MCI

Process Design and Analysis

Lecture 3


Junping Cai
MSc E.E, PhD
Office: Block E, Center for Product Development (CPD)
Email: junping@mci.sdu.dk
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Refrigeration system components
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RECAP FROM LAST TIME

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Summary - lessons learned lecture 2

More thermodynamics
Conservation of energy for CM processes from state 1 to 2

Conservation of energy for steady CV processes


Calculations with u, h, and c for ideal gasses, solids, and liquids
Solids and liquids



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MCI
Summary - lessons learned lecture 2

More thermodynamics
Explain what a reversible process is and why real processes are irreversible
Reversible process has no losses or friction
Reversible and adiabatic (Q=0 J) process is an isentropic process (ds= 0 J/kg-K).
Irreversible process (sliding contact friction, unrestrained expansion, viscous
fluid friction, heat transfer at final T)

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Summary - lessons learned lecture 2

1-stage vapour compression cycle, continued
Differences between ideal and real 1-stage vapour compression cycle.
Understand how TE and TC impacts the energy efficiency
Define and calculate COP (what we get / what we pay)
Learn about simple component models for the expansion valve, compressor
and heat exchangers (UA value).
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Real refrigeration cycle
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Sub-cooling, superheat, pressure losses,
and frictions losses contributed to a less
efficient cycle
Rules of thumb: COP improves 2-4%
when per 1C TE is raised or TC lowered
MCI
COP Coefficient Of Performance
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2w
Evaporation temperature TE

4
3
Condensation temperature TC

2s
1
Dh = real compressor work [kJ/kg]
2
Dh = cooling capacity [kJ/kg]
( )
( )
1 4
1 4 1 4
2 1 2 1
2 1
e
is
w s
w
m h h
Q h h h h
What you get
COP
What you pay W h h h h
m h h
q
| |

= = = =
|
|


\ .
MCI
Evaporator and Condenser

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Refrigerant
Ambient
amb
T
e
T
( )
e amb e
Q U A T T =
U: Overall heat transfer
coefficient
A: Surface area
Dimensioning - example:
0 . 10 . 10
amb e e
T C T C Q kW = = =
10
1
10
U A kW K = =
Find evaporator with UA-value of 1 kW/K at
dimensioning temperatures, with selected refrigerant
( )
c c amb
Q U A T T =
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UA-Value
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T
amb
=20C
T
cold
=0C
Small UA
evaporator
Large UA
evaporator
Small UA
condenser
Large UA
condenser
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Thermostatic expansion valve
Operating principle
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Evaporator
T
e
Exit temperature T
1
>T
e
Vessel (bulb) with two-phase
refrigerant at temperature T
1
T
e
T
1
p
1
p
e
p
e
Expansion
Valve
p
1
DT
sh
= p
1
-p
e
= spring
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Compressor sizing
Bore Bore
Stroke
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Displacement rate:
Max theoretical volume flow
through compressor :
( )
2
Speed
Moved volume per revolution
4
d rev
V Bore Stroke n
t
=
Real volume flow = volume flow in suction line =
1
V
1
V
Volumetric efficiency:
1
v
d
V
V
q
Sizing: Find from and
d
V
1
V
v
q
MCI
Summary - lessons learned lecture 2

Direct and indirect systems (secondary systems)
Keep refrigerant away from production areas
Minimize refrigerant charge

Refrigerants
Properties (performance , p & T, safety, compatibility, cost etc.)
ODP, GWP, TEWI, indirect/direct GHG emissions
Energy efficiency important for the indirect emissions
Common types and R-designation

Secondary refrigerants (see Stoecker)
Properties for secondary refrigerants
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Direct and indirect system
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Chilled water system
Load Production Heat rejection Distribution Distribution
Condenser water system Chiller
Chiller 3
M
Constant pumps
120/240/240 m3/hrs
dP = 6+2+2 = 10 mVS
TC min. = 10C
Control fouling risk
Back flush / CIP
M
M
2 x Cooling tower
2 x 1.75 MW (30/35C)
Remote sump
VSD fan (TC_opt)
Pump constant
dP= 6 mVS
Chiller 2
Chiller 1
Variable prim. pumps
3 x 170 m3/hrs, 1 x standby
Flow (dP) across 2-way valve
Leq = 500 m, DN300 or 2xDN200
dP_mains = 5 mVS
dP_pump = 6+5+6+2 = mVS
By-pass for min. flow
AHU
40 X 75 kW, 28.500 m3/hrs, SHR=0.9
Hand reg. valve + 2-way reg. valve
Leq = 50 m, DN65
dP = 2+2+2 = 6mVS
Load 40% base + 60% variable
Evaporator
dP = 6 mVS
Flow min. 70%
Flow (dP) across 2-way valve
Compressor max. 4 starts/hour
Capacity 20+40+40%
TT FS
TT FS
TT
TT TT
TT
TT FS
TT RH
TT
TT









