Lesson 3 Basic Vapor Compression Refrigeration System A simple vapor compression refrigeration system consists of the following equipment: a) Compressor b) Condenser c) Expansion valve d) Evaporator. Figure 3.1: Typical Compression Refrigeration System High pressure liquid refrigerant is fed from the receiver or condenser through the liquid line, and through the filter-drier to the metering device. It is at this point that the high pressure side of the system is separated from the low pressure side. Various types of control devices may be used, but for purposes of this illustration, only the thermostatic expansion valve (TEV) will be considered. The TEV controls the quantity of liquid refrigerant being fed into the evaporator. The TEV’s internal orifice causes the pressure of the refrigerant to the evaporating or low side pressure to be reduced. This reduction of the refrigerant pressure, therefore its boiling point causes it to boil or vaporize, absorbing heat until the refrigerant is at the saturation temperature corresponding to its pressure. As the low temperature refrigerant Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 passes through the evaporator coil, heat flows through the walls of the evaporator tubing into the refrigerant. The boiling action continues until the refrigerant is completely vaporized. The TEV regulates the quantity of refrigerant, (lb/min) through the evaporator to maintain a preset temperature difference or superheat between the evaporating refrigerant and the vapor leaving the evaporator. As the temperature of the gas leaving the evaporator varies, the expansion valve power element bulb senses this temperature, and acts to modulate the feed of refrigerant through the expansion valve. The superheated refrigerant vapor leaving the evaporator travels through the suction line to the compressor inlet. The compressor takes the low pressure vapor and compresses it, increasing its pressure and temperature. The hot, high pressure vapor is forced out of the compressor discharge valve(s), and into the condenser. As the high pressure high temperature vapor passes through the condenser, it is cooled by an external means. In air cooled systems, a fan, and fin-type condenser surface is normally used. In water cooled systems, a refrigerant-to-water heat exchanger is employed. As the temperature of the refrigerant vapor is lowered to the saturation temperature corresponding to the high pressure in the condenser, the vapor condenses into a liquid and flows back to the receiver or directly to the TEV to repeat the cycle. The refrigerating process is continuous as long as the compressor is operating. Figure 3.2: Schematic Diagram of Simple Compression Refrigeration System In a vapor compression refrigeration system, the suitable refrigerants are ammonia (NH3), R-11, R-12, R-22 and etc. This is commonly used in air conditioning, cold storage, and ice plant. 1|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Simple Principle of Operation The low temperature vapor from the evaporator is drawn in by the compressor and discharge is to the condenser which cause to increase the temperature and pressure of vapor due to mechanical compression. In the condenser, the vapor from the compressor at the condenser pressure or head pressure of the system is condensed by the available circulating water. After the heat rejection has caused condensation, the liquid refrigerant may be stored in a receiver. If the pressure on the resulting is lowered, a portion of the liquid evaporates immediately as the temperature drops, while the remaining liquid is vaporizing absorbs heat from its surroundings, thereby creating refrigerating effect. In the evaporating coils, the liquid refrigerant absorbs heat from brine or water or directly from the space being cooled, for this reason, the leaving refrigerant in the evaporator become saturated vapor. The schematic diagram of the arrangement is as shown in the Figure 3.2. The low temperature, low pressure vapor at state B is compressed by a compressor to high temperature and pressure vapor at state C. This vapor is condensed into high pressure vapor at state D in the condenser and then passes through the expansion valve. Here, the vapor is throttled down to a low pressure liquid and passed on to an evaporator, where it absorbs heat from the surroundings from the circulating fluid (being refrigerated) and vaporizes into low pressure vapor at state B. The cycle then repeats. The exchange of energy is as follows: a) Compressor requires work, δw. The work is supplied to the system from the surroundings. b) During condensation, heat δQ1 the equivalent of latent heat of condensation etc, is lost from the refrigerator. c) During evaporation, heat δQ2 equivalent to latent heat of vaporization is absorbed by the refrigerant. d) There is no exchange of heat during throttling process through the expansion valve as this process occurs at constant enthalpy. 