Más contenido relacionado La actualidad más candente (20) Similar a Refrigeration and air conditioning system (20) Refrigeration and air conditioning system2. Life cycle cost for A/C systems
• Vapour compression
• Vapour Absorption
Operating Cost 95%
Maintenance/
Consumables 1%
I nitial
I nv. 4%
Operating Cost 89%
Maintenance/
Consumables 1%
I nitial
I nv. 10%
• Life cycle : 15 years
• Cost of electricity :
Rs.3.40/kWh
• Steam Cost : Rs. 450/ton
3. Basic Cycles Vapour Compression
Cycle
Condensor
Evaporator
Compressor
Throttle
valve
Discharge
high pressure
gasHigh
pressure
liquid
Low
pressure
liquid and
flash gas
Suction low
pressure
gas
T1
T2
CHW in
or air in
CHW out
or air
4. Performance
COP = Amount of heat to be taken out
Amount of work required
= T1/ (T2 - T1)
where,
T1 = Evaporator temperature, in K
T2 = Condenser temperature, in K
Therefore,
COP = Maintain at higher T1
or
Maintain at lower T2
5. Effect of evaporator & condenser
temperatures on power
consumption
Decrease in
evaporator
temperature from
5°C to -20 °C
Increase in power
consumption by 89%
(theoretical)
Effect of evaporator temperature for same
condenser temperature
Effect of condenser temperature for same
evaporator temperature
Increase in condenser
temperature from
25°C to 45°C
Increase in power
consumption by 57%
(theoretical)
7. Utilise less power intensive
cooling medium as far as possible
• Typical power consumption of different
cooling mediums are:
Type of cooling Power consumption
medium (kW/TR)
Cooling water 0.10
Chilled water @ 10°C 0.70
Brine system @ - 20°C 1.80
8. Utilise less power intensive
cooling medium as far as possible
Gas at
600°C
CW at
27 °C
CW at
30 °C
Brine
-16 °C
Brine
-20°C Liquid
at 1°C
HE - 1 HE - 2
Gas at
33 °C
9. Utilise less power intensive
cooling medium as far as possible
Liquid
at 1°C
Gas at
600°C
CW at
25 °C
CW at
30 °C
HE - 1
CHW
12 °C
CHW at
8°C
HE - 2
HE - 3
Brine at
-20°C
Brine at
-7°C
33 °c
15 °c
10. INSTALL ADDITIONAL PLATES AND
OPERATE BREW TRANSFER SECTION
CHILLER
PLATE HEAT EXCHANGER
• TO CHILL BREW FROM 38° C TO 12° C
• BRINE -4° C
• POWER CONSUMPTION 30% HIGHER – BRINE/TR Vs CHILLED
WATER
BREW IN 38 ° C
BREW OUT 12 °
C
BRINE INLET - 4°
C
BRINE INLET 1° C
11. INSTALL ADDITIONAL PLATES AND
OPERATE BREW TRANSFER SECTION
CHILLER
MODIFIED - PLATE HEAT EXCHANGER
• BRINE REPLACED WITH CHILLED WATER
• REDUCED THE RPM OF 25 %
ANNUAL SAVINGS – Rs 10.90 LACS
INVESTMENT – Rs. 5.00 Lacs
PAYBACK – 7 Months
BREW IN 38 ° C
BREW OUT 12 °
C
““CHILLED WATER” 8CHILLED WATER” 8 °
C
Additional Hx
CHILLED WATER 12CHILLED WATER 12 °
C
12. What should be the ideal control
system for R & A/C ?
Control should start at the user point
What are the control systems for
Chilled Brine ?
2 Port Control
3 Port Control
13. Install Two Port Valves Instead of
Three Port Valves at Chilled Water
Users
Typically Three Port Valves Used in Chilled Water
Three Port
System
Cold
Well
Hot
Well
Chilled Water User
Chilled Water User
Bypass depending on load
3 - Port
Valve
Quantity
Constant
14. Annual savings = Rs.11.50
lakhs
Investment = Rs.6.00 lakhs
• Installed two port
valves for all users
& VFD for one pump
• One pump operation
stopped completely
• At design stage -
Investment also
comes down
Two port system
Cold Well Hot Well
Chilled Water
User
Chilled Water
User
2 -Port
Valve
15. What Are The Ways Of Capacity
Control of Compressors?
Reciprocating
Loading / unloading facility
Variable speed
motors
Dual speed motors
On-Off control
16. Variable frequency
Hot gas by pass
Suction throttling
What Are The Ways Of Capacity
Control of Compressors? (continued)
Reciprocating
17. Part Load Control By Gas By-pass
Condenser
Evaporator
Compressor
Throttle
valve
Cooling effect reduction α Fraction of total flow through by pass
18. What Are The Ways Of Capacity Control
of Compressors?
