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1 P (PSIA) METERING DEVICE SAT. LIQUID CONDENSER EVAPORATOR H (BTU / LB) SAT. VAPOR COMPRESSOR Some Misconcetions about te Refrigeration Cycle And ow use of te ressure/entaly diagram can el clear suc doubts By Rames Paranjey Tecnical Adviser & Consultant, Pune During my career sanning over nearly 0 years I ave come across many instances were due to lack of understanding of te basic refrigeration cycle, incorrect secifications are laid down by consultants, esecially tose consultants involved in cemical and rocess lant design. Most suliers do not take excetion and quote as er secifications wic can lead to inefficient lant design. It is terefore essential to educate suc eole in igligting te errors in teir secifications so tat tese can be corrected. ASHRAE Handbook also confirms tis in cater 6 on refrigeration in te cemical industry stating tat cemical engineers exect refrigeration, as any oter utility, like water, steam or comressed air and do not understand tat te refrigeration cycle erformance is linked wit te main cemical system beavior and a refrigeration lant cannot be turned on like a ta of water. Let me furnis some examles from my exerience:. In a water-cooled ciller selection some consultants secify water entry temerature as 0 C and water outlet as 8 C wit condensing as /5 C. Wen we ointed out tat suc ig condensing temeratures are not desired, as it would lead to ig ower consumtion and energy bills, tey argued tat wit 8 C temerature rise in te condenser water, te circulated water quantity gets reduced tereby saving uming cost. Similarly te eat excanger would become more economical. Tis is a total misconcetion, as any amount of saving in uming cost and initial lower cost benefits are insignificant and are totally nullified against te iger ower consumtion of a refrigeration comressor. Similarly an air-cooled system can never be as efficient as a water-cooled system and many engineers try to justify use of aircooled systems. Of course, tere are oter considerations for selecting an air-cooled otion over a water-cooled system but it can never be due to ower saving as can be seen in subsequent calculations.. Many refrigeration comressor manufacturers, esecially from te US and Jaan ublis teir comressor ratings wit 5 F subcooling. Wereas most Euroean manufacturers ublis ratings at saturated conditions witout any subcooling. Te refrigeration comressor is a volume dislacement macine and does not roduce any subcooling on its own. It is also known tat every degree of subcooling acieved in a system design increases caacity by aroximately 0.5 % for R- refrigerant, witout any extra ower consumtion and terefore te data for comressors ublised wit subcooling looks unnecessarily attractive giving an imression tat continued on age 68 About te Autor Rames Paranjey is a mecanical engineer wit an M.Tec in refrigeration from IIT Bombay wit over 5 years exerience. He as worked in very senior ositions starting wit Kirloskar Pneumatic in Pune, Carrier Transicold in Bangalore and Singaore as well as Voltas-Air International Pune. Presently e works for imself as a tecnical adviser & consultant. He is an ASHRAE Fellow, ast resident ASHRAE W.I. cater and ast resident ISHRAE Pune cater. He can be contacted at rames@vsnl.com Air Conditioning and Refrigeration Journal d Aril - June

2 Some Misconcetions about te Refrigeration Cycle continued from age 65 tese are more efficient comressors wit lower kw/tr values. In reality, it is not an ale-to-ale comarison and one needs to carefully read conditions for wic te data is ublised and aly suitable corrections. Te subcooling section as to be built into te system by roviding additional area or a searate subcooling section. If tis is not done, one cannot get subcooling benefits. It sould also be understood tat only liquid can be subcooled and a mixture of vaour and liquid resent in te condenser can never be subcooled and ence a searate arrangement for subcooling is a must if one wants to derive te benefit of subcooling.. Te tird myt is regarding useful suereat. If one studies in detail te termodynamic cycle, suereat is never useful as it increases te secific volume at te entry of te comressor tereby reducing te mass flow rate and tus te cooling caacity. It is useful in te sense tat it only els in rotecting te comressor by reducing te cances of getting liquid at te suction of te comressor. Similarly if suereat is roduced in te evaorator, te vaour zone area becomes larger, tereby making te evaorator less efficient, as exensive eat