2|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Figure 3.3: The T-S Diagram of a Simple Vapor Compression Cycle The Figure 3.3 shows a simple vapor compression refrigeration cycle on T-s diagram for different compression processes. The cycle works between temperatures T1 and T2 representing the condenser and evaporator temperatures respectively. The various process of the cycle A-B-C-D (A-B’-C’-D and A-B”-C”-D) are as given below: a) Process B-C (B’-C’ or B”-C”): Isentropic compression of the vapor from state B to C. If vapor state is saturated (B), or superheated (B”), the compression is called dry compression. If initial state is wet (B’), the compression is called wet compression as represented by B’-C’. b) Process C-D (C’-D or C”-D): Heat rejection in condenser at constant pressure. c) Process D-A: An irreversible adiabatic expansion of vapor through the expansion value. The pressure and temperature of the liquid are reduced. The process is accompanied by partial evaporation of some liquid. The process is shown by dotted line. d) Process A-B (A-B’ or A-B”): Heat absorption in evaporator at constant pressure. The final state depends on the quantity of heat absorbed and same may be wet (B’) dry (B) or superheated (B”). System: Evaporator The purpose of the evaporator is to receive low-pressure, low temperature fluid from the expansion valve and to bring it in close thermal contact with the load. The refrigerant takes up its latent heat from the load and leaves the evaporator as dry gas. The heat absorbed in the evaporator is commonly referred to as the refrigerating effect (RE). 3|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 First Law: Energy Balance QA + mrh1 = mrh4 QA = mr (h1 – h4) ; kW Also, RE = h1 – h4 ; kJ/kg Also, QA = mwCpβt ; kW Figure 3.4: The Evaporator section System: Condenser The purpose of condenser is to accept the hot, high pressure gas from the compressor and cool it to remove first the superheat and then the latent heat, so that the refrigerant will condense back to the liquid. First Law: Energy Balance QR + mrh3 = mrh2 QR = mr (h2 – h3) ; kW Also, QR = mwCpβt ; kW Figure 3.5: The Condenser section System: Compressor The purpose of compressor in a vapor compression cycle is to accept the lowpressure dry gas from the evaporator and raise its pressure to that of the condenser. 4|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 First Law: Energy Balance wC + mrh1 = mrh2 wC = mr (h2 – h1) ; kW WC = (h2 – h1) ; kJ/kg Figure 3.6: The Compressor section System: Expansion Valve The purpose of expansion valve is to regulate the flow of refrigeration. This is called a throttling or wire-drawing process. There is reduction of pressure with no change of enthalpy. First Law: Energy Balance mrh3 = mrh4 h3 = h 4 Figure 3.7: The expansion valve section where, h1 = enthalpy of refrigerant entering the compressor. h2 = enthalpy of refrigerant leaving the compressor. h3 = enthalpy of refrigerant leaving the condenser. h4 = enthalpy of refrigerant entering the evaporator. mr = mass flow rate of the regrigerant. Coefficient of Performance (Cop) also, The ratio of the useful refrigeration to the work required by the compressor. π πΈ πΆππ = ππ πΆππ = 5|Page ππ ππ Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Volumetric Efficiency (ππ ) The ratio of the volume flow rate entering the compressor to the displacement rate of the compressor. Factors influencing the volumetric efficiency are: The effects of valve and piston ring leackage, although these are expected to be small. The effect of surface and internal friction, ππ . The effect of superheating the refrigerant, ππ . The effect of clearance, ππ . Therefore, the actual volumetric efficiency is the product of these separate efficiencies, or ππ£ = ππ π₯ ππ x ππ where, where, ππ = 1 − π‘2 − π‘1 1330 = 1− π‘2 − π‘1 738.89 π2 1 ππΆ = 1 + π − π( )π (πππππππππ π£πππ’πππ‘πππ ππππππππππ¦) π1 π1 = 1 − π( − 1) π2 π£πππ’ππ ππππ€ πππ‘π πππ‘πππππ πππππππ π ππ ππ = πππ πππππππππ‘ πππ‘π ππ πππππππ π ππ π1 ππ π1 ππ = = ππ· ππ· π 