Centrifugal
Inlet vane control
Variable speed drives
19. Automatic Unloading/loading For
Refrigeration Compressor At LCP
• Present condition varies from - 7o
C to
-22o
C
• At -22o
C the suction pressure is too low and
compressor capacity utilisation is poor
• Results in higher power consumption per
ton of refrigeration
23. Which Compressor To Choose?
150 TR 150 TR 150 TR 150 TR
(A) (B) (C) (D)
(A) or (B)
(A) or (B) (C) or (D)
(A) & (B) (C) or (D)
Capacity Base Load Variable Load
150 TR
250 TR
400 TR
24. How do you optimise the number
of compressors in operation?
Operation of a compressor in full load
gives highest COP
In a battery of compressors, micro-
processor controls is the latest trend
Continuously monitor the load of all the
compressors and load optimally
25. Optimise the Cooling Tower Water
across Refrigeration condenser
Refrigeration Condenser
Measured ∆T across the condenser - 2°C
Increased to 4 °C – By throttling
Reduction in pump power – 6.5 kW
Increase in compressor power – 2.5 kW
Net reduction – 4 kW
Savings – Rs 1.28 lakhs
26. kW/TR at various Evaporator
Temperatures
Reciprocating – Full load operation
Evaporator
Temperatures
kW / TR
10°C 0.80
0°C 1.14
-4°C 1.26
-6°C 1.35
-8°C 1.44
-20°C 1.80
27. Comparison of Centrifugal,
Reciprocating & Screw Compressors
Reciprocatin
g
Centrifugal Screw
kW/TR at 10°C
chilled water
temperature
0.8 – 0.9 0.65 – 0.70 0.65 – 0.70
Capacity range > 0.5 TR > 150 TR > 100 TR
Cost
comparison
w.r.t
reciprocating
- 50% higher 50% higher
28. Earlier
• 1 x 120 TR - 83% load (10 out of 12 cylinders
loaded)
• 2 x 60TR - 66% load (6 out of 8 cylinders loaded)
Optimise Refrigeration Compressors
Operation
Modified
• 1 x 120 TR - 100% load & 1 x 60TR - 66% load
• 3rd compressor stopped for 10 months in a year
Annual Savings - Rs.3.00 lakhs (in amps - 28)
Investment - Rs.5.00 lakhs
Payback - 20 months
30. Lower Suction Pressure
• Results in less capacity
utilisation
• Higher specific power consumption
Reason
• Over design
31. Effect of cooling water system on
refrigeration compressor
• Cooling water temperature
- Cooling water temperature should be as
low as possible
- For every 1°C drop in approach, the
reduction in compressor power : 4
to 5%
32. Effect of cooling water flow on
refrigeration compressor
Typical design ∆T of cooling water (CW) across
condenser : 4 to 10 ° C
30°C 34°C
∆T = 4°C
Refrigeratio
n condenser CW outCW in
High ∆T
- Means less cooling water flow (reduction in
pump power)
- Slight increase in compressor power
• Can be off-set by increase in condenser area
33. CW Flow Optimisation Across
Condensers
• Adjust the valve, such that the temp. rise of
cooling water reaches the design value
• Cooling water requirement drastically comes
down
• Simultaneously, measure the amps of
refrigeration compressor
• Estimate the net saving (reduction in cooling
water pump power minus the increase in
compressor power)
34. 400 m3
/h
Condenser - 1
∆ T = 3-4°C
• If area is double, cooling water requirement
becomes half
Utilisation of two condensers for one
compressor
• Generally, spare condensers are available
• Excellent potential
35. 100 m3
/h
Condenser - 1
∆ T = 6-8°C
100 m3
/h
Condenser - 2
∆ T = 6-8°C
Utilisation of two condensers for
one compressor
36. Replace Conventional Shell & Tube
Type Ammonia Condensers with
Evaporative Condensers
Evaporative condenser – latest
technology
Vapour condensing
Operating cost very low ∼ 20% of ST
condenser
37. Replace Conventional Shell & Tube
Type Ammonia Condensers with
Evaporative Condensers
Features
Improved water to air contact within coil
Greater water flow rate over coil
Enhanced heat transfer η
Lower condensing temperatures
Reduced system power
38. Case Study
Existing System
MC Brine
compressor (204
m3
/hr x 2 no.s)
408 m3
/hr
MC Brine APV (1 no) 193 m3
/hr
MEG Brine 200 m3
/hr
Total cooling water 801 m3
/hr
39. Case Study
Modified – After
EvapcoOne cooling tower stopped – 600 m3
/hr
Power Savings
Pumps 2 nos. x 75 kW + 1 no. x
30 kW
180 kW
Fans 3 nos. x 7.5 kW 22.5 kW
Total 202.5 kW
MC Brine – Fan + Pump
(How)
(7.5 + 1.5) kW x 2 18 kW
MC Brine – Fan + Pump
(APV)
(7.5 + 1.5) kW x 1 9 kW
MEG Brine – Fan + Pump (7.5 + 1.5) kW x 1 9 kW
Total 36 kW
40. • Centrifugal compressors
- Energy efficient
- Less maintenance prone
