DX REFRIGERATION SYSTEM VS.

AMMONIA ABSORPTION REFRIGERATION SYSTEM

Fahim I. Siddiqui CEO/Principal Mechanical Engineer Fahim, Nanji & deSouza (Pvt.) Ltd Consulting Engineers

FAHIM I. SIDDIQUI

DX Refrigeration vs. Ammonia Absorption Refrigeration

A Case Study FND designed the refrigeration plant for an abattoir for Tata Best Foods at Landhi, Karachi within the precincts of Salfi Textile Mills. The facility includes a PEN (cattle storage) area, slaughtering halls and meat chilling rooms. The abattoir has a capacity to handle 540 Beef (6 chill rooms) and 3,000 lamb (6 chill rooms) carcasses per day. The carcasses are chilled to 2C in 16 hours and then shipped out. Preferred chill period 24 hours.
FAHIM I. SIDDIQUI 2

DX Refrigeration vs. Ammonia Absorption Refrigeration

Project initially designed on Central DX Refrigeration system with 4 x 75 TR (one stand by) Compressors. Cost-Rs 73.5 million Due to budgetary constraints, individual DX Refrigeration system adopted. Cost Rs 64.5 million Salfi Textile has own power generation plant with Gas Engines No waste heat recovery Connected load of 5.8 MW Maximum demand of 4.3 MW.
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DX Refrigeration vs. Ammonia Absorption Refrigeration

A feasibility study was carried out to produce steam from waste genset heat and operate Ammonia Absorption Refrigeration System. Steam generated through WHR Boilers calculated at approx. 3.7 TPH. Total refrigeration using Ammonia Absorption Refrigeration System and 3 TPH steam was calculated at 260 TR.

FAHIM I. SIDDIQUI

DX Refrigeration vs. Ammonia Absorption Refrigeration

Project: Abattoir for Tata Best Foods

Limited

Location: Landhi, Karachi

Product: Chilled beef & lamb

carcasses

Capacity: 540 beef/day (6 chill rooms) &

3000 lambs/ day ( 6 chill rooms)

FAHIM I. SIDDIQUI

DX Refrigeration vs. Ammonia Absorption Refrigeration

Refrigeration load of the carcasses:

Beef LambTotal

156 TR 114 TR 270 TR (Connected) 215 TR (Max. Demand)

FAHIM I. SIDDIQUI

DX Refrigeration vs. Ammonia Absorption Refrigeration

Refrigeration System: Individual

air-cooled condensing units with DX Evaporators ( Refrigerant 404A)

No. of Condensing Units: 30 Refrigeration capacity: 270 TR

FAHIM I. SIDDIQUI

70 65 60

BEEF CHILL - REFRIGERATION LOAD PROFILE

55
50 45
TOTAL LOAD (TR)

40 35 LOAD 30 25

20
15 10 5 0 1600 1700 1800 1900 2000 2100 2200 2300 0000 0100 0200 0300 0400 0500 0600 0700 0800 0900 1000 1100 1200 1300
TIME (HOUR)

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LAMB CHILL - REFRIGERATION LOAD PROFILE

70
65 60 55 50 45
TOTAL LOAD (TR)

40 35 LOAD 30 25 20 15 10 5 0 1600 1700 1800 1900 2000 2100 2200 2300 0000 0100 0200 0300 0400 0500 0600 0700 0800 0900 1000
TIME (HOUR)

FAHIM I. SIDDIQUI

BEEF + LAMB CHILL - REFRIGERATION LOAD PROFILE

130 125 120 115 110 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 1600 1700 1800 1900 2000 2100 2200 2300 0000 0100 0200 0300 0400 0500 0600 0700 0800 0900 1000 1100 1200 1300
TIME (HOUR)

TOTAL LOAD (TR)

LOAD

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BEEF + LAMB - ELECTRICAL LOAD PROFILE DX - CENTRAL SYSTEM

225

200

175

150 POWER (kW)

125 POWER 100

75

50

25

0 1600 1700 1800 1900 2000 2100 2200 2300 0000 0100 0200 0300 0400 0500 0600 0700 0800 0900 1000 1100 1200 1300 TIME (HOUR)

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BEEF + LAMB - ELECTRICAL LOAD PROFILE DX - INDIVIDUAL SYSTEM

325
300 275 250 225

200
POWER (kW)

175 POWER 150 125 100 75 50 25 0 1600 1700 1800 1900 2000 2100 2200 2300 0000 0100 0200 0300 0400 0500 0600 0700 0800 0900 1000 1100 1200 1300
TIME (HOUR)

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View of chill room lobby

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Temperature controllers

View inside the chill room

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Ammonia Absorption Refrigeration

3rd Option studied was ammonia refrigeration system using steam produced from WHR boilers on the gensets. Use Ammonia Absorption Refrigeration Plant and produce low temperature refrigeration at -10C. Ammonia absorption chiller operates on steam at 4 bars. Brine produced by the chillers at -10C is pumped to fan coil units in the storage areas.

