc)
© UNEP 2006
Assessment of Air Conditioning

Measure
Refrigeration & AC
• Airflow Q (m3/s) at Fan Coil Units (FCU) or Air

Handling Units (AHU): anemometer
• Air density  (kg/m3)
• Dry bulb and wet bulb temperature: psychrometer
• Enthalpy (kCal/kg) of inlet air (hin) and outlet air
(Hout): psychrometric charts
Calculate TR Q  ρ   h in  h out 
TR 
3024
30
© UNEP 2006
Assessment of Air Conditioning

Refrigeration & AC
Indicative TR load profile

• Small office cabins: 0.1 TR/m2
• Medium size office (10 – 30 people
occupancy) with central A/C: 0.06
TR/m2
• Large multistoried office complexes
with central A/C: 0.04 TR/m2
31
© UNEP 2006
Considerations for Assessment

• Accuracy of measurements
Refrigeration & AC
• Inlet/outlet temp of chilled and condenser

water
• Flow of chilled and condenser water
• Integrated Part Load Value (IPLV)

• kW/TR for 100% load but most equipment
operate between 50-75% of full load
• IPLV calculates kW/TR with partial loads
32 • Four points in cycle: 100%, 75%, 50%, 25%

© UNEP 2006
Air Conditioning
Introduction
Refrigeration & AC
33
© UNEP 2006
Energy Efficiency Opportunities
1. Optimize process heat exchange

Refrigeration & AC
2. Maintain heat exchanger surfaces

3. Multi-staging systems
4. Matching capacity to system load
5. Capacity control of compressors
6. Multi-level refrigeration for plant needs
7. Chilled water storage
34 8. System design features
© UNEP 2006
1. Optimize Process Heat Exchange

High compressor safety margins:

Refrigeration & AC
energy loss
1. Proper sizing heat transfer areas of
heat exchangers and evaporators
• Heat transfer coefficient on refrigerant side:
1400 – 2800 Watt/m2K
• Heat transfer area refrigerant side: >0.5 m2/TR
2. Optimum driving force (difference Te and

Tc): 1oC raise in Te = 3% power savings
35
© UNEP 2006

Evaporator Refrigeration Specific Power Increase

Refrigeration & AC
Temperature (0C) Capacity*(tons) Consumption (kW/TR) kW/TR (%)

5.0 67.58 0.81 -
0.0 56.07 0.94 16.0
-5.0 45.98 1.08 33.0
-10.0 37.20 1.25 54.0
-20.0 23.12 1.67 106.0
Condenser temperature 40◦C (National Productivity Council)
Condensing Refrigeration Specific Power Increase

Temperature (0C) Capacity (tons) Consumption (kW /TR) kW/TR (%)
26.7 31.5 1.17 -
35.0 21.4 1.27 8.5
40.0 20.0 1.41 20.5
36 *Reciprocating compressor using R-22 refrigerant. Evaporator temperature.-10◦ C
© UNEP 2006

3. Selection of condensers
Refrigeration & AC
• Options:
• Air cooled condensers
• Air-cooled with water spray condensers
• Shell & tube condensers with water-cooling
• Water-cooled shell & tube condenser

• Lower discharge pressure
• Higher TR
• Lower power consumption
37
© UNEP 2006
2. Maintain Heat Exchanger Surfaces

• Poor maintenance = increased power

Refrigeration & AC
consumption
• Maintain condensers and evaporators
• Separation of lubricating oil and refrigerant
• Timely defrosting of coils
• Increased velocity of secondary coolant
• Maintain cooling towers

• 0.55◦C reduction in returning water from cooling
tower = 3.0 % reduced power
38
© UNEP 2006
2. Maintain Heat Exchanger Surfaces

Refrigeration & AC
Effect of poor maintenance on

compressor power consumption
Specific Increase
Te Tc Refrigeration Power kW/TR
Condition
(0C) (0C) Capacity* (TR) Consumption (%)
(kW/TR)
Normal 7.2 40.5 17.0 0.69 -
Dirty condenser 7.2 46.1 15.6 0.84 20.4
Dirty evaporator 1.7 40.5 13.8 0.82 18.3
Dirty condenser 1.7 46.1 12.7 0.96 38.7
and evaporator
39
(National Productivity Council)
© UNEP 2006
3. Multi-Staging Systems
• Suited for
Refrigeration & AC
• Low temp applications with high

compression
• Wide temperature range
• Two types for all compressor types
• Compound
• Cascade
40
© UNEP 2006
3. Multi-Stage Systems
a. Compound
Refrigeration & AC
• Two low compression ratios = 1 high

• First stage compressor meets cooling load
• Second stage compressor meets load
evaporator and flash gas
• Single refrigerant
b. Cascade
• Preferred for -46 oC to -101oC
41 • Two systems with different refrigerants
© UNEP 2006
4. Matching Capacity to Load System

Refrigeration & AC
• Most applications have varying loads

• Consequence of part-load operation
• COP increases
• but lower efficiency
• Match refrigeration capacity to load

requires knowledge of
• Compressor performance
• Variations in ambient conditions
42 • Cooling load
© UNEP 2006
5. Capacity Control of Compressors