2 ππ· = π· πΏππ 4 ππ· = π£πππ’ππ πππ πππππππππ‘ π1 = π πππππππ π£πππ’ππ ππ πππππππππππ‘ πππ‘πππππ π‘βπ πππππππ π ππ, πππ‘πππ ππ π· = ππππππ‘ππ ππ ππ¦ππππππ (ππππ) πΏ = πππππ‘β ππ π π‘ππππ π = ππ’ππππ ππ π π‘ππππ πππππππ‘ππ πππ π’πππ‘ π‘πππ π = (π)(1)(ππ’ππππ ππ ππ¦πππππππ )πππ π πππππ πππ‘πππ πππππππ π ππ π = (π)(2)(ππ’ππππ ππ ππ¦πππππππ )πππ πππ’πππ πππ‘πππ πππππππ π ππ π = πππππππ π ππ π ππππ π = 1.304 πππ πππππππ 6|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 A single-acting compressor makes one complete cycle in one revolution. A double-acting compressor makes two complete cycles in one revolution. Mechanical efficiency Επ = πππππππ‘ππ π€πππ π1 = πππππ π€πππ ππ΅ The adiabatic compression efficiency or simply compression efficiency Επ is defined as: ππ πππ‘πππππ πππππππ π πππ Επ = πππ‘π’ππ π€πππ ππ πππππππ π πππ Examples: 1. An NH3 vapor compression refrigeration system has a condensing temperature of 250C and an evaporating temperature of -100C. The refrigerating capacity is 7 tons. The liquid leaving the condenser is saturated and compression is isentropic. Determine: a. The refrigerant flow rate, kg/sec. b. The refrigerant volumetric flow at compressor suction, liters/sec. c. The work of compression, kJ/kg. d. The theoretical compressor power, kW. e. The heat rejected from the system, kW. f. The COP. g. Quality of refrigerant before evaporator. 2. A simple saturated refrigeration cycle for R-12 system operates at an evaporating temperature of 260.96 kPa and condensing temperature of 400C. Determine: a. Draw the schematic and p-h diagram b. The refrigerant effect, kJ/kg c. The work of compressor, kJ/kg d. The heat rejected in the system, kJ/kg e. The COP CONDENSER QR f. Schematic Diagram 3 2 COMPRESSOR TXV Wc 4 QA EVAPORATOR 7|Page 1 Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Supplementary Problems: 1. A 15-ton refrigeration system is used to make ice. The water is available at 20 C. Refrigerant 12 is used with saturated temperature limits of –25 C and 54 C. Determine (a) the COP, (b) the refrigerant flow rate, (c) the temperature at discharge of the compressor, (d) the volume flow rate, and (e) the maximum kg of ice manufactured per day. 2. An air conditioning system of a high rise building has a capacity of 350 kW of refrigeration, uses R-12. The evaporating and condensing temperature are 00C and 350C, respectively. Determine the following: a. Mass of flash gas per kg of refrigerant circulated. b. Mass of R-12 circulated per second. c. Volumetric rate of flow under suction condition. d. Work compression in kW. e. COP 3. A simple vapor-compression cycle develops 13 tons of refrigeration. Using ammonia as refrigerant and operating at a condensing temperature of 240C and evaporating temperature of -180C and assuming that the compression are isentropic and that the gas leaving the condenser is saturated. Find the following: a. Draw the P-h diagram. b. Refrigerating effect in kJ/kg. c. Circulation flow in kg/min. d. Power requirement e. Volume flow in cc per minute per ton. f. Coefficient of Performance. g. Power per ton. 4. An ammonia refrigerating cycle operates at 247.14 kPa suction pressure and 1,230.70 kPa condenser pressure. Other data are the following: Refrigerating capacity ……………………………………… 29 kW Compressor capacity ………………………………………. 4kW Compression efficiency ……………………………………. 85 % Mechanical efficiency ……………………………………… 78 % Actual Volumetric efficiency ………………………………. 80 % Determine the following: a. The clearance volumetric efficiency. b. The ideal and actual COP. c. The mass flow rate of ammonia. d. The brake work. 5. A four-cylinder refrigerant 12 compressor operates between the evaporator and condenser temperatures of 40C and 430C. It is to carry a load of 20 tons of refrigeration at 1200 rpm. If the average piston speed is 213 m/min and the actual volumetric efficiency is 80 per cent, what should be the bore and stroke of the compressor? 8|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 6. A 100 x 200 mm ammonia compressor with a compressor with a compression efficiency of 80 per cent operates with a suction pressure of 291.6 kPa and a condenser pressure of 1204 kPa at 23 r/s. The refrigerant cools 102 kg/min of brine by 8 degrees in the brine cooler. The specific heat of the brine is 3.14 kJ/kg-0C. Electric input to the motor driving the compressor is 14.33 kW. Motor efficiency at this load is 92 per cent. Assuming 5 per cent of the useful refrigerating effect is lost by brine cooler from the room, determine the mechanical and volumetric efficiencies of the compressor. 