transfer area is used for suereating rater tan for latent eat transfer by way of evaoration, wic is te main function of an evaorator. Te most efficient system is one witout any suereating of suction gas, wic is ossible wit all flooded coolers, redominantly used in ammonia systems or centrifugal macines were ower consumtion becomes a main criterion for selection due to very ig caacities of large lants wic work round te clock. All tese concets will become clear once we look at te ressure/ entaly diagram and study various conditions and teir effect on system erformance. We will use HCFC- refrigerant for our study and wit benc mark values of +0 C saturated condensing temerature and +5 C saturated evaorating temerature, considering no subcooling of liquid and no suereating of suction gas. Similarly, equiment and iing ressure losses and eat gains are not considered for te sake of ease of understanding. Te comression rocess is assumed to be isentroic. Tis situation is considered as Condition. Refrigeration caacity required is assumed as 0 ton for calculation of mass flow rate. Refrigeration roerties are taken from te Danfoss software on Refrigeration Utilities. 68 Air Conditioning and Refrigeration Journal d Aril - June 006 Condition (Benc Mark Cycle) An introduction to te ressure /entaly diagram Figure + 0 C + 5 C Eva. Cond. Suct.Pr. Disc.Pr. Entaly Secific Entaly T Entaly Tem. Tem. Vol. V = C C Bar Bar -kj/kg m /kg -kj/kg C kj/kg From tis data we can derive tis useful information :. Refrigeration caacity: = (07.5) (9.67) = kj/kg. Power required for comression: = (.0) (07.5) =.89 kj/kg. Coefficient of erformance (COP): = (57.78) / (.89) = Comression ratio: discarge ressure/suction ressure = (5.5) / (5.88) = Discarge temerature at te end of isentroic comression: C 6. Secific volume at : m /kg 7. Mass flow rate = /secific volume = 0.006=.7757 kg/m 8. Mass flow rate to get 0 ton caacity: 0x660/57.78 = kg/r m /kg =. m /r 9. Heat rejection in condenser = = (.06) (9.67) = 8.9 kj/kg Condition Always kee te saturated discarge temerature as low as ossible. (Discarge temerature can increase due to various factors suc as undersized condenser, reduced / low water flow, blocked condenser tubes, strainer, overcarge, non C Figure Eva. Cond. Suct.Pr. Disc.Pr. Entaly Secific Entaly T Entaly Tem. Tem. Vol. V = C C Bar Bar -kj/kg m /kg -kj/kg C kj/kg continued on age 70

3 Some Misconcetions about te Refrigeration Cycle continued from age 68 condensibles etc.) Te diagram and calculations will sow you wy. Assume tat te discarge ressure is iger tan te benc mark +0 C (in Condition ) and te design is based on a iger condensing temerature, say +50 C. From tis data we can derive tat wen te discarge ressure is iger tan exected :. Refrigeration caacity: = (07.5) (6.5) =.899 kj/kg vs te benc mark kj/kg. Caacity reduces!. Power required for comression: = (7.0) (07.5) = kj/kg vs te benc mark.89 kj/kg. Power consumtion increases!. Coefficient of erformance (COP): ( ) ( ) =.899/0.058 =.787 vs te benc mark Efficiency dros!. Comression ratio : discarge ressure / suction ressure = (9.) / (5.88) =.6 vs te benc mark.667. Increases or volumetric efficiency dros! 5. Discarge temerature at te end of isentroic comression: C vs te benc mark C. Increases and comressor runs otter, leading to more wear & tear. 6. Secific volume at : 0.06 m /kg vs te benc mark m /kg. Remains te same! 7. Mass flow rate to get 0 ton caacity=660 0/ (.899) = ( ) kg/r (0.006) = 5.50 m / r vs te benc mark. m /r. Since more mass flow is required to get te same caacity, a bigger comressor is required. 8. Heat rejection in condenser = = (7.0) (6.5)= = 90.7 kj/kg vs.899 te benc mark 8.9 kj/kg. Heat rejection increases! Requires a bigger condenser. Also ratio of eat rejection/ cooling caacity increases as cycle becomes less efficient. Kee/select/design as low a saturated discarge temerature & ressure as ossible to get te best erformance witout affecting te design conditions in te remises or rocess fluid outlet temerature. Ensure te required ressure dro for te TXV, if used. Condition Always kee te saturated suction temerature as ig as ossible. Te following diagram and calculations will sow you wy. Assume tat te saturated suction temerature is lower tan te benc mark +5 C (as er Condition ) and te design is based on a lower evaorating temerature, say + 0 C. Tis can aen due to liquid line obstruction, evaorator coil or fan-motor damaged, less refrigerant carge, moisture in te system, under sizing of liquid line or exansion valve etc. 70 Air Conditioning and Refrigeration