Indirect system: Circuit with secondary refrigerant
between point of use and the primary refrigerant
MCI
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HCFC
R22
CFC:
R12, R502
Refrigerants
Natural
Ammonia (R717)
Water (R718)
Hydrocarbons
Propane (R290)
Propylene (R1270)
Isobutane (R600a)
Carbon dioxide (R744)
Air (R729)
Synthetic
HFC
R134a
R404A / R507
R410A
HFO-1234yf (R-1234yf )

Refrigerants overview most common
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AGENDA
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Agenda
Alternative processes
Absorption, Ejector , Stirling , Electric
Magnetic
Two stage vapour compression cycles
Open intercooler
Closed intercooler
Cascade
Injection/economizer
Transcritical CO2 cycles
Exercise on two stage cycle with open intercooler
Assignments for lecture 3
2-stage cycle in EES, R404A
Summary
Handouts

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ALTERNATIVE PROCESSES
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Objective

Most refrigeration systems use vapour
compression cycles with mechanical compressors
Brief introduction to alternative refrigeration
processes:
Absorption
Ejector
Stirling
Electric (Peltir)
Magnetic



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Absorption
Mixture used as fluid
NH
3
+ H
2
O
LiBr + H
2
O
Requires heat for generator
Requires power to pump

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Kondensator
Fordamper
Pumpe
Generator
QH
Qom
QL
Termisk kompressor
Absorber
Intern
varmeveksler
Qom
Thermal compressor
Generator
Internal
HX
Pump
Absorber
Condenser
Evaporator
Low efficiency
But interesting when
waste heat at
high temperatures
MCI
Ejector
Typically water
Requires heat added
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Ejektor Kondensator
Fordamper
Pumpe
Generator
QH
Qom
QL
Termisk kompressor
Thermal compressor
Pump
Generator
Ejector
Condenser
Evaporator
Difficult to produce
ejector
MCI
Stirling
www.sunpower.com www.globalcooling.com

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Electric (Peltir)
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Cold end
Hot end
+
-
Low efficiency
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Magnetic refrigeration
Magnetic Refrigeration at Room Temperature (IIR Bulletin 2007-5)
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TWO STAGE CYCLES AND
CASCADE SYSTEMS

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Objective

Learn how to show processes in
Piping and Instrument Diagrams (PI-D)
Cycles in log(p),h diagram
Establish mass and energy balances for model
purposes



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Why 2-stage vapour compression cycle?
Refrigeration for low temperature applications
Depending of the compressor and the refrigerant used two factors
put a limit on the practical use of 1-stage compression when the
pressure ratio p2/p1 becomes too high
Discharge temperature (too high)
Volumetric efficiency (decreases)
Isentropic efficiency also decreases
For ammonia a pressure ratio p2/p1 of 5-6 is too high
For halocarbon refrigerants (HCFC, HFC) a pressure ratio p2/p1 of
approx. 15 is too high
2-stage cycles offer possibilities of optimizing the energy efficiency


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Isentropic efficiency
At large pressure ratios, the efficiency of compressors decrease
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Two stage cycles
At large temperature lifts, discharge temperature gets to high:
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Two stage with open intercooler
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Simple
Risk of gas in liquid line to low
Temperature evaporator due to
pressure drop in long pipes
MCI
Two stage with closed intercooler
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No risk of gas in liquid line to low
Temperature evaporator due to
pressure drop in long pipes.
Heat exchanger in vessel means
lower efficiency (COP)
MCI
Finding compressor sizes
Very often most problems are solved by placing control volume around
intercooler:
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( )
1 8
1
,
:
e L
L
L
vol L
Low pressure
Q m h h
m v
V
q
=

=
2 6 7 3
1 2 7 8
3 4 5 6
2 6 7 3
3
,
:
:
:
L
H
L H L H
H
H
vol H
Intercooler
Mass balance
m m m m
Sationary
m m m m m
m m m m m
Energy balance
m h m h m h m h
m v
V
q
+ = +
= = = =
= = = =
+ = +

=
MCI
Finding compressor sizes
It turns out that everything is typically known if the intermediate pressure
is known!