7. A six-cylinder, 6.70 x 5.70 - cm, refrigerant 22 compressor operating at 30 r/s indicate a refrigerating capacity of 96.4 kW and a power requirement of 19.4 kW at an evaporating temperature of 50C and a condensing temperature of 350C. Compute a) the clearance volumetric efficiency if the clearance volume is 5 per cent, b) the actual volumetric efficiency, and c) compression efficiency. 8. A manufacturing company is intending to use its water cooled condenser for its proposed cold storage room. The name plate of the condenser gives the following specifications: Refrigerant ammonia Condenser water inlet 300C Condenser water outlet 400C Condenser temperature 350C Refrigerant flow 3.84 kg/min Circulating water flow 120 kg/min a. If the company decided to purchase a new compressor and evaporator, find the tonnage of the system and the temperature in the evaporator, b) what is the COP?, c)find the theoretical hp required. 9. A standard ammonia vapor compression cycle developing 20 tons of refrigeration operates with a condensing temperature of 320C and an evaporating temperature of -140C. Calculate a) refrigerating effect, b) circulating rate of refrigerant, c) theoretical power, d) COP, e) gallons per minute of cooling water in the condenser, if change in temperature is 80C, d) quality of the refrigerant entering the evaporator, and g) temperature of the refrigerant leaving the compressor. ( 1 gallon contains 8.33 lb of water). EFFECTS OF OPERATING CONDITIONS Objectives: 1. Know effects of increasing the Vaporizing temperature 2. Know effects of increasing the Condensing temperature 3. Know effects of superheating the suction Vapor 4. Know effects of subcooling the liquid 1. Effects of Increasing the Vaporizing temperature 9|Page Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 - A R-12 simple saturated refrigerating cycle operates at an evaporating temperature of -100C and a condensing temperature of 400C. Show the effects of increasing the vaporizing temperature. Properties of refrigerants: h3 = h4 = hf at 400C = 238.5 kJ/kg for the -100C evaporating cycle (cycle 1-2-3-4-1) v1 = vg at -100C = 0.07675 m3/kg h1 = hg at -100C = 347.1 m3/kg h2 = h at 961 kpa and s2 equals s1 = 373 kJ/kg-K for the 50C evaporating cycle (cycle 1’-2’-3’-4’-1’) v1 = vg at 50C = 0.04749 m3/kg h1 = hg at 50C = 353.6 m3/kg h2 = h at 961 kpa and s2 equals s1 = 371 kJ/kg-K Subcooling and superheating: In E refrigeration cycles, the temperature of the heat sink will be several degrees lower than the condensing temperature to facilitate heat transfer. Hence it is possible to cool the refrigerant liquid in the condenser to a few degrees lower than the condensing temperature by adding extra area for heat transfer. In such a case, the exit condition of the condenser will be in the subcooled liquid region. Hence this process is known as subcooling. Similarly, the temperature of heat source will be a few degrees higher than the evaporator temperature, hence the vapour at the exit of the evaporator can be superheated by a few degrees. If the superheating of refrigerant takes place due to heat transfer with the refrigerated space (low temperature heat source) then it is called as useful superheating as it increases the refrigeration effect. On the other hand, it is possible for the refrigerant vapour to become superheated by exchanging heat with the surroundings as it flows through the connecting pipelines. 10 | P a g e Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Such a superheating is called as useless superheating as it does not increase refrigeration effect. Subcooling is beneficial as it increases the refrigeration effect by reducing the throttling loss at no additional specific work input. Also subcooling ensures that only liquid enters into the throttling device leading to its efficient operation. The Figure below shows the VCRS cycle without and with subcooling on P-h and T-s coordinates. It can be seen from the T-s diagram that without subcooling the throttling loss is equal to the hatched area b-4’-4-c, whereas with subcooling the throttling loss is given by the area a-4”-4’-b. Thus the refrigeration effect increases by an amount equal to (h4-h4’) = (h3-h3’). Another practical advantage of subcooling is that there is less vapour at the inlet to the evaporator which leads to lower pressure drop in the evaporator. Figure 3.8: The P-H and T-S Diagram of the effects of sub-cooling