• Cylinder unloading, vanes, valves

Refrigeration & AC
• Reciprocating compressors: step-by-step

through cylinder unloading:
• Centrifugal compressors: continuous
modulation through vane control
• Screw compressors: sliding valves
• Speed control
• Reciprocating compressors: ensure
lubrication system is not affected
43 • Centrifugal compressors: >50% of capacity
© UNEP 2006
5. Capacity Control of Compressors

• Temperature monitoring
Refrigeration & AC
• Reciprocating compressors: return water (if

varying loads), water leaving chiller
(constant loads)
• Centrifugal compressors: outgoing water
temperature
• Screw compressors: outgoing water
temperature
• Part load applications: screw

44
compressors more efficient
© UNEP 2006
6. Multi-Level Refrigeration
Refrigeration & AC
Bank of compressors at central plant

• Monitor cooling and chiller load: 1 chiller full
load more efficient than 2 chillers at part-load
• Distribution system: individual chillers feed all
branch lines; Isolation valves; Valves to isolate
sections
• Load individual compressors to full capacity
before operating second compressor
• Provide smaller capacity chiller to meet peak
45
demands
© UNEP 2006
6. Multi-Level Refrigeration
Refrigeration & AC
Packaged units (instead of central plant)

• Diverse applications with wide temp range
and long distance
• Benefits: economical, flexible and reliable
• Disadvantage: central plants use less power
Flow control
• Reduced flow
• Operation at normal flow with shut-off periods
46
© UNEP 2006
7. Chilled Water Storage

Refrigeration & AC
• Chilled water storage facility with

insulation
• Suited only if temp variations are
acceptable
• Economical because
• Chillers operate during low peak demand
hours: reduced peak demand charges
• Chillers operate at nighttime: reduced tariffs
47 and improved COP
© UNEP 2006
8. System Design Features

Refrigeration & AC
• FRP impellers, film fills, PVC drift eliminators

• Softened water for condensers
• Economic insulation thickness
• Roof coatings and false ceilings
• Energy efficient heat recovery devices
• Variable air volume systems
• Sun film application for heat reflection
48
• Optimizing lighting loads © UNEP 2006
Training Session on Energy
Equipment

Refrigeration & Air

Refrigeration & AC
Conditioning Systems
THANK YOU
FOR YOUR ATTENTION
49
© UNEP 2006
Disclaimer and References
• This PowerPoint training session was prepared as part of

the project “Greenhouse Gas Emission Reduction from
Industry in Asia and the Pacific” (GERIAP). While

Refrigeration & AC
reasonable efforts have been made to ensure that the

contents of this publication are factually correct and
properly referenced, UNEP does not accept responsibility
for the accuracy or completeness of the contents, and shall
not be liable for any loss or damage that may be occasioned
directly or indirectly through the use of, or reliance on, the
contents of this publication. © UNEP, 2006.
• The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is
50 available on www.energyefficiencyasia.org
© UNEP 2006

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Refrigeration & Air

How does High Temperature

Low Temperature Reservoir

How does it work?

Thermal energy moves from left to right through five

loops of heat transfer:

4 (Bureau of Energy Efficiency, 2004)

• Air Conditioning (for comfort / machine)

Refrigeration systems for industrial

• Brine plants with brines as lower

Refrigeration at large companies

• Bank of units off-site with common

• More levels of refrigeration/AC, e.g.

Vapour Compression Refrigeration

• Highly compressed fluids tend to get

Vapour Compression Refrigeration

Vapour Compression Refrigeration

absorbs heat and

where its pressure is

raised Refrigeration cycle

into the evaporator

Vapour Compression Refrigeration

Vapour Compression Refrigeration

Choice of compressor, design of

Vapour Absorption Refrigeration

Vapour Absorption Refrigeration

Vapour Absorption Refrigeration

Vapour Absorption Refrigeration

High pressure generator

Vapour Absorption Refrigeration

• Air in contact with water to cool it close to ‘wet

Hot Air Cold

• Cooling effect: Tons of Refrigeration

TR = Q xCp x (Ti – To) / 3024

Specific Power Consumption (kW/TR)

Coefficient of Performance (COPCarnot)

• Standard measure of refrigeration efficiency

• COP in industry calculated for type of

COP increases with rising COP increases with

Assessment of Air Conditioning

• Airflow Q (m3/s) at Fan Coil Units (FCU) or Air

Assessment of Air Conditioning

Indicative TR load profile

Considerations for Assessment

• Inlet/outlet temp of chilled and condenser

• Integrated Part Load Value (IPLV)

32 • Four points in cycle: 100%, 75%, 50%, 25%

1. Optimize process heat exchange

2. Maintain heat exchanger surfaces

1. Optimize Process Heat Exchange

High compressor safety margins:

2. Optimum driving force (difference Te and

1. Optimize Process Heat Exchange

Evaporator Refrigeration Specific Power Increase

Temperature (0C) Capacity*(tons) Consumption (kW/TR) kW/TR (%)

Condensing Refrigeration Specific Power Increase

1. Optimize Process Heat Exchange

• Water-cooled shell & tube condenser

2. Maintain Heat Exchanger Surfaces