Providing free cooling from low temperature waste heat

Transcription

1 Providing free cooling from low temperature waste heat through By Dinesh Gupta Past President ASHRAE India chapter President, Bry-Air Asia

2 A. THE TECHNOLOGY Comparing the adsorption cycle with the refrigeration cycle...something you are already familiar with History of Adsorption Chiller More on the working principles of Adsorption Chiller The Adsorber... at the heart of it all Let us compare Adsorption Chiller with Absorption Chiller

3 Comparing the adsorption cycle with the refrigeration cycle... Something you are already familiar with THE REFRIGERATION CYCLE THE ADSORPTION CHILLER CYCLE The thermal compressor The electric compressor

4 Brief History of Adsorption Chillers 1848: Faraday produced cooling using adsorption refrigeration phenomena using silver chloride to adsorb ammonia : Albert Einstein and his former student, Hungarian-born American physicist Leo Szilard first patented the design for Absorption refrigeration in : The commercialization of Adsorption Chiller happened in Japan using silica gel and water pair. 2000: CCHP Adsorption machines were used in Germany 2008: PPI developed Eco Max Adsorption Chillers using Silica Gel and water pair. 2015: Bry-Air introduces Adsorption Chillers for the first time in India / Asia.

5 ADC WHITE BOARD PRESENTATION

6 How does the Adsorption Chiller Work? The principle of adsorption works with the interaction of gases and solids. With adsorption chilling, the molecular interaction between the solid and the gas allow the gas to be adsorbed into the solid. The adsorption chamber of the chiller is filled with solid material, silica gel, eliminating the need for moving parts and eliminating the noise associated with those moving parts. The silica gel creates an extremely low humidity condition that causes the water refrigerant to evaporate at a low temperature. As the water evaporates in the evaporator, it cools the chilled water.

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8 How it Works: Condenser Chamber 38 C(100:F) Refrigerant water 80 :C(182:F) Adsorption Chamber 2 Adsorption Chamber 1 External Water Trap Column (breaks pressure differential) 90 C(182:F) Hot Water Silica gel Silica gel Cool Water 29 C (85:F ) Flapper valves 12 C(53:F ) Cold Water Evaporator Chamber 7 C(44:F)

9 Mass Heat Normal Recovery: Cycle: 38 C(100:F) Adsorption Chamber 2 Adsorption Chamber 1 80 :C(182:F) 80:C(182:F) 90 C(182:F) Hot Water Silica gel Silica gel 30:C(85: F) 90:C(194: F) Cool Water Flapper valves 12 C(53:F ) Cold Water Evaporator Chamber 7 C(44:F)

10 Components of Adsorption Chiller

11 Current Range: 35 kw to 1180 kw (10 to 335 tons) Future Range: 10 kw to 35 kw (3 to 10 tons) the BryChill Range

12 Components of BOP and their importance 1. Heat source and heating, comprising The External System with BOP (Balance of Plant) External to the Adsorption Chiller Hot water (through waste heat or solar) Hydraulics package comprising the pump, expansion tank, meters, temperature probes and chemical treatment system (if needed) Interconnecting plumbing and valves Hot water tank for temperature buffering 2. Heat rejection equipment comprising Cooling tower or Dry Cooler with or without evaporative cooling or geo-thermal Hydraulics package comprising the pump, expansion tank, meters, temperature probes and chemical treatment system (if needed) Interconnecting plumbing and valves Plate frame heat exchanger 3. Chiller water comprising Interconnecting piping and valves Pump

13 Refrigeration Capacity Adsorption Chiller Vs Absorption Chiller Adsorption Chiller Works well at low hot water temperatures!

14 Adsorption is your only answer Complimentary or Competitive? Adsorption Absorption may be a better choice Absorption degrees C 80-90ᵒC Sweet spot of Adsorption

15 Adsorption Chiller Vs Absorption Chiller Limitations of Absorption Chiller Lithium bromide is highly corrosive and toxic Crystallization is very high High corrosion protection required Maintenance is very high Benefits of Adsorption Chiller Long life > 25 years Negligible maintenance Low noise and vibration Wide range of operating temperatures

16 B. HOW TO APPLY 1. Importance of: 1.1) Understanding COP 1.2) Waste heat Types of waste heat including generated heat 1.3) Hot water temperature and its impact 1.4) Cooling water temperature 2. Performance calculator and some working examples 3. BOP 3.1) Heat sources 3.2) Maintenance and lack of maintenance thereof

17 Understanding COP Coefficient of performance COP = Cooling Produced Heat Input COP is only important if heat has been generated though solar, steam, other sources for driving the heat into the chiller. COP is not important if there is abundant supply of waste heat

18 TYPES OF WASTE HEAT

19 Source 1: Process Waste Heat Examples: Food processing Beverage processing Hospitals, Universities Chemical processing Manufacturing sites Present installation(ppi): Fritolay, Charlotte; (potato chip line, 1 chiller) Network Appliance, Fresno,CA (3 chillers)

20 Source 2: Solar Heat Solar Array Examples: Commercial Light industrial Multi-Family Housing Present installation(ppi): Mixed use development,fletcher, NC by Vanir Energy (640 collectors & 2 chillers for heating, hot water, A/C)

21 Source 3: Tri-Generation Example: Turbine or diesel driven generators for electric power, heating & A/C Present installation(ppi): Vineyard 29, St. Helena, CA. (2 Gas Turbines, 1 Chiller)