If both compressors are ideal, the optimal intermediate pressure is found
as:


I.e. this (design) pressure will give the highest COP if both compressors are
ideal (and will also give the size of the compressors)

On the other hand: if you know compressor swept volumes and operating
conditions, you will be able to calculate the resulting intermediate
pressure
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m e c
P P P =
MCI
Intermediate pressure
Other normal used formulas for design intermediate pressure:

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| |
0.35
, [ ]
2
m e c
c
m e c
e
e c
m
P P P bar
T
P P P temperatures in K
T
T T
T
= +
=
+
=
MCI
Cascade
Two different refrigerants
Two 1-stage systems in sequence
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Example of industrial equipment
Cascade system with R744/R717 (CO2/ammonia)
High volumetric refrigerating effect of CO2 at low temperature
(fewer compressors required)
Only CO2 in production areas (safety)
CO2 condensed by ammonia, no problem with critical pressure
Penalty of using heat exchanger
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Supermarket cycles
Two one stage with common condenser
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Supermarket cycles
Two stage transcritical
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Transcritical parallel compression
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Supermarket cycles
Cascade CO2/ HFC or ammonia
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Language
Economizer
Injection of gas, liquid or mixture at strategic position in compressor (screws,
two-stage recip,)
Sometimes economizer also covers two-stage with open intercooler
(intercooler is called economizer)

Booster
Booster compressor is the low-stage compressor
Booster cycle is (sometimes) two-stage with liquid injection

CoolPack
This software tools provides you with an extensive number of cycles
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MCI
EXERCISE
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Exercise 1
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13
2
5
15
14
1
3
CYCLE ANALYSIS: TWO-STAGE CYCLE
T
4
:
T
1
:
T
2
:
T
E,HS
:
T
C
:
X
5
:
Q
E,HS
:
Q
C
:
W
HS
:
6
11 9
8
7
12
4
Q
E,LS
:
W
LS
:
X
9
:
T
14
:
T
13
:
34,0 [C]
129,0 [C]
-33,5 [C]
-9,0 [C]
-10,0 [C]
35,0 [C]
T
E,LS
: -35,0 [C]
0,08 [kg/kg]
0,16 [kg/kg]
200,0 [kW]
200,0 [kW]
548,5 [kW]
34,4 [kW]
128,8 [kW]
1,250 [-]
1,250 [-] n
CIRC,LS
:
n
CIRC,HS
:
10
60,4 [C]
m
TOT
: 0,396 [kg/s]
m
CIRC,HS
:
m
CIRC,LS
: 0,181 [kg/s]
0,192 [kg/s]
> FLOODED EVAPORATORS, OPEN INTERCOOLER, ONE-STAGE COMPRESSORS
SUBDIAGRAM
WINDOWS
REFRIGERANT : R717 COP :
COP*
HS
:
COP*
LS
:
2,452
n
CARNOT,HS
:
n
CARNOT,LS
:
0,57
0,61
3,359
5,833
CoolPack
Department of
Mechanical Engineering
Technical Univ ersity
TOOL C.5
1999 - 2001
of Denmark
Versi on 1.46
LOG(p),h-DIAGRAM
MCI
Exercise 2
1. Draw the log(p)-h diagram for the 2-stage cycle with open intercooler
(intermediate pressure pm = p3)
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Exercise 2 solution
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1
2
3
4
5
6
7
8
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EXERCISE WITH EES
Assignment (see Black Board under lecture 3)
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Summary

Heard about alternative processes like absorption, ejector, Stirling, electric, and
magnetic.
Studied two stage vapour compression cycles and cascade systems looking at PI-
diagram, log(p)-h diagram, mass and energy balances
Exercise on two stage cycle with open intercooler
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Handouts
PDF files to be found on Black Board
Lecture 3. Assignment
R404A Log(p)-h diagram




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