Equipment design

In this chapter, main refrigeration and air conditioning equipment will be discussed namely: Compressors. Condensers and cooling towers. Evaporators Throttles Air ducts Air handling units. 1. Compressors: Gas compressors are the heart of the compression refrigeration systems. Gas compressors can be divided based on operation method into two main categories: Positive displacement: in this type, gas compression is resulted from volume reduction. Very small tolerance is used between the stationary and moving parts to achieve the compression. Common types are reciprocating, rotary, screw and scroll compressors. Non-positive (or dynamic) compressors: in this type, gas compression is achieved by elevating the kinetic energy of the gas, then gas high velocity is converted to pressure using a diffuser. Common types are centrifugal compressors. Compressor performance can be presented in three main factors: Compressor brake power B.P. in kW. Compressor flow capacity The ratio of compressor power to the unit ton of refrigeration (B.P./ton) In the refrigeration cycle, two main factors can affect the compressor performance: evaporator temperature and condenser temperature as shown in the figure below.

I. Reciprocating compressors It is a popular type for small cooling capacities but it can be used in the range 0.25-1000 ton. it can operate in single direction (single act) or in both piston directions (double act). For small scale units, hermitically sealed compressors are used where compressor is maintenanceless and lubricating oil is mixed with the refrigerant. reciprocating compressors are suitable for low specific-volume refrigerants (low boiling point refrigerants), however, it suffers from the low volumetric efficiency and thus it has lower overall efficiency compared to other type of compressors. Theoretical volumetric efficiency is calculated using the following equation:

[( )

A correction factor is used considering the pressure and temperature difference between the evaporator outlet (e) and compressor inlet (c). The amount of power required to run the compressor is:

[( [( )

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For multistage compression, optimum intermediate pressure that provides minimum compressor power is:

II. Rotary compressors For applications where higher flow capacity is required, rotary compressors can achieve higher capacities compared to reciprocating compressors with similar weight. Compression method is based of positive displacement. Two main design are available: Rotary compressor with fixed blade and eccentric rotor: The rotor touches the cylinder at a single point with minimum clearance while rotating eccentrically with the cylinder. A single spring-loaded blade touches the rotor sealing the high pressure port from suction port.

Rotary vane compressor with eccentric shaft: The rotor is mounted on eccentric shaft and it does not touch the cylinder. However, a free moving blades on the rotor are moving radially due to centrifugal force compressing the vapor between rotor and cylinder. The advantages of rotary compressors over reciprocating are: Less noise and vibration. Can deal with higher specific volume refrigerants with low suction pressure. Preferred for lower temperature applications.

III. Scroll compressors This design consists of two scrolls, rotary and stationary, and rotary scroll is fixed on eccentric shaft. Vapor volume decreases when vapor is pushed towards the scroll center acting as positive displacement compressor. The advantages of this type are: Compared to reciprocating type, it has at least 10% higher efficiency for the same size since compression process is smooth and extends for about 540 to complete the cycle. Lower start-up power due to the smooth compression. High reliability and durability. Lower sound.

IV.

Screw compressors

Changing the compressor capacity:

In most large capacity refrigeration or central air conditioning, shutting down the compressor when evaporator temperature drops or at part cooling load capacity is not an option due to startup difficulty for large electrical motors. Thus, several methods are commonly used to control compressor capacity: Suction control valve is placed at the compressor inlet to restrict the gas flow rate. This method has the advantage of reducing the compressor power consumption due

to the gas flow rate drop. However, volumetric efficiency drops significantly especially with reciprocating compressors. Motor speed control: this method is the most efficient way in the small scale systems. However, it is not practical for large electrical motors due to the high price of the speed controller (invertors). Multiple units: this strategy is commonly used in the central air conditioning systems. In summer all compressors are working in parallel, and in winter (i.e. part load) some units are turned off to reduce the cooling capacity. Hot gas bypass: this technique is used not only for capacity reduction, but also for instant control of the cooling load. Part of the hot gas after the compressor is returned back to the inlet of the evaporator, and in some systems it is bypassed to the outlet of the evaporator to insure that the gas interring the compressor is superheated.

2. Condensers: In refrigeration cycles, pressure has to be raised, however, temperature will be inevitably raised as well. Thus, thermal power has to be removed in the form of latent heat (at constant temperature) to convert all vapor refrigerant into liquid. Condensers are used to cool-down the refrigerants in near Isothermal/ Isobaric process as shown in the figure below.

Main factors affecting the condensation process are: Cooling medium flow rate: Higher flow rate is required when air is used (30-35 m3/min/Ton), while about (7-20 liter/min/Ton) is required when water is used. Condensing surface area: Higher surface area is required when air is used (3-4 m2/Ton), while about (0.5-1 m2/Ton) is required when water is used. Cooling medium flow velocity: Higher air velocity is required (4.5-5 m/s) while only (2-3m/s) for water. Condensers can be divided into three main types: I. Air cooled condensers: Air is used as the cooling medium and it can be either with natural convection or forced convection.

II. III.

Water cooled condensers: Water is used as the cooling medium. many designs are used such as: Evaporative condensers: Thermal power is removed by the evaporating latent heat of cooling medium (commonly water). The water spray through nozzles in the form of fine droplets across the condenser hot tubes is evaporated, thus, removing thermal power from the tubes. This type used same theory as the cooling towers.