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Ammonia Absorption Refrigeration

Oldest known refrigeration technology invented in 19th century. Overshadowed by electric operated vapor compression technology due to:
development of CFC refrigerants, cheap availability of electric power, low initial cost due to mass production and simple controls.

Applications primarily limited to large scale plants:

Petrochemical Fertilizer Food Processing Industry.

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Ammonia Absorption Refrigeration Advantages of Ammonia Absorption Refrigeration

Potential for waste heat utilization

Low temperature range (+5C to -60C) Ammonia is an environment friendly refrigerant Readily available No specialized materials required Low maintenance cost No specialist required for operation & maintenance Fully automatic operation of the plant

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Ammonia Absorption Refrigeration

Advantages of Ammonia Absorption Refrigeration Excellent part load behavior-automatically modulating Simple back-up of all moving components possible Long life-more than 25 to 30 years Only small electricity consumption Equipment produces no noise other than pumps No oil required in the system If waste heat is available, running costs are very low. Plant rooms not necessary- chillers are designed for outdoor installation Steam can be produced by alternate fuels

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Ammonia Absorption Refrigeration

Ammonia, as refrigerant and water, as absorbent, has following advantages:

High affinity

High stability
Moderate operating pressure. No vacuum up to -30C Absence of solid phase

Non-corrosive to carbon steel

Zero ozone depletion potential

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Ammonia Absorption Refrigeration Disadvantages of Ammonia Refrigeration Plant More complex refrigeration system Capital cost higher than mechanical vapor compression plant

More space required

High grade heat required Perception that it is out-dated technology

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Ammonia Absorption Refrigeration

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Ammonia Absorption Refrigeration

Application Range Single stage
heat

source temperature from 95C to 180C, temperature from -5C to 40C, to 35C cooling water for absorber and de-sorber, temperatures lower than -40C (up to 60C), chilled water at 10-15C is preferred coolant.

evaporation 30C for

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Ammonia Absorption Refrigeration

Two refrigeration options are possible Option-1 To directly pump the liquid ammonia into the cold storage using a liquid overfeed system.

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Ammonia Absorption Refrigeration

Option-2: To run a separate glycol circuit which is cooled down to minus 10C at the AARP.

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Ammonia Absorption Refrigeration

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Ammonia Absorption Refrigeration

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Financials
Central Rack Refrigeration System: (life 20 years) Cost of Central Refrigeration System = Rs. 73,500,000/Power Consumption per day = 2,160 kWh Operating Cost = Rs. 21,605 (1kWh = Rs.10/-) Individual Units for Each Chill Refrigeration System: (life 10 years) Cost of Individual Units for Each Chill = Rs. 64,500,000/Power Consumption per day = 2,996 kWh Operating Cost = Rs. 29,964 (1kWh = Rs.10/-) Operational Saving per year @ 200 days = Difference of Central Rack System & Individual Units Simple payback period Rs. 1,671,000/Year

Rs 9,000,000 =5.4Years

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Financials
Ammonia Absorption Refrigeration System: (life 20 years) Cost of Central Refrigeration + WHR System = Rs 85,000,000/= Power Consumption per day = 900 kWh Water Consumption per day = 380 Gals/day Operating Cost = Rs. 9200/Central Rack Refrigeration System: (life 18 years) Cost of Central Refrigeration System = Power Consumption per day = Operating Cost = Operational Saving per year Difference of Central Rack System & Individual Units for Each Chiller Refrigeration System Simple payback period =

Rs. 73,500,000/2,160 kWh Rs. 21,605 (1kWh = Rs.10/-) Rs. 2,480,000/Year

= =

Rs 11,500,000 4.6 Years

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Financials
Ammonia Absorption Refrigeration System: (life 20 years) Cost of Central Refrigeration + WHR System = Rs 85,000,000/= Power Consumption per day = 900 kWh Water Consumption per day = 380 Gals/day Operating Cost = Rs. 9200/Individual Units for Each Chill Refrigeration System: (life 10 years) Cost of Individual Units for Each Chill = Rs. 64,500,000/Power Consumption per day = 2,996 kWh Operating Cost = Rs. 29,964 (1kWh = Rs.10/-)

Operational Saving per year Difference of Ammonia system & Individual Units Simple payback period

Rs. 4,150,000/Year

= =

Rs 20,500,000 4.9 Years

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Ammonia Absorption Refrigeration Conclusion great potential to offer economical and innovative solutions Appropriate application engineering is a key to success can provide a major boost to food processing, food storage and food preservation.

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Ammonia Absorption Refrigeration

References:
1. Literature of Transparent Energy Systems Pvt. Ltd. 2. Erickson, Extending the Boundaries of Ammonia Absorption Chillers; ASHRAE Journal, April 2007 3. AARP Article by Gordon Brothers Industries Private Limited 4. Colibri-Reliability of AARP in Chemical & Food Industries

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Thank You & Questions Please

FAHIM I. SIDDIQUI