22 Complimentary or Competitive? Process Waste Heat Condensed Water from Food Frying Engine Jacket Water Solar Flat Plate / Evac Tubes ADsorption ADsorption is your only answer Process Waste Heat Turbine Exhaust Gas ABsorption ABsorption may be a better choice degrees C 80-90ᵒC Sweet spot of Adsorption

23 Actual Performance at 52 / 30 / 9.4 C

24 Cooling Capacity Vs Condenser Water Temperature

25 U.S. Embassy Monrovia, Liberia U.S. Dept. of State, OBO (Overseas Building Operations) 52 F chilled water Tri-generation application Shipped 1 st Qtr, 2010

26 U.S. Embassy Monrovia, Liberia FACTS On-site diesel generator producing 1,000 kw of electricity 1,300 kw of waste hot water available at 90 C Need 150 tons of cooling at 52 F (11 C) Evaporative cooling is available at 30 C CRITERIA FOR SELECTION Heat check: 1,300 kw x 0.55 COP = 715 kw (204 tons) is possible, so more than enough heat is available.

27 U.S. Embassy Monrovia, Liberia 90 C hot water 30 C cooling water 11 C chilled water 120% actual output vs nominal

28 U.S. Embassy Monrovia, Liberia Which chiller model is required? Knowing that 120% of nominal output will be provided at these conditions 150 tons / 1.2 = 125 ton (nominal) will provide the required cooling output So a model E-125 would be the proper selection, but that is not available. A model E-120 and E-140 are available. By contacting the manufacturer, we learn that a model E-125 can easily be produced and will have the same dimensions as the E-120.

29 Ed W. Clark High School Las Vegas, NV HVAC Modernization Project 105TR Solar application

30 Ed W. Clark High School Las Vegas, NV Fact HVAC Modernization Project 105TR Solar application 500 solar hot water panels expected to produce 2,290,000 BTU/hr (671kW) of hot water at 88 C Evaporative cooling available at 28 C Chilled water design temperature 7 C Selection Criteria Heat check: 671 kw x 0.55 COP = 369 kw (105 tons)

31 Ed W. Clark High School Las Vegas, NV 90 C hot water 28 C cooling water 7 C chilled water 104% actual output vs nominal

32 Ed W. Clark High School Las Vegas, NV 671kW of hot water at 88 C Evaporative cooling available at 28 C Chilled water design temperature 7 C What size chiller is needed? 1. Heat check: 671 kw x 0.55 COP = 369 kw (105 tons) 2. Size: 369 / 1.04 = 354 kw (100 tons) A nominal 100 ton chiller model E-100 can be used. For added safety factor, a slightly larger model E-105 was actually used.

33 Zero Carbon Building Hong Kong New construction no emissions 20 TR On-site power generation

34 Zero Carbon Building Hong Kong Facts 45% Less Energy Consumption than Standard Design Heat source: Biodiesel Generator Electric Power Output: 100 kw Hot Water Production: 100 kw at 80 C 1% Summer Design Conditions: 91 dry bulb / 79 wet bulb (33 / 26 C) Dry cooler is required (assume 5 C approach) Chiller COP = 0.55 Required output: 46 kw of cooling at 7 C Selection criteria Heat check: 100 kw * 0.55 = 55 kw possible (enough heat is available)

35 Zero Carbon Building Hong Kong 80 C hot water 38 C cooling water 7 C chilled water 65% actual output vs nominal

36 Zero Carbon Building Hong Kong Hot Water Production: 100 kw at 80 C Chiller COP = 0.55 Required output: 46 kw of cooling at 7 C What size chiller is needed? 1. Heat check: 100 kw * 0.55 = 55 kw possible (enough heat is available) 2. Size: 46 kw / 0.65 = 70.7 kw nominal size (20 tons) The model C-20 will deliver 46 kw of cooling.

37 Heat Sources and heat exchangers thereof Onsite power production e.g. Tri-Generation (CHP), DG Sets, Gas engines Radiator - Jacket water Exhaust gas heat - Hex required Industrial waste heat Flue gas exhaust heat Boiler condensate Boiler blow down Process waste heat e.g. Refineries Power plants Food processing, and beverages Chemicals Pharmaceuticals Plastic extrusion Pulp and paper Aluminum Cement Steel Solar thermal Evacuated tube collectors Flat plate collectors Concentrated parabolic collators, dish and trough

38 Items to maintain Minimal Maintenance Monthly - Dispose of condensed water from vacuum pump Monthly - Visual inspection of Chiller Quarterly - Replace vacuum pump oil Annually - Inspect butterfly valves seals Inspect vacuum bellows, pneumatic actuators, temperature sensors Please note: No chemical additives No compressors No fluorocarbon/corrosive/toxic refrigerants

39 Adding Water is Simple (if ever required)

40 The Bry-Air Adsorption Chillers

41 Leaders in Dehumidification Worldwide 1964 USA 1981 India 1991 Malaysia 1999 China 2006 Bry-Air Asia acquired global business interests including the Bry-Air brand from Bry- Air Inc., USA 2010 Switzerland 2013 Brazil

42 Partners in innovation Bry-Air manufactures Adsorption Chillers in India under license from Power Partners Inc., USA (PPI).

43 Power Partners, Inc., Athens, GA, USA Facility: Square footage: 677,400 Products: Overhead Distribution Transformers Solar Water Heaters Adsorption Chillers Milestones: 52 Years in Operation 7 Years as Power Partners, Inc. More than 8 million overhead transformers produced

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45 Question and Answers

46 Thank you!