• kW/TR comparison
- Centrifugal : 0.65 to 0.80
- Reciprocating : 1.00 to 1.20
• Centrifugal ideal for high capacities
(say 200TR and above)
Replace Reciprocating Compressors
With Centrifugal Compressors
41. Replace Reciprocating Compressors
With Centrifugal Compressors
• Better to incorporate at initial stage
• 200TR reciprocating compressor replaced
with centrifugal compressor
Savings - Rs. 15.00 lakhs
Investment - Rs. 50.00 lakhs
Pay back - 40 months
42. Approach for energy savings in
cooling tower pumps
Typical reasons for excess power consumption
• Excess capacity
• Excess head
• Under loaded process
Approach is different from conventional pumps
• Unique approach
43. • Excess cooling water flow on account of over-
sizing - May go unnoticed
Heat exchangers designed with following ∆T’s
Criteria for estimating excess flow
- Temp. difference (∆T) between supply and
return water across heat exchanger
Air compressors : 10°C
Process applications : 5-10°C
Turbine condensers : 10°C
Refrigeration condensers : 7-8°C
44. Phase - I
• Fix the required header pressure
- Pressure meter to be fixed
• Measure the inlet and outlet cooling water temperature across
condensers
- By comparison of measured ∆T with design ∆T, flow is
sufficient or excessive
• Select the condensers, where ∆T is less than design value
- Throttle the delivery side valves of the
condensers, till the design ∆T is achieved
45. • While throttling valves, process conditions to be monitored
continuously
- Increase in header pressure
• Pump delivery valve to be throttled to maintain the required
header pressure
- Optimum cooling water requirements will be
achieved
• Partial energy savings can be achieved with the steps in
phase - I
46. Phase - II
• Critical condensers to be studied for their Log Mean Temp.
Difference (LMTD)
- Heat transfer area can be increased
• Estimate cooling water requirements after increasing the areas
• Install correct size pumps (matching capacity and head)
- Possible to tap full savings potential
47. • Alternatively, a VFD can be installed for the existing pumps
- Can be operated at lower speed
- ∆T across condensers as the control
parameter
• Combination of Phase - I and Phase - II to be attempted
- Will result in maximum energy savings
50. Vapour Compression vs
Vapour Absorption
• Air conditioning load : 200TR
• Recip. comp. consumption : 220 kW
• Double effect VAHP selected
• Specific consumption : 4.5 kg/TR
• Steam requirement : 0.9 TPH
51. Vapour Compression vs
Vapour Absorption
• Vapor comp. oper. cost : Rs.60 lakhs/yr
• VAHP operating cost : Rs.22 lakhs/yr
(live steam cost @Rs.300/Ton)
• Savings : Rs.38 lakhs/yr
• Investment on VAHP: Rs.60 lakhs
• Simple pay back : 1.6 years
52. Details VAC VAHP
Capacity 65TR 65TR
Steam consumption Nil 325 kg/hr
Steam cost Nil Rs.152/hr
Electricity consumption 72 kW 3 kW
Electricity cost Rs.216/hr Rs.9/hr
Total cost Rs.216/hr Rs.161/hr
Capital cost Rs.10 lakhs Rs.20 lakhs
Vapour Compression vs
Vapour Absorption
53. • Annual savings - (216 - 161) Rs./hr
x 8000 hrs/yr
- Rs.4.40 lakhs
• Investment(differnce)- Rs.10.00 lakhs
• Pay back - 2.2 years
• Going by initial cost alone is
misleading
Vapour Compression vs
Vapour Absorption
54. Possibilities at Coke
Optimisation Chilled Brine
Temperature Present Operating Temperature -2° C
Is it possible to increase temperature ?
CO 2 Absorption ?
Higher Operating Temperature
-2 ° C 1.20 KW/TR
-4 ° C 1.26 KW/TR
-6 ° C 1.36 KW/TR
55. Possibilities at Coke …
Replacement with Screw Chiller With VFD
Lower KW/TR – 25 % Lower
Lower Loads – KW/TR Nearly Same
Chiller at Coke
33 % ____ KW/TR
66 % ____ KW/TR
100 % ____ KW/TR
56. Possibilities at Coke …
Chilled Brine Pumping System
– Any Possibility
3 Port Valve
Conversion to 2 Port System
VFD – For Tapping Full Savings
57. Possibilities at Coke …
Conversion of Chilled Brine System
– One Pass
Possible ?
What Advantages ?
Equipment Reduction
Pump Energy Saving
More Chilled Brine Storage
58. Possibilities at Coke …
Cooling Water Use In Chiller Condenser
Operating “ T” – ie.,
Design “ T” - ?
Any Possibility ?
59. At Coke …
Develop a Template for Monitoring
Month Pump
(kW)
Compre
(kW)
Chilled water
temp (°C)
Amb. Temp
(°C)
01.01
02.01
03.01
04.01
05.01
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