the liquid. Useful superheating increases both the refrigeration effect as well as the work of compression. Hence the COP (ratio of refrigeration effect and work of compression) may or may not increase with superheat, depending mainly upon the nature of the working fluid. Even though useful superheating may or may not increase the COP of the system, a minimum amount of superheat is desirable as it prevents the entry of liquid droplets into the compressor. The figure shows the VCRS cycle with superheating on P-h 11 | P a g e Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 and T-s coordinates. As shown in the figure, with useful superheating, the refrigeration effect, specific volume at the inlet to the compressor and work of compression increase. Whether the volumic refrigeration effect (ratio of refrigeration effect by specific volume at compressor inlet) and COP increase or not depends upon the relative increase in refrigeration effect and work of compression, which in turn depends upon the nature of the refrigerant used. The temperature of refrigerant at the exit of the compressor increases with superheat as the isentropes in the vapour region gradually diverge. Figure 3.9: The P-H and T-S Diagram of the effects of superheating the vapor. To summarize, the following are the results of effects of different operating conditions. 1. Effects of increasing the vaporizing temperature: 12 | P a g e Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 2. 3. 4. 5. - The refrigerating effect per unit mass increases. - The mass flow rate per ton decreases. - The volume flow rate per ton decreases. - The COP increases. - The work per ton decreases. - The work per ton decreases. - The heat rejected at the condenser per ton decreases. Effects of increasing the condenser temperature. - The refrigerating effect per unit mass decreases. - The mass flow rate per ton increases. - The volume flow rate per ton increases. - The COP decreases. - The work per ton increases. - The heat rejected at the condenser per ton increases. Effects of superheating the suction vapor When superheating produces useful cooling: - The refrigerating effect per unit mass increases. - The mass flow rate per ton decreases. - The volume flow rate per ton decreases. - The COP increases. - The work per ton decreases. Effects of superheating the suction vapor When superheating produces without useful cooling: - The refrigerating effect per unit mass remains the same. - The mass flow rate per ton remains the same. - The volume flow rate per ton increases. - The COP decreases. - The work per ton increases. - The heat rejected at the condenser per ton increases. Effects of sub-cooling the liquid. - The refrigerating effect per unit mass increases. - The mass flow rate per ton remains decreases. - The volume flow rate per ton decreases. - The COP increases. - The work per ton decreases. - The heat rejected at the condenser per ton decreases. 13 | P a g e Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Examples: 1. A R-12 simple saturated refrigerating cycle operates at an evaporating temperature of -100C and a condensing temperature of 400C. Show the effects of increasing the vaporizing temperature to 50C. 2. A simple saturated refrigerating cycle using R-12 as the refrigerant, operates at a condensing temperature of 400C and an evaporating temperature of -100C. Show the effects of increasing the condensing temperature to 500C. Supplementary Problems: 1. A simple saturated refrigerating cycle for R-12 system operates at an evaporating temperature of -50C and a condensing temperature of 400C. Show the effects of superheating the suction vapor from -50C to 150C. 2. A simple saturated refrigerating cycle using R-12 as the refrigerant operates at an evaporating temperature of -50C and a condensing temperature of 400C. Show the effects of sub-cooling the liquid from 400C to 300C before reaching the expansion valve. 14 | P a g e Romblon State University |Department of Mechanical Engineering BS Mechanical Engineering REFRIGERATION ENGINEERING | Second Semester | School Year 2017-2018 Reference: A.B. Trillllana, N.C. Dela Rama, 1995, Simplified Design of Refrigeration and Air Conditioning C.P. Arora, 2009, McGraw-Hill International Edition, Refrigeration and Air Conditioning H.B. Sta.Maria, Third Edition, 2001, Refrigeration and Air Conditioning PN. Ananthanarayanan, 1999, Second Edition, Refrigeration and Air Conditioning R.S. Alcorcon, 2005, Power Plant Engineering 15 | P a g e