Journal d Aril - June 006 Figure 5 C 0 C Eva. Cond. Suct.Pr. Disc.Pr. Entaly Secific Entaly T Entaly Tem. Tem. Vol. V = C C Bar Bar -kj/kg m /kg -kj/kg C kj/kg From tis data we can derive te following:. Refrigeration caacity = = (05.70) (9.67) = kj/kg vs te benc mark kj/kg. Caacity reduces!. Power required for comression: = (.9) (05.70) = / = 8.8kJ/kg vs te benc mark.89kj/kg. Power consumtion increases!. Coefficient of erformance (COP): ( ) ( ) = /8.059=5.5 vs te benc mark Efficiency dros!. Comression ratio: discarge ressure/suction ressure = 5.5/.976=.088 vs te benc mark.667. Increases or volumetric efficiency dros! 5. Discarge temerature at te end of isentroic comression: 58. C vs te benc mark C. Increases and comressor runs otter, leading to more wear & tear! 6. Secific volume at : 0.07 m /kg vs te benc mark m /kg. Increases! 7. Mass flow rate to get 0 ton caacity = 660 0/ = 8. kg/r 0.07 m /kg = 8. m /r vs te benc mark. m /r. Since more mass flow is required to get te same caacity, a bigger comressor is required! 8. Heat rejection in condenser = = = / = kJ/kg vs te benc mark8.9 kj/kg. Heat rejection increases! Requires a bigger condenser. Also ratio of eat rejection / cooling caacity increases as te cycle becomes less efficient. Kee/select/design as ig a saturated suction temerature & ressure as ossible to get te best erformance witout affecting te design conditions in te remises or rocess fluid outlet temerature. Condition Always kee suction gas suereat to te minimum. Tis illustration is based on external suereat after te evaorator. continued on age 7

4 Some Misconcetions about te Refrigeration Cycle continued from age 70 Figure 0 C suereat Eva. Cond. Suct.Pr. Disc.Pr. Entaly Secific Entaly T Entaly Tem. Tem. Vol. V = C C Bar Bar -kj/kg m /kg -kj/kg C kj/kg +5(+0 C) suereat From tis data we can derive tis useful information:. Refrigeration caacity: = (07.5) (9.67) = kj/kg. Power required for comression: = (8.) (.90) = 6.5 vs te benc mark.89 kj/ kg. Hence as suereat increases, ower consumtion increases.. Coefficient of erformance (COP): ( ) ( ) = 57.78/6.5 = 5.9 vs te benc mark System efficiency dros!. Comression ratio : discarge ressure/suction ressure = 5.5/5.88 =.667. Remains unaltered, as suereat does not alter te comressor discarge or suction ressure. 5. Discarge temerature at te end of isentroic comression: 75.7 C vs te benc mark C. Discarge temerature increases. Comressor runs otter, leading to more wear & tear. 6. Secific volume at : m /kg vs te benc mark m /kg. Increases! 7. Mass flow rate to get 0 ton caacity = 660 0/ = = m /r vs te benc mark. m /r. Since more mass flow is required to get te same caacity, a bigger comressor is needed. 8. Heat rejection in condenser = = = 98.7 kj/kg vs te benc mark 8.9 kj/kg. Requires a bigger condenser! Also te ratio of eat rejection / cooling caacity increases as te cycle becomes less efficient. Suer eat is always bad for refrigeration cycle efficiency. In direct exansion lants we normally kee tis to around 5 to 6 C to rotect te comressor from liquid entry. Electronic exansion valves ave a faster resonse and ence are being increasingly used as tey work wit low suereat settings and ence from te same evaorator more area is available for latent eat 7 Air Conditioning and Refrigeration Journal d Aril - June 006 transfer tan for suereating and tus te cycle efficiency imroves. Ideally, flooded systems wit a saturated suction wit no suereat gives best efficiency and erformance. Hence most of te big cillers were ower consumtion is critical like centrifugal macines or screw ciller ackages work on flooded oeration, wit no suereat. It is a myt to mislead eole by calling it useful suereat. Suereat is never useful for te refrigeration cycle excet tat it rotects te comressor from ossible liquid refrigerant at te suction valve. Any amount of suereat acieved in te evaorator is in reality a loss, since exensive area of te evaorator is being used for suereating wereas in reality it sould ave been used for latent eat transfer i.e. evaoration. Condition 5 Always increase sub cooling as muc as ossible. Te following diagram and calculations will sow you wy: Figure 5 0 C subcooling Eva. Cond. Suct.Pr. Disc.Pr. Entaly Secific Entaly T Entaly Tem. Tem. Vol V = C C Bar Bar -kj/kg m /kg -kj/kg C kj/kg wit C sub cooling Tis condition considers external subcooling witout use of refrigeration From tis data we derive tis useful information. Refrigeration caacity: = (07.5) (6.65) = 70.50kJ/kg vs te benc mark kj/kg. Increases!. Power required for comression: = (.06) (07.5) =.89 vs te benc mark.89 kj/ kg. Remains unaltered!. Hence subcooling increases caacity witout any increase in ower. Coefficient of erformance (COP): ( ) ( ) = 70.50/.89 = 7.6 vs te benc mark System efficiency imroves! 5. Comression ratio : discarge ressure/suction ressure = 5.5/5.88 =.667. Remains unaltered, as subcooling does not alter te comressor discarge or suction ressure. 6. Discarge temerature at te end of isentroic continued on age 76

5 Some Misconcetions about te Refrigeration Cycle continued from age 7 comression: C vs te benc mark C. Does not increase, remains te same! 7. Secific volume at : m /kg vs te benc mark 0.006m /kg. Remains te same! However as cooling caacity er kg of refrigerant as increased, less mass flow to get same caacity is required. Hence a smaller comressor can do te job! 8. Mass flow rate to get 0 ton caacity = 660 0/ = = 9.96 m /r vs te benc mark. m /r. Since less mass flow is required to get te same caacity, a smaller comressor is needed! 9. Heat rejection in condenser = = (.06) (6.65) = 9. kj/kg vs te benc mark 8.9 kj/kg. Requires a bigger condenser! As can be seen subcooling te liquid always is beneficial. It adds to te caacity witout increasing ower consumtion. Subcooling also ensures tat te metering device receives liquid only. If gas bubbles are resent in te liquid at te entry, it causes many roblems as is known to all of us. Any degree of subcooling is not ossible and deends on te cooling medium temerature available as well as te saturated discarge temerature. It also adds to te cost but advantages more tan comensate for tis additional cost. Condition 6 Tis condition takes into account bot suereating of suction gas and subcooling of liquid refrigerant normally acieved by use of suction liquid line eat excangers. Tis condition considers external subcooling wit out use of refrigeration. From tis data we can derive tis useful information. Figure 6 0 C subcooling. Refrigeration caacity: = = 70.50kJ/kg vs te benc mark Caacity increases!. Power required for comression: = (8.) 0 C suereat Eva. Cond. Suct.Pr. Disc.Pr. Entaly Secific Entaly T Entaly Tem. Tem. Vol. V = C C Bar Bar -kj/kg m /kg -kj/kg C kj/kg +5(+0 C) +0 wit suereat 0 C sub cooling (.90) = 6.5 vs te benc mark.89 kj/ kg. Increases!. Coefficient of erformance (COP): ( ) ( ) = (70.50) / (6.5) = 6. vs te benc mark System efficiency is sligtly lower. Altoug caacity as increased due to subcooling te ower consumtion as also increased due to suereating.. Comression ratio : discarge ressure/suction ressure = 5.5/5.88 =.667. Remains unaltered. 5. Discarge temerature at te end of isentroic comression: 75.7 C vs te benc mark C. Increases, leading to iger wear & tear. 6. Secific volume at : m /kg vs te benc mark m /kg. Increases! 7. Mass flow rate to get 0 ton caacity = 660 0/ = =.5 m /r vs te benc mark. m /r. Less mass flow wic would ave been required due to subcooling is nullified due to increase in secific volume on account of suereat. Hence to get te same caacity, more or less te same comressor swet volume would be required. 8. Heat rejection in condenser = = (8.) (9.6) = 98.8 kj/kg vs te benc mark 90.7 kj/kg. Requires a bigger condenser! A suction /liquid line eat excanger is a useful device as it els in subcooling liquid tere by giving additional caacity. Te resulting suereat increase ensures tat te comressor as less cance of liquid coming troug te suction gas. Selection of exansion valve and location of bulb needs to be studied to ensure tat suereat due to exansion valve and troug subcooler do not add and lead to abnormal suereating. Summary For any design, weter it is for air conditioning or rocess lant, te best teoretical efficiency is te Carnot cycle, wic means eat absortion at te same conditions as te sace/cooling medium temerature to be maintained and rejecting eat at te same temerature as te eat sink. Tis is, in actual ractice not ossible and ence we design eat excangers wit a certain otimum temerature differences. However, a designer must kee in mind tat closing te temerature differences between condensing and evaorating will always imrove te system erformance. Similarly it sould be ket in mind tat tere is noting like useful suereat. Suereat is always bad were as subcooling is always useful. In sort, lower discarge ressures, iger suction ressures, low suereat, ig subcooling and lower comression discarge temerature is te best formula for any vaour comression refrigeration system design. v 76 Air Conditioning and Refrigeration Journal d Aril - June 006

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